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Sector Level Workshop- Thermal Power Plant Sector, 28th October 2015

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Date/Time
Date(s) - 28/10/2015
9:00 am - 6:00 pm

Location
Reliance Infrastructure Limited

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28 October, 2015, Dahanu, Maharashtra : The 1st Thermal Power Sector workshop for promoting exchange of “Best practices in Energy Efficiency in Thermal Power Sector” under Knowledge Exchange Platform (KEP) initiative was hosted by Dahanu Thermal Power Station, Reliance Infrastructure Limited, on 28th October, 2015 at Dahanu, Maharashtra. KEP is a joint initiative of Bureau of Energy Efficiency (BEE) and Institute for Industrial Productivity (IIP) for promoting energy efficiency through best practice transfer in industries covered under the Perform Achieve and Trade (PAT) scheme. KEP provides the institutional framework to catalyze the transfer of best practices within and across the industry sectors covered under PAT Scheme.

The best practice workshop in thermal power sector was an important event under KEP as it was not just relevant for 144 Designated Consumers (DCs) that have been mandated to enhance their energy efficiency under the 1st cycle of PAT scheme but for other industry sectors like cement, aluminium as well, which have sizable number of Captive Power Plants (CPP). The workshop was attended by 230 participants, which included 100 representatives of thermal power sector and 130 representatives of aluminium, cement, pulp & paper, fertilizer, textile, iron & steel sectors, energy auditors and energy managers, technology providers and senior Industry professionals amongst many others.

The workshop was inaugurated by Shri Rajendra Nandi, Project Director, Sr. Vice President, Dahanu Thermal Power Station, Reliance Infrastructure Limited. In his inaugural address, he highlighted importance of best practice sharing which will assist the industries in identifying cost-effective measures that can reduce energy consumption and developing systematic approach towards energy efficiency improvements.  He also mentioned that the knowledge sharing and best practice sharing will motivate the industries to collaborate among the wider members and stakeholders. Shri Nandi hoped that this platform will also support the work being undertaken by the industries in the area of energy efficiency and to explore additional channels for the promotion of cleaner technologies.

 Welcome address was delivered by Ms. Ritu Bharadwaj, Senior Program Manager, Institute for Industrial Productivity. She made a brief presentation on the rationale behind KEP, objectives and vision and the milestones achieved so far with the continued support of industries. Ms. Bharadwaj highlighted the fact that although KEP although being in infancy stage, has undertaken commendable work. Three Best practices workshops for Aluminium, Cement, and Paper and Pulp have been successfully organized, attended by more than 600 industry professionals. 60 plants from all the PAT sectors have agreed to participate in Friendly Energy Efficiency Exchange Visits. Policy Roundtables on ESCerts Trading, Financing and Spent Pot Liners (SPL), a hazardous waste, generated from the aluminium sector and its gainful utilization in the cement industry, have been organized.

She also informed the participants KEP has launched an interactive website (www.knowledgeplatform.in) that facilitates knowledge transfer and discussion between stakeholder groups related to different PAT sectors and requested participants to give their feedback on different features to ensure that it met industry’s expectations and needs. She also mentioned that IIP was committed to work alongside BEE in taking this initiative forward and helping the industry achieve PAT objectives. While concluding her welcome address, Ms. Bhardwaj hoped that with these initiatives, KEP will be able to deliver significant energy efficiency benefits for the industrial sector and help sustain continuous improvement by promoting cost effective efficiency measures.

Special address was delivered by Shri K. K. Chakarvarti, Expert Consultant, BEE. In his address, he mentioned that the success of KEP depended on pro-active industry participation. Vote of thanks was delivered by Shri Bhaven Sheth, Addl. Vice President, Dahanu Thermal Power Station, conveyed his thanks to the dignitaries, speakers and delegates for their presence and participation in the workshop and assured the full support of Dahanu Thermal Power Station in future activities under KEP initiative.

