22-09-2019
20th National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2019” 16th to 18th SEPT, 2019: HICC, HYDERABAD
NTPC Limited
Presented By:
Manoj K Jha (AGM-EEMG)[EA-5670] Sathish Chandra (Sr.Mgr- BMD) [EA-28806] Ashwin Raja (Mgr-EEMG)
‘TO BE THE WORLD’S LEADING POWER COMPANY, ENERGIZING INDIA’S GROWTH’
NTPC Ramagundam
o NTPC & RSTPS Profile o Production Process o SEC (heat rate and APC ) trend o Energy Saving Projects (2016- 2019) o Innovative Projects o Renewable Energy Use o Utilization of Waste Material at Plant and Township o GHG & Green Supply Chain o Heat Rate, APC improvements - Monitoring and Mitigations o Awards & Accolades o Conclusion
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
1 22-09-2019
NTPC Ltd. & RAMAGUNDAM (RSTPS) Profile
NTPC Ltd. Pan India presence
th rd 12 Largest & 3 Largest coal based Power Generator in the world
NTPC - Ramagundam Vision “Corporate Plan 2032”. • 30 GW Solar by 2032 “To be a World Class Power Station • 30% No-fossil based capacity by 2032. actualizing NTPC Vision”
2600MW (3x200 + 3x500 + 1x500 ) + 10 MW Solar
Today 2032 TeSTTP Planned 800 MWx5 55.78 GW 130 GW Under Construction : 2 Units of 1600 MW
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
NTPC Ramagundam Profile
Power Generation Process
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
2 22-09-2019
Energy Consumption Overview
Type of Energy Used HR (Kcal/Kwh) MU Million Kcal Toe
Thermal Energy 2361 18547.9 43791591.9 4.37915919
Electrical Energy consumption - 1154.82 719.45286 0.000071945
Over all Energy Consp - - - 4.379231135
% of Thermal and Electrical Energy Use in 2018-19
99.99% 0.0016%
National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2019
RSTPS Performance for Past 4 Years
100 Availability Factor Vs PLF 94 95 93 92 90 90 89 86 83 85 81 80 75 2015-16 2016-17 2017-18 2018-19
100000 10.00 7.66 8.06 80000 8.00 5.98 77124 60000 4.96 6.00 56767 RE Injection 40000 48666 4.00 Backing Down 20000 33848 2.00 0 0.00 2015-16 2016-17 2017-18 2018-19
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
3 22-09-2019
Sp. Energy Consumption in last 3 years
2600 NET Heat Rate Vs Normative HR
2548 2548 2548 2548 2550 2516 2514 2505 2501 2500
2450
2015-16 2016-17 2017-18 PAT Audited2018-19* Net Heat Rate
Thermal Eff. Over the Years 36.8 36.6 36.6 36.6 36.4 36.4 36.5 36.4 36.3 36.3 36.3 36.3 36.2 36.0
35.8
2018-19 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
Specific Power Consumption % (100%): 6.23%
NTPC Ramagundam PAT Cycles Performance Base line NHR & YEAR TARGET HR AUDITED NHR No of Ecerts Received 2012-13 PAT CYCLE I 2013-14 2517.3 (Avg of 2007-2010) 2014-15 2500.3 2483.69 26946
2015-16 2507.64 PAT CYCLE II2017-18 2018-19 2495 2472.5 45476
50000 2500 45000 2495 40000 2483.69 45476 2490 35000 2485 30000 2480 25000 2472.5 20000 26946 2475 Ecerts 15000 2470 10000 2465 NHR 5000 2460 0 2455 PAT Cycle I Audited PAT Cycle II Audited (2014-15) (2018-19)
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
4 22-09-2019
Specific Power Consumption % (100%): 6.23%
CEP:5.46 ESP:3 Mills:8.28 CHP:1.91 ECW: 1.75 Comprs: 1.95 BFP: 10.86 AHP: 1.73 CC Pumps: 1.64
CW Pumps:12.86 20.69 Others: 9.22
Lighting : 6.15 Draft :35.2
Almost 94% of Total Aux Power Consumptions are Remote monitored through In- house developed PB Display tools for improvements recommendations
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
NTPC Ramagundam
APC monitoring through PI/SEED/OLEMS
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
5 22-09-2019
Information on Competitors, National & Global benchmark
NHR: Internal benchmarking of NTPC Ramagundam
2630 2620 2616 2580 2550 2591 2514 2546 2530 2544 2505 2480 2501 Ramagundam Korba Singrauli 2016-17 2017-18 2018-19 NTPC Ramagundam has been BEST performing station amongst its internal peers over the years.
