Project name : LDO Optimization Through Orifice Valve & Atomizer
By : Atif Eqbal
Company : Tata Power
Location : Tata Power, Jojobera, Jamshedpur
Valuable contributors : Sarthak Patnaik, Ananta Behera, Usha Agrawal, Jaigopal Soni
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"This innovation at Tata Power pertains to the optimisation of light diesel oil consumption through the application of the orifice valve and modified nozzle tip in the oil guns of steam generators," says Atif Eqbal
Oil guns using light diesel oil (LDO) are used in coal-fired boilers for initiating combustion in the boiler and are then taken over by pulverised coal for creating a stable fire ball. Oil guns are often used during monsoon for coal mill blockage, breakdowns and other emergency situations for supporting the fire ball to make the unit stable and give uninterrupted power supply to the customers.
The trigger
The trigger for this innovation came as a remark (for higher oil consumption in boiler) from a customer. Also LDO being a very costly raw material for the division and one of the most vital natural resources of the nation inspired the team to innovate the orifice valve and modified nozzle tip. This zeal to give a better performance to its customers made the team go back to the grassroots level to have better understanding of the fuel-firing system inside the boiler. After opening of LONV in the oil line, a considerable quantity of oil flowed through the pipe to the oil gun which, in turn, got atomised and created combustion inside the boiler. But in the process, a high quantity of LDO was consumed, which was to be borne by the customers.
Ideation and improvement
The Sankalp (ideation and improvement) team of Tata Power, Jojobera, during their project "optimisation of LDO" innovated the orifice valve and modified nozzle tip to be fitted in the oil gun for regulating LDO flow with better flame Intensity. It resulted in a total reduction of 73 percent of LDO consumption and an annualised saving of INR 14.3 crore / year. This innovation resulted in cost-effective generation of power supply. It would further result in preserving the nation's natural resources and decrease the company's carbon footprint.
More for less
Previously, the flame intensity obtained was 60 percent. After installation of innovations, the consumption through 1 oil gun decreased. Now the flame intensity obtained is 70 percent. The design and application of orifice valve in 120MW boiler is a unique innovation for regulating the flow of LDO. The innovation improved the performance and controlled extra cost levied upon customers. It would preserve India's vital raw materials and in the process reduce the emission of greenhouse gases.
Economic benefit
The quantum of economic benefit realized from the innovation till the time of writing this article was INR 4 crore.