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Shri Rajendra Nandi, Project Director, Sr. Vice President, Dahanu Thermal power Station, delivering his inaugural address

The inaugural event was followed by three technical sessions and a panel discussion. The first technical session was Chaired by Shri K K Chakarvarti, Expert Consultant, Bureau of Energy Efficiency. The discussion in the session focused on Monitoring and Verification (M&V) arrangements under PAT Scheme and Trading mechanism proposed for Energy Saving Certificates (ESCerts). BEE presented the M&V provision under PAT for Thermal Power sector, wherein the participants were informed about the current status as well as next steps proposed with regard to M&V. The presentation also covered the methodology to be adopted for second PAT cycle and the new plants proposed to be added in second cycle of PAT. The presentation on ESCerts by BEE focused on key aspects of ESCerts trading scheme and the progress made so far, which included status of ESCerts Exchange Regulations, roles and responsibilities of entities involved, formulation of business procedures for ESCerts exchange on Power Exchanges and up-gradation of PATNet Portal including M & V process.

Besides PAT, the session also focused on sharing of experience of the industry on implementation of innovative best practices. The industries that shared their experience included  Dahanu Thermal Power Station,  The Tata Power Company Limited, Trombay Thermal Power Station, National  Aluminum Company  Limited (NALCO) and UltraTech Cement Limited.

Sharing and discussing their innovative best practices, the presentation by Dahanu Thermal Power Station, focused on benefits achieved by Installation of Variable Frequency Drive (VFD), Boiler Feed Water Pump (BFP) Cartridge replacement and replacement of Manganese Liner by Hi-Crome Liner in Coal Mill, which lead to annual energy saving of 5.2 million units (MU), 2.6 MU and 6.72 MU respectively. The presentation by The Tata Power Company Limited, Trombay Thermal Power Station highlighted the energy savings achieved by modification in Air & Flue gas path in the 250 MW Unit 8, Combustion Optimization in Unit 5of 500 MW capacity and Soot blowing drain steam recovery system, which lead to annual monetary saving of Rs. 19 million, Rs. 36.3 million and Rs. 0.9 million respectively. The presentation by NALCO highlighted the energy efficiency gains achieved by reducing the Boiler Feed Regulating Stations (FRS), improvement in Turbine Condenser Vacuum, replacement of CT Fan GRP blades with FRP blades, and Dry Oil gun testing to save fuel oil consumption.Explaining new approaches to energy efficiency, a presentation by GIZ, described the importance of Coal Blending and its effects on Boiler Performance viz. the effect of  Volatile Matter, Fixed Carbon, Moisture, Ash and Flame stability. The last presentation in the Technical Session 1 covered the best practices adopted by UltraTech Cement Limited (Andhra Pradesh Cement works). The presentation explained the strategy and benefits achieved by installing Boiler Feed Pump VFD Speed cascading with Drum Pressure.  This helped in reducing Auxiliary consumption of the Boiler feed pumps significantly.

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Shri K K Chakarvarti with the panelists of the first technical session

The second technical session was focused on sharing of experience of the industry on implementation of innovative best practices, was Chaired by Shri A K Asthana, Sr. Technical Expert, GIZ. The industries that shared their experience included JSW Energy Limited,  Budge Budge Generating Station, CESC Limited, Jaypee Bela Cement Plant, Aditya Birla Management Corp Pvt. Ltd and Mangalam Cement Ltd.

The presentation by JSW Energy Limited, highlighted the energy saving achieved by reduction of ID Fan Power by introduction of VFD and reduction of CEP’s Power by introduction of VFD which lead to saving of 210 kW and 190 kW respectively. The presentation by Budge Budge Generating Station, CESC Limited, highlighted the energy savings achieved by Speed optimization of Unit-1 & 2 Boiler Feed Pump (BFP) Hydraulic Couplings, which lead to energy saving of approximately 17 MWH per day per unit in full load condition with a payback of 6 months and reduction of Hydraulic oil temperature by 30°C which in turn reduced the cooling water demand for the pump. The presentation by Jaypee Bela Cement Plant, described the benefits achieved by installation of Medium Voltage VFD of 6.6 Kv for 605 kW BFP motor, Fan less Cooling Tower, Energy saver Lighting Transformer and ACC fins Chemical Cleaning. The presentation by Aditya Birla Management Corp Pvt. Ltd explained the root cause analysis and impacts achieved by the CPP Business Intelligence (BI) Tool and simulation methodology, which lead to monetary annual saving of Rs. 300 Lakhs. The presentation by Mangalam Cement Ltd highlighted the energy saving schemes which helped in improving the station heat rate of 2×17.5 MW plant from 3131 kcal/kWh in 2012-13 to 3023 kcal/kWh in 2014-15. Explaining best practice approaches to achieve energy efficiency, a presentation by Senergy Consultants (P) Ltd, explained the benefits of installation of VFD for BFP, PA, SA & ID Fans, Cooling Water System, Air Cooled Condensers and strategies to be adopted for Ash / Coal Handling System .