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
Roadmap & Targets For Heat rate
Road Map for Heat Rate Improvement with Major Works Expected UHR Station HR Action Plan Proposed improvemen improvement expected t (Kcal/Kwhr) 2019-20 2020-21 2021-22 (Kcal/Kwhr) 2019- 2020- 2021-22 20 21 Oct-Dec 2019. Unit 4 HPT turbine OH 8 1.54 Boiler OH & HPT OH Turbine replacement U#3 Mega R&M (Turb upgrad) 100 7.69 with capacity of 210 MW Turbine replacement U#2 Mega R&M (Tur Upgrdn) 50 3.85 with capacity of 210 MW U#1 Mega R&M, Blr OH & Turbine replacement with 50 3.85 Chem cleaning capacity of 210 MW Under SG R&M: In Stage I units for LP Feed water Augmentation of LP 15 1.15 heating from FG. Expected Economiser in Stage I units Temp reduction by 15-20 deg C Unit 6 BLR. & LPT annual OH 18 3.46 July-Aug 20 Unit 5 BLR. & UNIT AUX. 8 1.54 Oct-20 annual OH Unit 7 BLR. & UNIT AUX. 8 1.54 8 Nov 2020 to 2 Dec 2020 annual OH Total HR Improvement 242 1.5 11.5 10.4 NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
6 22-09-2019
Roadmap for APC reduction
Roadmap for APC Reduction
Action Plan Proposed Expected APC Reduction Implementation Years (MU) 2019-20 2020-21 2019-20 2020-21
IE3 motors stg I&II CT (60 nos of 67 kw) 0.6832 Feb-20 Conversion of Lightinginto EE lighting 4.3800 Jan-20 U1 BFP Cartridge replacement/refurbishment 3.1536 Sep-19 U3 BFP Cartridge replacement/refurbishment 3.1536 Apr-20 U2 BFP Cartridge replacement/refurbishment 3.1536 Sep-20 VFD for ID Fan of unit 4 3.5478 Oct-19 VFD for ID Fan of unit 5 3.1536 Nov-20 VFD for ID Fan of unit 6 3.1536 Jul-20 Coversion of Admin building into Net Zero bulding 4.4676
125 KW Solar on CW Channel 0.0548
Total (MU) Improvement 16.287 12.6144
In addition to above Structured APC Reduction plan has been made and being followed wherein equipment running optimisations based on performance are done
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
Energy Saving projects implemented in for last three years
SUMMARY
No. Of Investment Savings Payback Year Proposal (In Rs. Lakhs) (In Rs. Lakhs) Months
2016-17 9 466 486 12
2017-18 18 2556 2700.21 9
2018-19 11 282.75 222 7.8
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
7 22-09-2019
Energy conservation projects 2016-17
RSTPS Energy Savings on account of specific efforts towards Energy Total Energy Saving S. No. Activities Investment Payback for 2016-17 Rs. In In Energy Rs. In Lakhs Years (MU) Lakhs 1 Corrocoating in Stage III CW Pump 7B and CW Pump 6 of Stg I 1.24 29.82 6 0.2 2 Conversion of lighting to LED 1.26 30.24 100 3.3 3 U7 OH and APH complete basket replacement 8.64 207.36 150 0.7 4 U5 APH OH duct repair 1.73 41.47 50 1.2 5 U6 APH OH duct repair 0.73 17.42 50 2.9 6 Use of Energy efficent Motors in CT Fans in Stage-I 0.31 7.33 80 10.9 Use of Energy efficent Motors in Ash Slurry Pump house in 7 Stage-II (Cont. From Previous Year) 0.97 23.33 50 2.1 Stage-I ESP hopper Cut-in Cut-off optimised with incorporation 8 of timers 4.14 99.36 9 Stage-I DAETP Energy efficent compressors 0.4 9.68 Total Savings 19.42 466 486 1.04
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
Energy conservation projects 2017-18
RSTPS Energy Savings through Energy Conservation activities 2017-18 Type of Activities Total Savings for 2017-18 Investment Payback Sr No Energy Mus MT coal Rs in lakh Rs in lakh Years 1 Corrocoating in stage-I CW pumps (sustained from 2016-17) Electrical 1.58 37.95 0 2 U7 OH APH complete Basket Replacement (sustained from 2016-17) Electrical 15.77 378.43 0 3 U5 APH OH based on trending of DPs (sustained from 2016-17) Electrical 1.84 44.15 0 4 U6 APH OH (sustained from 2016-17) Electrical 1.10 26.49 0 5 Use of Energy Efficient Motors in CT Fans Stg I/II (sustained from 2016-17) Electrical 1.05 25.23 0 (under EC Capital Budget)
6 Use of Energy Efficient Motors in CHP (sustained from 2016-17) Electrical 1.31 31.54 0 (under EC Capital Budget) 7 Stage-1 ESP hopper heater cut-in cut-off optimised with incorporation of Electrical 2.63 63.07 0 timers (sustained from 2016-17) 8 Saving due to Lighting conversion -Sustained From 2016-17 Electrical 5.69 136.66 0 9 Stage-1 DAETP Energy efficient compressors (sustained from 2016-17) Electrical 0.35 8.41 0 10 Lighting -Conversion in 2017-18 1.08 25.92 200.00 7.72 11 U1/2/3 BFP cartridge replacement based on trending (two pumps in each units in 5.18 124.42 6.00 0.05 2016-17) 12 U5 SCAPH Jet cleaning in opportunity 0.43 10.37 0.00 13 U4 APH Complete Basket replacement 1.30 31.10 50.00 1.61 14 U6 Condenser Jet cleaning during Opportunity based on HR deterioration trending 3840.00 126.72 0.00 15 U5 Condenser Opportunity CLEANING based on HR deterioration trending 1920.00 63.36 0.00 16 U4 28% Economiser Coil Addition (System modification based performance 6000.00 198.00 1000.00 5.05 monitoring) 17 U6 28% Economiser Coil Addition (System modification based performance 19466.67 642.40 1000.00 1.56 monitoring) sustained from 2016-17 18 Stage II CT renovations (all 6 units) based on performance assessments 22000.00 726.00 300.00 0.41 Total Savings 31.33 53226.67 2700.21 2556.00 0.9
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
8 22-09-2019
Energy conservation projects 2018-19
Total savings in Total Savings for Investment Payback FY18-19 2017-18 S.NO. ACTIVITIES In Energy term Rs in lakh Rs in lakh Years Mus ESP hopper heater cut-in cut-off optimised with 2.9512 26.25 0 1 incorporation of timers 2 Saving due to Lighting conversion into LED 14.02 27.5 200 7.3 3 U5 SCAPH jet cleaning done in opportunity in May 2018 0.216 5.4 0
U4 APH Complete Basket replacement and duct 3.412 28 6 0.2 4 repairs/belows replacement during OH in Feb 2018
