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ODISHA
INDIA
PLANT
SITE
CPP :
IPP :
Optimized need based soot-blowing resulting in flue gas exhaust temperature from
141C to 137C and reduction in super-heater spray by 2% that is 8 T/hrs.
Annual saving- 5.82 MTOE
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
Running of Dry-Ash conveying system in level mode from timer mode resulting in
stoppage of 1 compressor.
Annual saving- 188.31 MTOE
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
Very hot startup time reduced to 1hr 35min to 1hr 10min 0.50
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
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
BEFORE AFTER
4/29/2015 KEP WORKSHOP
Aluminium & Power, Jharsuguda
BEFORE AFTER
4/29/2015 KEP WORKSHOP
Aluminium & Power, Jharsuguda
BEFORE
Ultra-filtration System
4/29/2015 KEP WORKSHOP
Aluminium & Power, Jharsuguda
BEFORE AFTER
4/29/2015 KEP WORKSHOP
Aluminium & Power, Jharsuguda
Earlier Turbine hall & compressors house consisted of 72 & 16 electrics fans
respectively.
Designed ESP had 5 fields Last 2 fields replaced with Bag filter
Ammonia dozing was in process Ammonia dozing stopped
Avg. SPM was more than 100 Existing Ash Conveying system is
mg/Nm3 modified
Avg. SPM < 30mg/Nm3
BEFORE
BEFORE
AFTER
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
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
BEFORE
AFTER
DAILY MONITORING
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.
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
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.
CPP :
2482.82 IPP : 10595
MTOE MTOE
Total
Savings:
13077
MTOE
6th India
Power Award
2013
THANK YOU