UltraTech CementPresentation

Limited -APCW Content

APCW Tadipatri

“The law of conservation of energy tells us we cant get something for nothing,
but we refuse to believe it”

Journey of Past 21 Months (FY 19 & FY 20 YTD Dec)

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Integrity Commitment Passion Seamlessness Speed
 Contents:
APCW Tadipatri
Presentation Content

 What Went Well

 Environment
 Key Performance Indicators
 Benchmarking
 Methodology
 Process Capability Analysis of KPI’s
 Pareto analysis (Identification of focus areas)
 Project Identification & Selection
 Some Key Projects in Detail
 Results
 Challenges
 Way Forward

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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 ever lowest TPP Aux. Power -7.10% for December-19.

 Achieved Third rank in TPP heat rate across all UTCL units for YTD Dec-19.

 New WHRS Project commissioned having capacity 12.40 MW.

 Low cost fuel (Dolachar) consumed in TPP of around 5%, Targeted to consume 10% progressively.

 Achieved lowest APC 2.55% in the month of Dec-19 in WHRS -2.

 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

New Emisión Standard & Compliance Major Projects:

60
50
50
40  ESP is designed for less than 50 mg/Nm³ with one field out condition.
40
30
 ESP Operation in IE mode.
20
10
0  Individual SOx analyser installed in Boilers
PM mg/Nm3
 Raw meal sizing 90 microns used to control the SOx .
610 600
600  Automation of rawmeal screw feeder to maintain SOx with in limits.
590
580
570  Utilization of existing recirculation bin to feed raw meal in the event of outage of rawmeal
560
560 screw feeder.
550
540  Compliances of NOx within norms by controlling:
Sox mg/Nm3
Excess oxygen
Excess rawmeal feeding
400 Maintaining below screen temperature
300
300 230
200
100
0
NOx mg/Nm3
APPCB limit Emission

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Integrity Commitment Passion Seamlessness Speed
 Key PerformancePresentation
APCW Tadipatri
Content
Indicators (Year Wise)

Auxiliary Power Consumption ( % ) Heat Rate (Kcal/Kwh)

10.09 2% 80 kcal/kwh
8.99 3147
8.12

3067
3055

FY 18 (Baseline) FY 19 FY 20 YTD Dec FY 18 (Baseline) FY 19 FY 20 YTD Dec

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Integrity Commitment Passion Seamlessness Speed
KPI (Benchmarking) Presentation Content
APCW Tadipatri

Across Indian Cement Industry:

7.9

2932

Across UltraTech Cement:

Baseline : FY 17-18
Auxiliary (%) Heat Rate (kcal/Kwh)
11th 11.57 11.87 12.02
3386
11th 3320
9.62 9.78 9.79 9.82 10.09 3252
8.92 9.01 9.18 9.35 9.58
8.39 3113 3128 3129 3137 3147
3075 3102
3018 3030
2946
2869

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

Define Measure Approach Implement Control

DMAIC Approach

Integrity Commitment Passion Seamlessness Speed

 Process capability analysis for Auxiliary & Heat Rate:
APCW Tadipatri

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

Identification of Focus areas

Mostly Preferred Area Less Preferred Area
1. Boiler Fans
35% 120% 2. Boiler Feed Pump
30.23% 3. Compressors
30% 28.61% 98.10% 99.31% 100.00% 100%
90.69% 93.41%
95.80% 4. ACC Fans
87.53%
25% 80.03%
84.11% 5. Miscellaneous area
80%
70.81%
20%
58.84% 60%
15%
11.97%
40%
10% 9.22%

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

* Data’s taken are representative of one month only

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Integrity Commitment Passion Seamlessness Speed
 Presentation
Project Identification
APCW Tadipatri
& Selection Content

FY 18-19

Auxiliary Heat Rate

Project identified Selected to move on Dropped Project identified Selected to move on Dropped
10 8 1 1 9 8 1 0 Microsoft Excel
Worksheet
OPEX CAPEX OPEX CAPEX

FY 19-20

Auxiliary Heat Rate

Project identified Selected to move on Dropped Project identified Selected to move on Dropped
28 28 0 0 5 5 0 0 Microsoft Excel
Worksheet
OPEX CAPEX OPEX CAPEX

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Integrity Commitment Passion Seamlessness Speed
 Boiler Fans
APCW Tadipatri

 PA fan flow Maintained 20 to 18.5 Kg/s

FY 18
 SA fan speed regulating manually with respect to
Sp. power-
Oxygen
30.39 Kwh/MWh
 Boiler Draft maintained -30 mmwc

 Reduce PA fan flow from 20 to 17.5 Kg/s

FY 19  APH leakages arrested.
Sp. power-  Auto regulation of SA fan speed with respect to Oxygen.
28.97 Kwh/MWh  Boiler Draft reduced to -20 mmwc

30.39

 Reduce PA fan flow from 17.5 to 15 Kg/s

FY 20 YTD Dec  Advanced process Controller taken into service.
28.97 Sp. power-  IGV removed in Boiler fans.
28.15 Kwh/MWh
28.15

FY 18 FY 19 FY 20 YTD Dec

Integrity Commitment Passion Seamlessness Speed

 Boiler Feed Pump
APCW Tadipatri

 Fixed BFP discharge Pressure

FY 18  Fixed Differential pressure set point
Sp. power-
28.96 Kwh/MWh

 Variable Differential pressure set point (8-12 Kg/cm²)

FY 19  Single BFP operation whenever load is less than 32 MW to
Sp. power-
operate Two Boilers
26.65 Kwh/MWh

28.96

FY 20 YTD Dec  Drum level set point to BFP by avoiding Control

Sp. power- valve pressure loss
26.65 26.36 Kwh/MWh  Single BFP operation whenever load is less than 44
26.36
MW to operate Two Boilers

FY 18 FY 19 FY 20 YTD Dec

Integrity Commitment Passion Seamlessness Speed

 Compressor
APCW Tadipatri

 Conveying systems Operation in Probe mode.