U1 BFP cartridge replacement in sep 2017 OH based on 1.81 43 0 5 trending No of CW Pumps running optimisation during part load in 1.72 23.5 0 6 June 2018 (stg I&II) No of Mills running optimisation during part load in June 0 7 2018 (stg I&II) 0.94 27.6 No of CT Fans running optimisation during part load in 0 8 stg II&III units 1.104 30 Baskets replacements, ducts modification in U6 OH in 0.2 9 July 2018 2.1872 26.5 5 Baskets replacements, ducts modification in U5 OH in 0.2 10 Oct-Nov 2018 1.28 25 5 0.3 11 CW Pumps U7 Coracoting 0.24 20 6 Total saving at Year end 29.88 282.75 222.00 0.78
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
Innovative Projects implemented
Major Implemented Projects for Performance Improvement
List of Major Innovative Projects Implemented ✓Penthouse sealing in Stage 1 ✓In-house developed DSM App incorporated into OEM DCS logic ✓Use of PAUT for Old Joint Healthiness checking ✓Installation of Ultrasound sensors in APH bearings
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
9 22-09-2019
Innovative Projects implemented Innovative Project :1 : Performance Improvements through Pent House Air Sealing Works in U#3, 200 MW Ash Pile-up in Pent House
Gaps After cleaning the Boiler The thermal expansion & contraction causes movement of Boiler tubes, Structure etc resulting into ----
➢ Welding cracks ➢ Metallic Bellow cracks The cooling down time of Over the time, this weight ➢ Refractory cracks fly ash is very high and it on the Boiler roof may usually takes more than a result in metallurgical ➢ Fin Cracks week. This leads to delay strain, may cause to tube Leads to BTL causing in other maintenance failures. activity every time. HR/APC loss
.
Airseal is a flexible, air tight sealing solution made from layers of High Density ceramic fibre, high temperature ceramic sealant, a special anti- corrosion ceramic paste , secured with S S Stud and Spl Alloy Metallic Mesh for application up to 1200C
Pent House (after) Air Sealing
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
10 22-09-2019
Innovative Projects 1
Benefits of AIRSEAL Cost of air sealing
➢ Boiler Efficiency Increase ✓Cost incurred for air sealing of one ➢ Draft Power saving 200 MW Boiler pent house is: ➢ Water usage reduction Rs16,09,400.00 ➢ Generation Revenue Loss Po No”4000183554 ➢ Improved Working atmosphere in Boiler & Surround ➢ Increased life time of Steel Structure ➢ Reduce safety risk.
Payback calculations
Investment: Rs 16 Lakhs In compared to Unit Outage
Payback: Immediate
Potential to replicate in all thermal plants
Innovative Project 2
Innovative Project 2: In-house developed DSM App incorporated into OEM DCS logic
In-house developed software based logic for the existing OEM Distributed Control System (DCS) of Turbo generator to optimise the ramp up and down thereby directly taking input set point from grid demand and keeping efficiency and profitability in mind
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
11 22-09-2019
Innovative Project 2
Benefits: (1) Smooth Ramp up of units with less deterioration of HR (2) Generation : Monitory savings : 5.52 Crore Rupees (Per Annum) Investment: Nil Payback: Immediate
REPLICABLE in all ISGS thermal plants with certain Customization
Innovative Project 3
Innovative Project :3 : Performance Improvements through Use of PAUT in Boiler for weld joints checking – Tube Leakages Drastically Reduced
PHASED ARRAY ULTRASONIC TESTING (PAUT) to BENEFITS assess weld joint healthiness. •Safe technique : In 2017-18 : Outage (BTL) due to Old joints Failure = 8 Nos. harmful Radiation In 2018-19 (after PAUT Implementation) : Outage (BTL) gamma rays of due to Old joints Failure = Nil Radiography can be avoided Investment: 10 Lakhs •Parallel working inside boiler. Oil Saved: 400 Kl (HR saving 4 Kcal/Kwhr), Generation saved: more than 50 Mus (120 Million Rs Revenue) •Drastically Unit downtime reduced. Payback: Less than a Month REPLICABLE for all Boilers
12 22-09-2019
Innovative Projects implemented
List of Major Energy conservation Project Implemented
(1) Through Capital Investment ✓28% economiser addition in Stage 2 (2018-19)-U5 ✓Z-panel replacement in St-2 units ✓Air sealing of Air-preheater Guide bearings
(2) Through Internal Energy Audits ✓RSTPS Air Compressor Header pressure optimization ✓Mill System optimization based on SEC
In Pipeline: Turbine Replacement & R&M of St-1 Boilers …
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
NTPC Ramagundam Capital Project :1 Heat Rate Improvement through 28% Extra Eco coil Addition in U5, 500 MW
13 22-09-2019
Description Before Modifn After Modifn
Heating Surface in Economiser 12833 Sq.mtr 16426 Sq.mtr
Feed water Eco. i/l Temp 254 °C 254 °C
Feed water Eco. o/l Temp 317 °C 321 °C
FGT at Eco i/l 438/477 °C 442/484 °C FGT at Eco o/l 375 °C 333 °C • Boiler efficiency improved by 0.75% • Annual coal consumption reduced by 16000MT ➢ Total cost incurred each unit: Rs 10 Cr ➢ Annual Benefit due to coal saving: Rs 9.6 Cr. PAY BACK PERIOD: Annual CO2 Emission reduction : 19000 MT 10 Months
Innovative Projects implemented
List of Major Energy conservation Project Implemented
✓Z-panel replacement in St-2 units
In 2017-18: BTL in Z-Panel was 6 Nos. In 2018-19: BTL in Z-Panel is NIL NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
14 22-09-2019
Innovative Projects implemented
List of Major Energy conservation Project Implemented
(2) Through Internal Energy Audits ✓RSTPS Air Compressor Header pressure optimization ✓Mill System optimization based on SEC
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
NTPC Ramagundam
Energy conservation Project: Through Internal Energy Audits RSTPS Air Compressor Header pressure optimization – With No Investment
STAGE-III Before (Day Kwh) After (Day Kwh) IAC 7684 6964 PAC 5874 5794 Total 13558 12758 Before • Approximately, 720 KWh saving achieved per day . IAC Continuously Loaded •Accounts to Rs. 6.57 lakhs Savings per annum.
