Evaluating performance

Smart and efficient operations for sustainable and reliable power generation

Our pursuit of operational excellence combines efficient fuel sourcing techniques, a customer centric approach, and reliability. SEIL’s operations maintained an average Plant Load Factor (PLF) of 81.11%, producing PAT-positive results. Among Indian Independent Power Producers, SEIL continues to be one of the most dependable power providers with an annual availability of 92.79% on a complex basis. We developed an extensive integrated sheet to facilitate collaborative working between the coal and operations teams.

Domestic Coal Eligibility:

As a coastal power plant, SEIL was previously eligible for domestic coal up to 70% of the requirement. This led to higher fuel costs, resulting in lower offtake/back down under the PPA. In April 2024, the eligibility of coal supply against the AP PPA 625MW increased from 70% to 100%. This change allows SEIL to reduce backdown under the PPA due to improvement in merit order.

Coal Sourcing:

a. SEIL secured the commodity exposure of PPAs through annual contracts for the non-escalable energy components, thereby assuring sustainable returns.

b. As part of its coal sourcing strategy, SEIL procured off-specs coal up to ~30% (1.57 million tons) against the last 3 years’ average of ~26% (2.1 million tons) with an SRMC saving of 0.38 INR/ kWh, resulting in overall savings of INR 1016 million during the year. This was achieved through extensive coal market analysis and collaboration with plant operations.

Coal Operations & Commercial updates:

a. SEIL achieved Domestic Coal Supply at 96% materialisation of the eligibility, against the average of 88% for the last three years. This resulted in the substitution of high cost imported coal with domestic supplies.

b. Coal inventory levels were managed at optimised levels amid multiple concomitant challenges.

Effective and regular cross functional team coordination within the commercial department and other departments such as finance, risk, and operations have helped achieve targets.

  • We leveraged strong market intelligence and secured multiple short-term power sale contracts at attractive tariffs, significantly improving margins and cash flows.
  • The implementation of GNA regulations from 1st October 2023 has resulted in a reduction in transmission charge obligations and better bus bar tariff realisation.
  • Domestic coal eligibility has been enhanced from 70% to 100% for both plants.
  • Monthly instalments of old outstanding payments and payments against monthly bills are being paid in line with MoP LPS Rules 2022, which has helped improve cash flow.
  • We have secured domestic coal under various auctions under the Shakti policy.

Capital Overhauling
of Project 1, Unit – 1

Total manpower engaged
in COH activities:

2011

Total manhours:

526,028

Safe manhours:

526,028

As part of the planned maintenance activity of overhauling the asset, the capital overhauling of Unit 1 of Project 1 was undertaken on 16 November 2023 and successfully completed on 23 December 2023. This herculean task was safely completed in a record 38 days with meticulous planning and effective execution. During the capital overhauling, the main Turbine and Generator were disassembled and inspected.

Flow path clearance checks were done, and extensive maintenance works were carried out in the Boiler, AHP, and the rest of the plant area to ensure the reliability and improved efficiency of the unit. Generally, the capital overhauling exercise is conducted once every 5 years. The previous capital overhauling was done between October 2018 and January 2019. As a responsible and reliable power supplier, SEIL undertakes all maintenance activities as per planned schedules to safeguard the assets and ensure the supply of quality power.

Capital Overhauling
of Project 1, Unit – 1

Total manpower engaged
in COH activities:

2011

Total manhours:

526,028

Safe manhours:

526,028

As part of the planned maintenance activity of overhauling the asset, the capital overhauling of Unit 1 of Project 1 was undertaken on 16 November 2023 and successfully completed on 23 December 2023. This herculean task was safely completed in a record 38 days with meticulous planning and effective execution. During the capital overhauling, the main Turbine and Generator were disassembled and inspected.

Flow path clearance checks were done, and extensive maintenance works were carried out in the Boiler, AHP, and the rest of the plant area to ensure the reliability and improved efficiency of the unit. Generally, the capital overhauling exercise is conducted once every 5 years. The previous capital overhauling was done between October 2018 and January 2019. As a responsible and reliable power supplier, SEIL undertakes all maintenance activities as per planned schedules to safeguard the assets and ensure the supply of quality power.

5S Journey

5S is a systematic way of organising workplaces by eliminating waste, improving flow, and reducing the number of processes where possible. In August 2021, SEIL management decided to implement the 5S Workplace Management concept to make the workplace safe and efficient in the long run. SEIL tied up with the Quality Circle Forum of India (QCFI), the pioneer NGO for the introduction, training, handholding, and conceptualisation of 5S.

