APCW Tadipatri
APCW Tadipatri
APCW Tadipatri
“The law of conservation of energy tells us we cant get something for nothing,
but we refuse to believe it”
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Integrity Commitment Passion Seamlessness Speed
Contents:
APCW Tadipatri
Presentation Content
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Integrity Commitment Passion Seamlessness Speed
What Went Well Presentation Content
APCW Tadipatri
Achieved first rank in Auxiliary power consumption (APC) amongst UTCL units since Sep-19 and second rank for YTD Dec-19
Achieved Third rank in TPP heat rate across all UTCL units for YTD Dec-19.
Low cost fuel (Dolachar) consumed in TPP of around 5%, Targeted to consume 10% progressively.
Achieved second lowest APC 14.08% in the month of Nov -19 in WHRS -1 (ORC Based). (Previous lowest 13.89%, Nov-2012).
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Integrity Commitment Passion Seamlessness Speed
Environment
APCW Tadipatri
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Integrity Commitment Passion Seamlessness Speed
Key PerformancePresentation
APCW Tadipatri
Content
Indicators (Year Wise)
10.09 2% 80 kcal/kwh
8.99 3147
8.12
3067
3055
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Integrity Commitment Passion Seamlessness Speed
KPI (Benchmarking) Presentation Content
APCW Tadipatri
7.9
2932
t-A nt-
B t-C nt-D nt-
E t-F H -I t- J -L t- A nt-
B t-C nt-D nt-
E t- F H -I t-J -L
n n n n t-G nt- ant an P CW ant t- M nt- N n n n n t-G nt- ant an P CW ant t-M nt-N
a a a a a a a Pl n a a a a Pl n
Pl Pl Pl Pl Pl Pl Pl
a
Pl Pl A Pl Pl
a Pl
a
Pl
a
Pl Pl Pl
a Pl Pl Pl
a
Pl
a Pl A Pl Pl
a Pl
a
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Integrity Commitment Passion Seamlessness Speed
Methodology
APCW Tadipatri
Sustenance
Impact &
Consequences
Monitoring
Implementation
Brainstorming
Comparison
Energy & Gaps
Mapping Identification
DMAIC Approach
Process Capability Report for Heat Rate (kcal/kwh) FY 18 Process Capability Report for Auxiliary % FY 18
USL USL
Process Data Overall Process Data Overall
LSL * Within LSL * Within
Target * Target *
USL 2900 Overall Capability USL 8 Overall Capability
Sample Mean 3076.8 Pp * Sample Mean 9.28946 Pp *
Sample N 201 PPL * Sample N 209 PPL *
StDev(Overall) 41.7755 PPU -1.41 StDev(Overall) 0.515257 PPU -0.83
StDev(Within) 31.7802 Ppk -1.41 StDev(Within) 0.419228 Ppk -0.83
Cpm * Cpm *
Potential (Within) Capability Potential (Within) Capability
Cp * Cp *
CPL * CPL *
CPU -1.85 CPU -1.03
Cpk -1.85 Cpk -1.03
2920 2960 3000 3040 3080 3120 3160 8.0 8.4 8.8 9.2 9.6 10.0 10.4
Performance Performance
Observed Expected Overall Expected Within Observed Expected Overall Expected Within
PPM < LSL * * * PPM < LSL * * *
PPM > USL 1000000.00 999988.42 999999.99 PPM > USL 1000000.00 993835.01 998950.29
PPM Total 1000000.00 999988.42 999999.99 PPM Total 1000000.00 993835.01 998950.29
Conclusion: Conclusion:
1. Ppk value is -1.41 which should be greater than 1 for a good process. 1. Ppk value is -0.83 which should be greater than 1 for a good process.
2. Standard deviation is also very high 41.78 2. Standard deviation is also very high 0.52
Unit Unit
1 2 3 4 1 2 3 4
Standard Deviation 56 61 57 60 Standard Deviation 1.00 1.03 0.81 0.70
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Integrity Commitment Passion Seamlessness Speed
Pareto Analysis (Auxiliary power consumption)
APCW Tadipatri
5% 4.08% 20%
3.41% 3.17% 2.72% 2.39% 2.30%
1.21% 0.69%
0% 0%
Boiler Fans BFP Compressor ACC fan Misc AC & Vent ESP ACWP CEP CHP Lighting WTP
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Integrity Commitment Passion Seamlessness Speed
Best in UTCL Vs APCW
APCW Tadipatri
FY 17-18
Auxiliary Heat Rate
Best in Best in
S. No. Equipment UOM APCW Variance S. No. Heat balance summary UOM APCW Variance
UTCL UTCL
1 BFP 1 Turbine Heat Rate 2737 2641 +96
28.97 24.02 +4.95
2 Boiler Efficiency Kcal/kwh 89.72 87.83 + 1.89
2 Boiler fans 30.40 28.64 +1.75
10 ACC fan Plant Heat Rate 3050 3007 +43
11.11 10.79 +0.32
11 Compressors %
11.94 2.91 +9.02
14 Miscellaneous 32.80 11.77 +21.03
Auxiliary Power Consumption
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Integrity Commitment Passion Seamlessness Speed
Presentation
Project Identification
APCW Tadipatri
& Selection Content
FY 18-19
FY 19-20
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Integrity Commitment Passion Seamlessness Speed
Boiler Fans
APCW Tadipatri
30.39
FY 18 FY 19 FY 20 YTD Dec
28.96
FY 18 FY 19 FY 20 YTD Dec
11.93
In addition to ESP hoppers , probe installed in conveying
7.25 vessel also. By this modification avoided empty conveying
FY 20 YTD Dec
4.84 cycles.