Source of idea: Implemented Through Compressor Internal Audit
Since, IAC pressure is maintaining high (6.3 KSC) at far most point in Boiler sootblowing station, it was reduced by reducing loading and unloading set point of Pressure
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
15 22-09-2019
NTPC Ramagundam
Energy conservation Project: Mill System optimization based on SEC – Operational practice - Without Investement
Mills coal flow and specific energy consumption (SEC) for RSTPS 500 MW Unit
UNIT UNIT 4 UNIT 5 UNIT 6 UNIT 7 Average SEC Average SEC Average SEC Average SEC Power Average (kW/T) Power Average (kW/T) Power Average (kW/T) Power Average (kW/T) Coal Coal Coal Coal Cons Flow Cons Flow Cons Flow Cons Flow MILL (kW) (T/Hr) (kW) (T/Hr) (kW) (T/Hr) (kW) (T/Hr) MILL A 449 57 7.8 344 53 6.6 355 53 6.6 415 50 8.3 MILL B 300 48 6.3 331 51 6.5 431 57 7.5 446 57 7.8 MILL C 348 46 7.5 332 51 6.6 315 47 6.7 419 50 8.4 MILL D 393 57 6.8 351 57 6.2 386 49 7.9 406 50 8.1 MILL E 326 54 6.1 342 51 6.7 327 50 6.6 424 49 8.6 MILL F 324 56 5.7 401 56 7.2 402 56 7.2 379 56 6.8 MILL G 479 57 8.5 422 57 7.4 372 54 6.9 424 52 8.1 MILL H 360 55 6.5 277 34 8.1 415 53 7.8 409 47 8.6 MILL J 436 48 9.0 MILL K 352 38 9.2
Mills taken into service based on SEC priority by Operational Engineers based on above Study.
It was advised to keep mills with lower SEC in service first.
NTPC Ramagundam
Energy conservation Project: Mill System optimization based on SEC – Operational practice - Without Investement
Before CASE 1: Original : Power at 48 TPH If Mill Running Then KW Bottom Mill Mill E 424 Top Mill Mill J 436
CASE 2:By Prioritizing via SEC: After Power at 48 TPH If Mill Running Then KW Bottom Mill Mill D instead on Mill E 406 Top Mill Mill H instead of Mill J 409
Saving CASE 2 vs. CASE 1 Power at 48 TPH If Mill Running Then KW Saving Bottom Mill Mill D 18 Top Mill Mill H 27
Energy saving potential: by prioritizing Mills based on SEC Suppose consider the following two cases: (Unit 7 data is used as reference) Thus, Saving will be as follows: With Mill D instead on Mill E : 18 (Kw) * 2.6 (INR/Kwh) * 500 (avg. Mill running Hrs/Month) = 23,400 INR/ Month With Mill H instead of Mill J : 27 (Kw) * 2.6 (INR/Kwh) * 500 (avg. Mill running Hrs/Month) = 35,100INR/ Month
16 22-09-2019
Utilization of renewable energy sources
Installed Generation Plant Location : Ramagundam Capacity (million kWh) Installation Date 1 Permanent Store roof top 25 kW 0.0365 18-Sep-13 2 Township - Executive club roof top 5 kW 0.0073 2014-15 3 Township - Ladies club roof top 5 kW 0.0073 2014-15 4 Unit-7- Car parking sheds roof 100 kW 0.146 2015-16 5 10 MW Solar PV Plant 10 MW 14.6 29.01.2014 (COD Date) Total (kW) 10135 kW 14.7971
Under Implementation 1 125 KWp Solar PV over CW channel of Stage 2 125 KW - Erection in progress
Under Approval/Execution 1 25 MW Solar PV Plant 25 MW - Under approval 100 MW Floating Solar PV over Balancing 2 Reservoir 100 MW - Under Execution NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
Renewable Energy Use in Plant and Township
Light Pipes used in Office Stores 100 KW solar car parking
E Vehicle Charging Station Solar Power operated Trolley in plant
35 KW Roof Top Solar in Public building