FY 18
 Minimum conveying time from 40 to 20 sec.
Sp. power-
 Instrument air pressure maintained 6 Kg/cm²
11.93 Kwh/MWh
 Service air Pressure maintained 5 Kg/cm²

 Air leakages arrested.

FY 19  Conveying cycles optimised.
Sp. power-  Minimum conveying time reduced up to 10 Sec.
7.25 Kwh/MWh  Instrument air pressure maintained 5.5 Kg/cm²
 Service air Pressure reduced to 4.5 Kg/cm²

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

Integrity Commitment Passion Seamlessness Speed

 ACC Fans
APCW Tadipatri

FY 18  Water storage under ACC fans.

Sp. power-  Sealing of gaps to avoid air losses .
11.10 Kwh/MWh

 Helium leak test carried out and arrested identified leakages.

FY 19  Periodic bundle cleaning carried out with water.
Sp. power-  Periodic inspection of Ejector nozzles ,traps and Bundles.
6.44 Kwh/MWh  Steam dumping reduced by close monitoring.

11.1

 ACC fan blades replaced with energy efficient

FY 20 YTD Dec
6.44 blades.
Sp. power-
5.17  ACC bundles foam cleaning carried out.
5.17 Kwh/MWh
 Feed forward logic provided to dump to avoid
excess steam dumping.

FY 18 FY 19 FY 20 YTD Dec

Integrity Commitment Passion Seamlessness Speed

 Miscellaneous
APCW Tadipatri

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

Integrity Commitment Passion Seamlessness Speed

 Heat Rate
APCW Tadipatri

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

Integrity Commitment Passion Seamlessness Speed

 Specific Energy consumption of Equipment
APCW Tadipatri

If you cannot do great things,

Sp. Energy consumption Significant Resultant Area
(KWh/MWh) do small things in a great way.
32.80
30.40
28.97 28.9828.15
26.6526.36

20.78

14.32
11.11 11.94

6.44 5.18 7.25

4.85

BFP Boiler Fans ACC fans Compressor Miscellaneous

FY 18 FY 19 FY 20 YTD Dec
% Saving

59.41 56.33
53.40

8.99 7.38

BFP Boiler Fans ACC fans Compressor Miscellaneous

Integrity Commitment Passion Seamlessness Speed

 Digitalization initiatives/Technological innovations
APCW Tadipatri

• Implementation of Advance process control for TPP Phase -2 resulted in

Savings in heat rate by 8 kcal/kwh & also reduced process parameters variation.

• DCS Based Energy monitoring system resulted in

Real time monitoring of deviation in Auxiliary of individual drives

• Synchronization of all protection relays standalone controller with GPS

Strengthened the troubleshooting process & improved the reliability.

• System developed for automatic SOX control in Phase-2 Boilers

Optimized the sulphur absorbent consumption at the same time maintaining norms.

Integrity Commitment Passion Seamlessness Speed

 Results
APCW Tadipatri

APCW (Y-o-Y):
Auxiliary (%) Heat Rate (kcal/kwh)
3147
10.09
8.99 2% 80 kcal/kwh
8.12

3067
3055

FY 18 FY 19 FY 20 YTD Dec FY 18 FY 19 FY 20 YTD Dec

Across UltraTech Cement: (FY 20 YTD Dec)

2nd
3rd

Integrity Commitment Passion Seamlessness Speed

 Key Challenges
APCW Tadipatri

Sr. No. Project

1 Reduced PLF due to commissioning of new WHRS Project having capacity 12.4 MW & increased renewable
power obligation.
2 Unit 1 & 2 remains Idle due to no demand.
3 Ban on pet coke.
4 Year average High ambient temperature 31.1 Deg. C.
5 Reduction of unburnt carbon less than 4%.
6 Single fan operation in Phase-1 Boilers (Equipped with 2*60% Fans) at low loads.

Integrity Commitment Passion Seamlessness Speed

 Way forward
APCW Tadipatri

FY 21 Target

Auxiliary Heat Rate

Project identified Selected to move on Project identified Selected to move on
11 6 5 8 7 1
OPEX CAPEX OPEX CAPEX

3067

8.12
7.85

3029

FY 20 FY 21 Target
FY 20 FY 21 Target

Integrity Commitment Passion Seamlessness Speed

 Way forward (Activities)
APCW Tadipatri

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

Integrity Commitment Passion Seamlessness Speed

 Way forward (Activities)
APCW Tadipatri

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

Integrity Commitment Passion Seamlessness Speed

APCW Tadipatri

Thanks

Thanks

Integrity Commitment Passion Seamlessness Speed