Sp. power- Single compressor used for both instrument and service air
4.84 Kwh/MWh
(5 &3.5 Kg/cm²).
Service air pressure reduced up to 3.2 kg/cm²
FY 18 FY 19 FY 20 YTD Dec
11.1
FY 18 FY 19 FY 20 YTD Dec
FY 18 Major Projects:
Sp. power-
32.796 KWh/MWh ACW pressure reduced to 2.5 Kg/cm².
CHP throughput increased from 130 to 200 TPH.
SSF pump completely stopped by changing SSF supply to
ACW discharge.
Shut-off valve provided in Unit-3 & Unit-4 cyclone static
FY 19 cooler to isolate ACW water in case of not running of cyclone
Sp. power- static cooler.
20.77KWh/MWh Lightings power optimised by taking control on DCS system.
WTP power optimized by running two parallel stream of RO
plant with single MGF feed water pump.
ESP Hoppers fluidising pads air optimised by providing SOV
32.796 FY 20 YTD Dec and timer function
Sp. power- single pump for two streams of WTP.
14.323 KWh/MWh CEP logic through CRT level controller, by this Control valve
20.770
DP eliminated.
14.323
FY 18 FY 19 FY 20 YTD Dec
FY 18 Major Projects:
Heat Rate
3199 Kcal/Kwh TG -3 Major overhauling done .
TG- 4 Major overhauling done.
Helium leak test of vacuum circuit of all units
TG -3 wet washing done.
TG -4 wet washing done.
False air minimised by arresting APH tube leakages.
FY 19
Safety valves overhauled to avoid passing.
Heat Rate
Steam dumping minimised.
3055 Kcal/Kwh
Auxiliary steam taken from TG extraction.
Air egress arrested in air side of ACC bundles
3199
FY 20 YTD Dec
3055
3067 Heat Rate
3067 Kcal/Kwh
FY 18 FY 19 FY 20 YTD Dec
20.78
14.32
11.11 11.94
FY 18 FY 19 FY 20 YTD Dec
% Saving
59.41 56.33
53.40
8.99 7.38
APCW (Y-o-Y):
Auxiliary (%) Heat Rate (kcal/kwh)
3147
10.09
8.99 2% 80 kcal/kwh
8.12
3067
3055
2nd
3rd
FY 21 Target
3067
8.12
7.85
3029
FY 20 FY 21 Target
FY 20 FY 21 Target
Auxiliary
Sr. Project Description OPEX/CAPEX
No.
1 Bed ash cooler auto operation OPEX
2 Further reduction of ACW pressure 1.7 kg/cm2 OPEX
3 Installation of separate IFC for conveying systems OPEX
4 Booster auxiliary cooling water pump for compressor and SWAS CAPEX
5 Installation VAM and reduce chillers operation (Based on utilization of steam from Turbine extraction) CAPEX
6 Zero loss Drain-traps in compressed air system in place of Manual & Timer based. OPEX
7 MOP & AOP power comparison and replacement with efficient pump CAPEX
8 Phase-2 Boilers Conveying vessel capacity enhancement by replacing it with Phase-1 Boilers OPEX
9 Ph-1 BFP dummied stage to be removed in VFD installed pumps- will impact in BFP power consumption OPEX
10 L91BC4 extension up to Boiler-1 CAPEX
11 Zero DP PAD for ACC building CAPEX
Heat Rate
Sr. No. Project Description OPEX/CAPEX
1 TA Nozzle reduction from 96 mm to 80 mm to increase combustion efficiency by 6.42% OPEX
2 Reduction in make-up water from present 2% to 0.5 ~ 0.7 %. OPEX
3 Trial of Fuel additives to enhance heat value. OPEX
4 TG-1 & 2 SH spray tapping modification from BFP discharge to FRS inlet OPEX
5 Changing the DP in Boiler Draft system to bring ID Fan Loading at lower side, leads to savings in APC and avoids air ingress in OPEX
boiler.
6 Choking of ACC Bundles in ACC 1 & 3. OPEX
7 ACC tube bundle replacement( TG-1 to TG-2) CAPEX
8 Routing of PA Air to syphon through static cooler thus elimination of ACW water in static cooler OPEX
Thanks
Thanks