17 22-09-2019
Utilization of Waste Material as Fuel
Types of waste material : House hold Kitchen - Biodegradable Waste Waste utilization in last three years: 180 Commercial LPG Cylinders SAVED! Township- 200kg/ Waste Per day: Saving 4 Commercial LPG Cylinders/Month Plant Canteen - 50 kg/ Waste per day - Saving 1 Commercial LPG Cylinders/Month
Waste Management at Township and Plant
Under Guidance from M/s IGS, Chennai ▪ Door to door campaign in township ▪ Training to Housewives, sanitary workers, Municipality representatives, self help groups of neighboring villages ▪ Distributed 2 color dustbins for waste segregation
▪ Waste management Workshops conducted for Management, Employees, Township Residents and School children
GHG Inventorisation
Energy Savings and CO2 Emission reduction trend Year Annual saving due to EC activities MU Rs Lakh 2014-15 10.73 257 2015-16 11.96 287 2016-17 19.42 466 2017-18 31.33 721 2018-19 29.88 747
CO2 Emission reduction by Energy Conservation Activities ( in Metric Tons) 30000 24712 23269 20000 15585 9375 10031 10000
0 2014-15 2015-16 2016-17 2017-18 2018-19
18 22-09-2019
CO2 Emission Avoided through the Years
GHG Inventorisation and public disclosure made over the years
Cumulative Tentative CO2 Avoided By NTPC Ramagundam through Performance Improvement (in LMT)
2005-06 120472 1.20 2006-07 120472 154904 3.96 2007-08 120472 154904 34184 7.05 2008-09 120472 154904 34184 20822.2 10.36 2009-10 120472 154904 34184 20822.2 5516 13.72 2010-11 120472 154904 34184 20822.2 5516 1215 17.09 2011-12 120472 154904 34184 20822.2 5516 1215 0 20.46 2012-13 120472 154904 34184 20822.2 5516 1215 0 8232 23.91 2013-14 120472 154904 34184 20822.2 5516 1215 0 8232 13244 27.50 2014-15 120472 154904 34184 20822.2 5516 1215 0 8232 13244 54847 31.63 2015-16 120472 154904 34184 20822.2 5516 1215 0 8232 13244 54847 -9838 35.67 2016-17 120472 154904 34184 20822.2 5516 1215 0 8232 13244 54847 -9838 18494 39.89 2017-18 120472 154904 34184 20822.2 5516 1215 0 8232 13244 54847 -9838 18494 25061 44.36 2018-19 120472 154904 34184 20822.2 5516 1215 0 8232 13244 54847 -9838 18494 25061 48721 49.32
CO2 Avoided from EmissionChart Title in atmosphere (LMT) 60.00 44.36 49.32 35.67 39.89 40.00 27.50 31.63 20.46 23.91 13.72 17.09 20.00 7.05 10.36 1.20 3.96
0.00
2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
GHG Inventorisation
Absolute Emissions and Emissions intensity Parameters Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7 SOX (ppm) 722 715 689 752 765 788 689 NOX (ppm) 478 365 580 294 300 307 400 Opacity (mg/Nm3) 68 82 84 62 68 65 64
SOX: 600 ppm
NOX:
(1) 200/500 MW old units 600 ppm (NTPC Ramagundam Stg I&II units (2100 MW) (2) 500 MW Unit 7: 300 ppm
FGD: Contract in place on BHEL for all 500 MW units, Target Date: Dec 2022
Opacity Under limit of 100 mg/NM3
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
19 22-09-2019
Water Consumption
Specific Water Norms is 3.5 l/kwh Specific Water RSTPS (L/kwh) 6 4.043 3.997 4 3.418 3.33 3.29 2 0 2014-15 2015-16 2016-17 2017-18 2018-19
Specific Water reduction achieved by:
•Implementation of Zero Liquid Discharge (ZLD).
•Wireless Water consumption data monitoring using Ultrasonic Flow meter.