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Shri A K Asthana with the panelists of the second technical session

The third technical session focused on energy efficiency technologies available for thermal power sector. The session was Chaired by Shri K K Chakarvarti, Expert Consultant, Bureau of Energy Efficiency. This session was planned in a manner that it brought together the technology providers and industry representatives with a view to promote interactions between the two stakeholder groups that can help in facilitating adoption of cleaner technologies. The session had presentations on technologies available for various operating areas viz. solutions to improve upon energy efficiency in compressed air system for thermal power by Atlas Copco (India) Limited and energy efficient motors and distribution transformers by Crompton Greaves.

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Shri K K Chakarvarti with the panelists of third technical session 

Technical sessions was followed by a panel discussion on future strategies to be adopted and need for promoting innovative, new and cutting edge technologies and cross-sectoral best practices. The panelists were the members of Sector Learning Group. The panelist briefly explained the key discussion points of the SLG meeting, which was held a day before the workshop (27th October, 2015) and concluded that KEP can play an important role in facilitating policy discussions around PAT, particularly, as it is moving in to the next cycle where the thermal power industry is expected to have new targets and more plants are expected to come under the ambit of PAT. Panelist also felt that KEP will be in a position to assist the industries to meet the new targets by bringing in international best practices and technologies and also promoting cross sectoral exchange of best practices in thermal power sector and PAT industries having captive power plant.

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SLG members as the Panelists at the Panel discussion

On behalf of Bureau of Energy Efficiency and Institute of Industrial Productivity, Shri K K Chakarvarti  thanked the top management of Dahanu thermal power station, in particular, Shri Rajendra Nandi, Project Director, Sr. Vice President,   Shri Anup Ghosh,  Head O&M, ,  Shri Bhaven Sheth, Energy Manager, Addl. Vice President, Shri Pandurang Jalkote, Asst. Vice President, and the entire team of Dahanu Thermal Power Station for extending their earnest support to the KEP initiative and pulling through an event of this scale. He also thanked Ms. Aishwarya, Shri Ramesh Chandra Shukla, Admin, Fire & Security, and the entire NGH team for managing the accommodation and making the stay of each and every participant comfortable and memorable.

He also expressed his appreciation to the speakers and delegates who participated in the workshop and thanked them for their comments and suggestions and assured that each will be given consideration so that future workshops will be even more of a success.

The workshop had participation from over 230 eminent industry leaders of thermal power stations and other PAT industries.

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Alongside to the Best practice workshop, a visit to Dahanu Thermal Power plant (2×250 MW) was also organized. Delegates of the workshop were taken around the control room, model room, boiler room, coal handling plant and other plant areas. This industrial visit facilitated interaction with the plant personnel on energy efficiency improvement initiatives, maintenance practices, planning process to maintain high level of plant load factor (PLF), efficient operation, and monitoring practices.   At the conclusion of plant visit, delegates thanked the management of Dahanu Thermal Power Station and congratulated the plant management in becoming the first thermal power station in the world to receive  ISO 50001 Energy Management System Certification and wished to have frequent interactions with the power plant engineers.