After several stages of the continuous process, including the formation of zone-wise committees, a steering committee, and a facilitation committee, and conducting regular self-audits, documentations, and management audits, the 5S concept was well adopted throughout the organisation. In October 2022, QCFI conducted the final certification audit and awarded 5S Certification to SEIL with scores eligible for applying for 5S Certification from the Union of Japanese Scientists and Engineers (JUSE).

In November 2023, SEIL was awarded 5S Certification by JUSE during the National Convention of Quality Circles held in Aurangabad. The implementation of 5S at SEIL paved the way for the establishment of an overall cultural change and discipline. Recently, SEIL teams participated in chapter-level and national-level conventions held by QCFI and brought laurels by winning Par Excellence Awards. SEIL is moving forward to take the workplace to the next level with Kaizens and small group activities to strengthen and sustain the 5S standards.

5S Journey

5S is a systematic way of organising workplaces by eliminating waste, improving flow, and reducing the number of processes where possible. In August 2021, SEIL management decided to implement the 5S Workplace Management concept to make the workplace safe and efficient in the long run. SEIL tied up with the Quality Circle Forum of India (QCFI), the pioneer NGO for the introduction, training, handholding, and conceptualisation of 5S.

After several stages of the continuous process, including the formation of zone-wise committees, a steering committee, and a facilitation committee, and conducting regular self-audits, documentations, and management audits, the 5S concept was well adopted throughout the organisation. In October 2022, QCFI conducted the final certification audit and awarded 5S Certification to SEIL with scores eligible for applying for 5S Certification from the Union of Japanese Scientists and Engineers (JUSE).

In November 2023, SEIL was awarded 5S Certification by JUSE during the National Convention of Quality Circles held in Aurangabad. The implementation of 5S at SEIL paved the way for the establishment of an overall cultural change and discipline. Recently, SEIL teams participated in chapter-level and national-level conventions held by QCFI and brought laurels by winning Par Excellence Awards. SEIL is moving forward to take the workplace to the next level with Kaizens and small group activities to strengthen and sustain the 5S standards.

Energy Saving Certificates:

Under National Action Plan for Climate Change (NAPCC) , the National Mission for Enhanced Energy Efficiency (NMEEE) was launched. To encourage energy saving initiatives in large energy intensive sectors, like power sector Perform, Achieve and Trade (PAT) scheme was launched and was assigned to Bureau of Energy Efficiency (BEE).

  • SEIL P1 was identified as designated consumers and given with energy saving targets to meet in subsequent years.
  • SEIL P1 surpassed energy saving targets and received 22,289 number of energy saving certificates(ESCerts).
  • Minimum trading price for is fixed at 2165 INR (10% of 1 MTOE price) by MoP, considering it total value of ESCerts available with SEIL is 48.2 Mn INR.

Energy Saving Certificates:

Under National Action Plan for Climate Change (NAPCC) , the National Mission for Enhanced Energy Efficiency (NMEEE) was launched. To encourage energy saving initiatives in large energy intensive sectors, like power sector Perform, Achieve and Trade (PAT) scheme was launched and was assigned to Bureau of Energy Efficiency (BEE).

  • SEIL P1 was identified as designated consumers and given with energy saving targets to meet in subsequent years.
  • SEIL P1 surpassed energy saving targets and received 22,289 number of energy saving certificates(ESCerts).
  • Minimum trading price for is fixed at 2165 INR (10% of 1 MTOE price) by MoP, considering it total value of ESCerts available with SEIL is 48.2 Mn INR.

Key Updates:

  • In FY 23-24, effective planning and optimisation within operating constraints has helped to achieve better DS.
  • Effective and regular cross functional team co-ordinations within commercial department and other departments such as finance, Risk and operations has helped achieve targets for the FY.
  • Leveraged on strong market intelligence and secured multiple Short-Term power sale contracts at attractive tariff which significantly improved margins and cashflows.
  • Implementation of GNA regulations from 1st October
  • 2023 has resulted in reduction in transmission charges obligations and better bus bar tariff realisation.
  • Domestic coal eligibility has enhanced from 70% to 100% for both plants.
  • Monthly instalments of old outstanding and payments against monthly bills are getting paid in line with MoP LPS Rules 2022, this helped in better cash flow.
  • SEIL secured Domestic coal under various auctions under Shakti policy.