Water Saved in 2018-19: 7.4 Cubic meters Monetory Saving in 2018-19: Rs. 17 Lakhs
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
Fly ash utilization
FLY ASH UTILIZATION 110.31 100.95 100.00 93.16
75.00
50.00
25.00
0.00 2016-17 2017-18 2018-19
Means of Ash Utilizations:
•By Rail rake Transportation to Cement Plant •For use in Geo Polymer Road •Manufacturing of Fly Ash bricks •Mine Stowing •Road Construction – By State government •Agriculture use as additives •Collection of Cenosphere
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
20 22-09-2019
Team work, Employee Involvement & Monitoring
Energy Efficiency/conservation through Team Work:
Involvement of Multifunctional department: a. VFD in ID Fans implementation by EMD b. LED implementation by EMD c. IE3 Motors replacement by EMD d. TAC Replacement by AHM e. PAC replacement by TMD f. Solar PV implementation by EEMG g. Offline performance deviations Monitoring by EEMG h. Online Performance monitoring by Operations & EEMG
Meetings When Headed By Corrective actions Planning Meeting Daily O&M Head generated from monitoring & review Operational Review Team Meeting Monthly Plant Head meetings implemented in Operational and Regional Operational Performance Review Yearly D(O) Maintenance Practices
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
Heat Rate (SEC) Monitoring
➢ Monitoring of HR deviation based on Average Parameters on Daily basis and reviewed in Daily Planning Meeting
➢ Regular performance testing using Off-line instruments and gap analysis
➢ Optimized and Efficient Light up plan
➢ HR deviation analysis and action plan in ORT
➢ Implementation during opportunity/ OH
➢ Keeping track of MDBFP running hours
➢ All Cold Start Ups with TDBFP only
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
21 22-09-2019
NTPC Ramagundam
Efficiency monitoring and actions for Improvement
Performance/Efficiency Monitoring tools
1. Heat Rate (SEC) monitoring through TLA
2. HR monitoring through PI and PI tools
3. APC monitoring through OLEMS & SEED & PI
4. Real time Performance Monitoring Package directly from DDCMIS data
Correct and Timely monitoring can result into tremendous saving of natural resources
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
Performance: Remote monitoring through TLA tool
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
22 22-09-2019
NTPC Ramagundam
Equipment wise Specific Energy Consumption monitoring through SEED
Mill Outlet Temp FA ratio on Line Monitoring through SEED
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
NTPC Ramagundam Heat Rate Improvement due to OH correction UNIT 5 Improvements after OH - 2018-19 Boiler (Eco coil addition, APH Baskets replacements, TG Aux TYPE OF O/H OH) OVERHAUL PERIOD 01/10/18 to 03/11/18 (35 Days) PARAMETER UNITS Design PRE O/H POST O/H BOILER EFFICIENCY % 87.28 86.19 87.04 TURBINE HR Kcal/Kwhr 1988 2078.0 2068.6 UNIT HR Kcal/Kwhr 2277.7 2410.95 2376.61 APH Leakage (SAPH A/SAPHB/PAPH 14.6/10.1/24.3/36 A/PAPH B) % 5.2/20.8 .9 8.4/6.2/24.6/23.4 GAIN IN UNIT HR Kcal/Kwhr 34.3 Loss due to CW inlet temp from Pre-O/H to -8.8 Post-O/H Kcal/Kwhr TOTAL GAIN IN UNIT HR DUE TO O/H Kcal/Kwhr 43.1
Lakh BENEFIT - HR reduction Rs/Month 110.36
Lakh ID Fan power Cons reduciton Rs/Month 19.66
Lakh Total Benefit after OH (Approx) Rs/Month 130.02 EXPENDITURE Lakh Rs 1500.00 PAYBACK Months 11.54 NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
23 22-09-2019
NTPC Ramagundam Heat Rate Improvement due to OH correction UNIT 6 IMPROVEMENTS - 2018-19 TYPE OF O/H BLR. & UNIT AUX.+LPT+GEN OVERHAUL PERIOD 23/06/18 to 28/07/18 (35 Days)
PARAMETER UNITS Design PRE O/H POST O/H BOILER EFFICIENCY % 87.28 86.27 87.41 KCAL/KWH TURBINE HR R 1988 2068.1 2052.4 KCAL/KWH UNIT HR R 2277.7 2397.2 2348.0 APH Leakage (SAPH A/SAPHB/PAPH 11.9/12.5/31.3/35 A/PAPH B) % 5.2/20.8 .5 5.6/5.8/20.5/18.6 KCAL/KWH GAIN IN UNIT HR R 49.2 Loss due to CW inlet temp from Pre-O/H to KCAL/KWH -7.0 Post-O/H R KCAL/KWH TOTAL GAIN IN UNIT HR DUE TO O/H R 56.2 Lakh BENEFIT - HR reduction Rs/Month 143.79 Lakh ID Fan power Cons reduciton Rs/Month 11.23 Lakh Total Benefit after OH (Approx) Rs/Month 155.03 EXPENDITURE Approx Lakh Rs 1340.00 PAYBACK Months 8.64
Recent Case Analysis for Condenser Vacuum deterioration on partial load using Remote data
TEST DATE: 1-Sep-19 DURATION: 13:27 to 14:27 TAG TEST DATA UNIT VALUE G6_MW Unit Load (from ABT) MW 256.2 6tag0185 VACUUM mmHg 51.4 6tag0285 CW IL 1ST PASS Deg C 31.0 6tag0286 CW IL 2ND PASS Deg C 31.5 Average: 31.2 6tag0287 CW OL 1ST PASS Deg C 37.3 6tag0288 CW OL 2ND PASS Deg C 37.6 Average: 37.5 6tag0352 CW_DP_RHS kg/cm2 0.71 6tag0353 CW_DP_LHS kg/cm2 1.19 6tag0236 CW FLOW T/Hr 67921812 6tag0389 AIR_SUC_MIX_TEMP Deg C 40.1 6TAG0394 LPT exhaust temp #DIV/0! 6TAG0396 CEP-A suction temp 40.2 6TAG0397 CEP-B suction temp 41.6 6TAG0398 CEP-C suction temp 42.1
AIR SUCTION DEPRESSION 2
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RSTPS: Separate budget for Energy Conservation
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
RSTPS: Energy efficiency / awareness training program
• ISO 50001 Auditors three days Training to 12 executives. All executives are now qualified for internal audit
• One Efficiency training to Operation department
• One day training module to Maintenance department
• Training on commercial impacts of Efficiency improvement to all executives
• Three days Commercial workshop is proposed in Nov 2019 at RSTPS
• Awareness through Posters on Efficiency improvement tips
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
25 22-09-2019
Projects implemented through Kaizens
Kaizens Projects ( Workers and Supervisor level)
(1)Mill Reject modification for reducing mill fire and outages
(2) Flue gas utilization in PH reduction of ash pond recirculation water
(4) Brick pavement across the CT Outlet channel to prohibit rain mud water entry into CW system.