Untitled

1st WORKSHOP ON "BEST PRACTICES IN ENERGY EFFICIENCY IN THERMAL POWER SECTOR”
PLANT VISIT: 3.30 PM ONWARDS
INAUGURAL SESSION (9.30 AM- 10.00 AM)
Welcome Address, introduction and expectations from the workshop Ms. Ritu Bharadwaj, Senior Program Manager, Institute for Industrial Productivity, India
Special AddressShri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
Inaugural AddressShri Rajendra Nandi, Project Director, Sr. Vice President, Dahanu Thermal Power Station, Reliance Infrastructure Limited
Vote of ThanksShri Bhaven Sheth, Energy Manager, Addl. Vice President, Dahanu Thermal Power Station, Reliance Infrastructure Limited
TEA BREAK (10.00 AM -10.15 AM)
TECHNICAL SESSION I (10.15 AM - 12.00 PM): Best Practice Presentation by Industry Representatives
ChairmanShri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
PAT Scheme Updates for Cycle 1 & 2Shri S Vikash Ranjan, Technical Expert, GIZ
ESCerts Trading Mechanism by Bureau of Energy EfficiencyShri Girja Shankar, Assistant Energy Economist
Best Practices adopted by Dahanu Thermal Power StationShri Kailas Nerkar, Addl. VP, Electrical
Coal Blending and its effects on Boiler Performance by GIZ, IndiaShri A K Asthana, Sr. Technical Expert, GIZ
Best Practices adopted by The Tata Power Company Limited, Trombay Thermal Power StationShri Kapil Mandloi, Lead Engineer- Performance Department

Shri Harshad Pande, Lead Engineer-Office of Chief-Trombay Station

Shri Ramamurthy P, Senior Control Room Engineer- Operation dept.
Best Practices adopted by National Aluminum Company Limited
a) ISO 50001
b) Captive Power Plant
Shri Suresh Chandra Samal, AGM (Elect.)

Shri Arpan Ghosh, DGM (Elect)
Best Practices adopted by UltraTech Cement LtdShri Sreenivasulu. A, Assistant Manager-Thermal Power plant
TECHNICAL SESSION II (12.00 PM - 01.00 PM): Best Practice Presentation by Industry Representatives
ChairmanShri A. K. Asthana, Sr. Technical Expert, GIZ
Best Practices adopted by JSW Energy LimitedShri BV Srinivas, DGM
Best Practices adopted by Budge Budge Generating Station, CESC LimitedShri Kaushik Chaudhuri, Manager (Main Plant Operation)
Best Practices adopted by Jaypee Bela Cement PlantShri S K Garg, General Manager
Best Practices adopted by Aditya Birla Management Corp Pvt. LtdShri Sudarshan Goyal, General Manager - Mech & Group CPPP services

Shri Rashid Shaikh, Dy. General Manager - Group CPPP services
Best Practices adopted by Mangalam Cement Ltd.Shri Subir Kumar Basu, Asst. Vice President
Presentation on Best Practices at Thermal Power Stations by Senergy Consultants (P) LtdShri Ravindra Datar, Director
LUNCH BREAK (01.00 PM- 02.00 PM)
TECHNICAL SESSION- III (02.00 PM - 02.30 PM) : Energy Efficient Technologies for Thermal Power Sector
ChairmanShri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
How to improve upon energy efficiency in compressed air system for thermal power by Atlas CopcoShri Milind Mehta, Business Marketing Manager - Oil Free Air
Energy Efficient Drives by Crompton GreavesShri Tushar Patankar, Senior Regional Manager Business Development - IS (West)

Shri Vivek Sarkar, Assistant General Manager Power Systems (West )
PANEL DISCUSSION (02.30 PM - 03.00 PM) : SLG MEMBERS
Future Strategies to be adopted; need for promoting innovative, new and cutting edge technologies and identify the areas for sharing of Cross- Sectoral Best practices
CONCLUDING REMARKS (03.00 PM - 03.15 PM)
Shri Rajendra Nandi, Project Director, Sr. Vice President, Dahanu Thermal Power Station, Reliance Infrastructure Limited,
Shri Anup Ghosh, Head (O & M), Dahanu Thermal Power Station, Reliance Infrastructure Limited &
Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
TEA BREAK (3.15 PM- 3.30 PM)

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