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INNOVATION JSW ENERGY BOLT | ISSUE 1

same. Some of the major areas identified drastically which resulted in reduction of

were Fan Power Consumption, LHS Power, Auxiliary Power consumption by 12.8 MW JSWEL, Vijayanagar
ESP Power, LT drive’s, Compressor (1.18%). It resulted in increase in EBIDTA

Running Hr. by Rs. 18.72 Cr. /yr. Optimization Of AHP & ESP Aux Power (300 Mw)
A major chunk of excess power
How the team felt on the problem being
consumption was seen in Fan Power. resolved?
After further study & analysis it was How and Why was the avoid ash solidification. hours were studied in detail

observed that the APH tubes were It gave the Team immense pleasure on problem identified? These heaters are controlled and the decision was taken
prematurely. The normal schedule for overcoming the problem & indulging Ash Handling Plant (AHP) with primary sensors to stop the compressors for

replacement of APH tube was triennial. confidence to tackle such problems. and ESP was identified for installed at last row of ESP 6 hours in a day without
Since the tubes were failing prematurely, Any specific aspects which you may like power consumption hoppers. Since temperature affecting ash conveying

we started to inspect tube leakages in to mention? optimisation as both the of last row normally remains cycles and also ensuring
side APH during opportunity and plug areas had good potential for low, all the heaters used to hoppers are evacuated.
Also, we would like to extend our be ON along with last row
them. But this practice was also not energy savings. Continuous ESP : Since last row sensors
Gratitude to the Top Management at which resulted in high
sustainable as tubes were losing the monitoring and analysis on were used for controlling all
RWPL for extending their support both power consumption.
strength due to corrosion, the fan power power consumption pattern hopper heaters, it was
technically as well as financially from Apart from that, the modes
consumption was reducing initially but revealed significant energy decided to install additional
Idea Initiation till project execution. of ESP fields operation set
was increasing again over a period. As saving option in ash sensors at every alternate
Plugging was a temporary solution and conveying air compressors were to keep the fields in hopper to have fine control

was not lasting for longer period. Team Members and ESP fields and continuous charged on heaters. Further to
condition, which does not
How was the problem solved? Hopper heaters. reduce ESP power
Manoj Kumar Roy require for the ash being consumption, Field mode of

It was decided to replace the Tube bundle C.V.R. Reddy Ash Handling Plant : As the generated in the operation was changed

of APH Biennially with higher thickness of Jevesh Srivastava ash conveying system is present scenario. along with duty ratio to have
tubes. But the time duration for Mustakhusen Malek designed to operate at How was the problem intermittent charging
replacement was a major challenge. Atul Joshi dense phase mode, it was solved? against continuous

Initially it took 25 days for replacement of observed that operating charging in earlier mode.

APH tubes. It was not acceptable to cycles were run with lean AHP : Ash handling
management for keeping Unit out of Bar phase mode, which in turn compressors operation
for long duration. So,another challenge was consuming compressor

was to reduce the tube replacement time. power more than the

So, after optimization of the tube required.
replacement activities, it got reduced and Electrostatic precipitator
now we can replace APH tubes in 15 days. (ESP) : Hoppers which

Impact of solution to the business? collect ash is provided with
electric heaters for keeping
After APH tube replacement, the fan
hoppers in hot condition
power consumption got reduced
and ash in fluidising state to

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