(5) Cleaning of SCAPH using water jet during opportunity.
(6) Coal Conveyor running optimization for APC reduction
(7)Fuel oil pump house control from Unit Control room
(8) Unit 1,2,3 & 7 corrosion mapping done for detoriated tube identification
(9) No of air compressors running hour reduction
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
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NTPC Ramagundam
Major Innovative Kaizen Project :1 Mill Reject modification for reducing mill fire and outages
45 Degree
Before After Source of idea: Through Brainstorming amongst workers • Mill outage due to Reject chockage reduced & Mill availability Replication potential: incresaed. Yes, can be done Monitory gain Per day: Due to Mill availibility 8 Hrs (Mill Downtime)*6 (Incident Per Month) *20 MW Loss*7 Units*Rs. 2.5= 16.8 Million Rupees/Month
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
NTPC Ramagundam
Major Innovative Kaizen Project :2 Stage 1 Fuel oil pump house temperature & pressure control from control room
Before
After
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
27 22-09-2019
NTPC Ramagundam
Major Innovative Kaizen Project :2 Stage 1 Fuel oil pump house temperature & pressure control from control room
Loss before Implementation:
If unit light up delayed by 1 hr then unit generation may loss by 100MW on an average.
100 MWx1000 =100,000 =100000 Units 1Unit cost =Rs.2.50 ------100000xRs. 2.50=Rs.250000
Gains After Implementation: in one 200 MW Unit is Rs. 810000 /- (approx 3 hrs lightup delay)
Investment in one unit Cost for cable laying works: Rs. 5000/- Cost of Smart Positioners (4 No’s)= Rs. 110000
Total Savings=810000-115000=Rs. 695000/-
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
ISO 50001
▪Internal ISO 50001 Auditor Certification obtained.
▪15 No. Of Internal ISO 50001 Auditors at Ramagundam.
▪Internal audit and management review completed
▪Certification PO awarded to IRCLASS, Mumbai Certification audit in progress By Oct 2019
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Innovative Projects
By Waste Heat Recovery : Under implementation Performance Improvements through LP Economizer Installation in St-I 200 MW
Potential Waste Heat Energy = 680*1000*1.1*27 = 20196000 KJ/hr
➢ Reduction in Flue gas Exit temperature by 25 deg C ➢Improvement in Boiler Efficiency by 1.3% Replication potential ➢Reduction in Extraction steam from LP turbine Potential to replicate other units of NTPC/ Others ➢SH spray reduction ➢Improvement of Heat rate. Description Existing After Installation Environmental benefits Condensate Temp. 85 Deg.C 93 Deg.C ➢Improvement in ESP collection efficiency. at inlet of LPH-2 ➢Emission of GHGs reduction (CO/CO2 / SOx /Nox) FGT at ESP inlet 167 Deg.C 140 Deg.C
By Waste Heat Recovery Performance Improvements through LP Economizer Installation in St-I 200 MW Payback calculations Monetary Benefits Reduction in Flue Gas Exit 1 20 deg C temperature
✓ Cost of the project: Corresponding Heatrate 2 20 kcal/kwhr reduction • Material cost: Rs 170 Lakhs Million • Services cost: Rs 20 Lakhs 3 Per annum Energy savings 35040 kcal • Total cost incurred Rs 1.9 Cr. 4 Energy equivalent of coal 10554 MT of coal ✓ Monetary Benefits achieved: 5 Saving in Rs Cr / year 3.078 Rs Cr • Benefit due to coal saving: Rs 6.22 Cr. Expenditure incurred for the • Energy Certificates earning in PAT cycle-III 6 1.9 Rs Cr Project (PAY BACK PERIOD: 3.6 Months)
7 Pay back Period 7.4 Months
Coal Saving upto 10554 MT/Year and saving upto 3.078 Crore/Year
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Innovative technologies implemented
Additive Manufacturing : Brick Manufacturing & Cenosphere collection
Benefits achieved from Ash brick Manufacturing : ▪Jobs to local people ▪Ash utilization increase
Benefits achieved from Cenosphere sale : ▪Cenospheres collected from Ash pond ▪Used in various industries requiring high temperature application
Particulars UOM 2016-17 2017-18 2018-19
Ash dyke raising/construction % 1.62 0.00 11.77 Clay ash brick units % 28.04 19.53 31.92 Land development % 1.02 18.14 15.90 Agriculture/bottom ash cover/others % 9.31 4.67 1.39 Pond ash cement industries % 0.00 0.10 0.00
Innovative technologies implemented
AI: C&I Chat Bot App & Mobile monitoring app
Benefits achieved : ▪Instant real time alerts to management. ▪Trend comparison & Analysis ▪Data access from anywhere in the World
Dr. PP Kulkarni Mathew Varghees
30 22-09-2019
Long Term Vision on EE
Long Term Target of Energy Efficiency: (1) 200 MW Turbine Replacement by 20-21 Two Units and 21-22 One Unit (2) FGD in All 7 RSTPS Units. For Units 1 to 6 Contract awarded to BHEL (Target 20-22 Dec). (3) ID Fan VFD conversion under progress. Completion by 20-21
Support required to achieve target:
Technical support: All above contracts awarded Financial Support: Financial supports granted Supplier engagement: Contract material mobilization in progress.
RSTPS – % Investment on Turnover
Generation Annual Sales Thermal (Rs. Crores) 6200 6000 5800 5600 5400 5960 5200 5471 5491 5000 2016-17 2017-18 2018-19
Profit Before Tax (Rs. Crores) 900 800 700 807 734 703 600 2016-17 2017-18 2018-19
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Awards & Accolades Received during 2017-19
1. Ramagundam Received Excellent Energy Efficient Unit Award for Excellence in Energy Management consecutively twice for 2017, 2018 & Organised by CII at Hyderabad.
2. Golden Peacock Award on Energy Efficiency 2018 By IOD
3. APEX India Energy Efficiency Award-2018 on Energy Management System and innovations
4. Runner-up Annual Heat Rate Trophy-2017-18 across all NTPC Plants and First amongst all Sub critical units
5. Ramagundam Winner in Swarn Shakti Award- 2015-16, 2016-17 & 2017-18
6. Greentech Safety Gold Award 2017 & 2018
7. Selected for Eminent Safety Gold Award 2017 in OHS Power Sector from Ek Kaam Desh Ke Naam (to be received on 15 January,2018 at New Delhi).
8. Awarded Second in PEM matrix evaluation across NTPC (2017-18).
Major achievements Station Highlights during calendar year 2018-19
• Annual Generation of 18547.9 Mus (PLF 81.44%) against Target of 18231 Mus (PLF 80.04%) for FY 2018-19 well before time.
• No Generation loss on Less Coal Stock/Receipt in FY 2018-19
• U3 Continuous run for 250 days (18th Oct’17 to 26th June 2018)
• RSTPS recorded the Yearly DC of 89.34% which ensures the Full fixed cost recovery
• Power trading started in open market and for worth around 1.5 Crore Rupees power traded.
•100 MW Floating solar contract awarded. CoD by Dec 2020
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Major achievements Station Highlights during calendar year 2018-19
Environmental Aspects:
• Implementation of ZLD : ZLD projects are completed.
• Water consumption monitoring and Consumption: RSTPS is the first plant across NTPC which started Wireless Water consumption data monitoring using Ultrasonic Flow meter. RSTPS Sp water consumption has reduced to 3.29 l/kwhr in comparison to allowable limit of 3.5 l/kwhr.
Other Highlights:
• E Bikes started in township
• Electric Vehicle Started in Plant area for commuters
100 MW Floating Solar at NTPC Ramagundam : Under execution by M/S. BHEL COD Target By: Dec 2020
Manoj K Jha ([email protected]) Sathish ([email protected]) Ashwin Raja ([email protected])
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Innovative Projects implemented
List of Major Energy conservation Project Implemented
✓ Air sealing of Air-preheater Guide bearings
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
NTPC Ramagundam Major Innovative Kaizen Project :1 Mill Reject modification for reducing mill fire and outages
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
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NTPC Ramagundam
HPT Poor Performance
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
LP Economizer Installation in St-I
LP Condensate outlet calculations M fg x Cp x Del.T of fg = M cond. x Cp of Cond. x Diff. in cond. temp. 680*1000 kg/Hr*0.27*(167-140) = 560*1000 kg/Hr*1*(T2-85) LP Economiser Condensate outlet temperature (T2) = 93 Deg.
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Innovative technologies implemented
By Waste Heat Recovery : Under implementation Performance Improvements through LP Economizer Installation in St-I 200 MW
Present Stage-1 Flue gas analysis
APH exit Flue gas Temperature:167 Deg.
Flue gas flow:680 T/Hr.
Max. allowed FGT : 140 deg C owing to the consideration of dew point temperature
Potential Waste Heat Energy = 680*1000*1.1*27 = 20196000 KJ/hr
Targeted Benefits
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NTPC Ramagundam
Analysis of Poor Equipment Performance through Cause and effect diagram Condenser Poor Performance:
NTPC Limited – RAMAGUNDAM SUPER THERMAL POWER STATION
RSTPS: Elements of Energy Management System
Systems Approach – Continuous Improvements
Evaluation & Accurate Gap Dissemination Assessment
Retrofits Modus- Operandi Gap analysis
PIPs Action Plans
Implementation Resource Mobilization
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Without Efficiency Based SP Trimming HEAT RATE Untrimmed Load Savings With 20 MW UNIT Total kCal (kCal/Kwh) (MW) SP Trimming UNIT 4 2472 500 1236000000 UNIT 5 2398 500 1199000000 ❑ Total Kcal saved : UNIT 6 2382 500 1191000000 16,86,829 kCal/hour Total 1500 3626000000 ❑ Considering coal GCV as : 3400kCal/kg With Efficiency Based 20 MW SP Trimming Coal Saved : 496 Kg/Hr Efficiency trimmed Load ❑ UNIT Total kCal correction (MW) ❑ Savings: ₹ 1260 per hour UNIT 4 -20 480 1186560000 : ₹ 30,240 per day UNIT 5 7.07 507.07 1215961463 UNIT 6 12.93 512.93 1221791707 Total 1500 3624313171
Savings With 20 MW SP Trimming : ₹ 1.104 Cr per Annum
Allowing 100 MW SP trimming leads to saving of ₹ 5.52 Cr per Annum
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