9.NTPC Kawas CII Award Final [Repaired] · 3urfhgxuh ri frpshqvdwlrq fdofxodwlrq zdv lvvxhg rq wk...
Transcript of 9.NTPC Kawas CII Award Final [Repaired] · 3urfhgxuh ri frpshqvdwlrq fdofxodwlrq zdv lvvxhg rq wk...
Excellence in Energy Management-2018
Kawas Gas Power Project
KAWAS
Delivered by: Sh S Balasubramanya (Leader)Sh A K Barlewar (EM)Sh Jayesh Behede (EA)
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55
22 66
Company & Station ProfileCompany & Station Profile
Energy Conservation Projects 77
88
GHG Inventorization
Renewable and Waste Utilization
Efforts Towards Green Company
Awards & AccoladesAwards & Accolades
Content
Specific Energy Consumption Trend & Benchmarking
Innovations at Project
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Installed Cap : 53651 MW
Under Construction : 14000+ MW
RE :928 MW
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Location Hazira, Surat (Gujarat, India)
Installed Capacity Stage-I 656.2MW (2 Identical blocks, each block consisting of 2 GTs and 1 ST) in 568Acres
Type Combined Cycle Gas Power Plant
Gas Turbines 4 Nos. of GE 9001-E of 106 MW each
Steam Turbines 2 Nos. of Alsthom Rateau 116.1 MW each
Fuels Natural Gas (GSPCL, GAIL), Naphtha (HPCL), HSD (IOC/ HPCL)
Source of Water River Tapti: Pump House at Variav
Power EvacuationThru’ 8 Nos. of 220 KV Transmission lines:i) Haldarva-1,2 ii) Dastan-1&2 iii) Vav 1,2 iv) Ichapore 1,2
Beneficiaries Gujarat, MP, Maharashtra, DNH, Daman & Diu, Goa and J&K
MH31.14%
GUJARAT (28.5%)
MP21.36%
DNH12.38%
D&D4.73%
GOA1.89%
J&K0.01%
MW Share % Share
656.2 MW
POWER ALLOCATION
Station Profile
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Specific Energy Consumption in last 3 years
Year GrossGeneration
Thermal SEC (Kcal/Kwh)
Electrical SEC (%)
2017-18 2405.84 2038* 2.63*
2016-17 1717.97 2013 2.49
2015-16 1212.40 2064 2.90
WHY ?
*HR & APC Higher from 2016-17, On account of partial loading till 55 % of ON Bar DC
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New Policy & Tariff Regulations Changed Operating Scenario
On grid Requirement: The technical minimum
schedule for station was brought to 55 % of Installed Capacity
For gas based Stations, compensation shall be
decided based on the characteristic curve provided
by the manufacturer and after prudence check of
the actual operating parameters of Station Heat Rate, Auxiliary Energy Consumption, etc.
Procedure of compensation calculation was issued
on 5th May 2017
Partial Load compensation joint exercise was
carried out at Kawas on 08th & 09th March 2018
along with the WRPC, WRLDC and station
beneficiaries for developing the compensation
mechanism
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Partial Load Compensation: Joint Exercise Results
Full Module (2 GT combine Cycle Operation)
Loading Factor
Results
HR APC
85 % 2025.5 2.37
75 % 2061.2 2.42
65 % 2133.3 3.61
55 % 2262.2 4.09
Half Module (1 GT combine Cycle Operation)
Loading Factor
Results
HR APC
85 % 2100.6 3.62
75 % 2179.5 4.63
65 % 2269.9 5.30
55 % 2407.8 5.30
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Block-wise Load Factor for FY 2017-18
Full Module (2 GT combine Cycle SG>160 MW)
SG/DC(onbar)No of
Blocks%
>= 85 % 13122 44.66
85 % > and >=75 %
5682 19.34
75 % > and >=65 %
3819 13.00
65 % > and >=55 %
5431 18.48
Less than 55 % 1330 4.53
29384 100
Half Module (1 GT combine Cycle SG<160 MW)
SG/DC(On Bar)No of
Blocks%
>= 85 % 496 43.28
85 % > and >=75 %
177 15.45
75 % > and >=65 %
78 6.81
65 % > and >=55 %
244 21.29
Less than 55 % 151 13.18
Under S/D 1630 100
2776
36 % of total Time blocks we were under 75 %
loading
115 Days Kawas operated at less than 70% of ON bar DC out of 335 Days of run
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Deviation Performance Station Analysis For FY 2017-18
2050
2105
2038
2000
2020
2040
2060
2080
2100
2120
TargetHeat Rate
WeightedAvg
Calculated
Heat RateActual
Heat Rate
2.5
2.99
2.63
2.22.32.42.52.62.72.82.9
33.1
Target APC WeightedAvg
Calculated
APC Actual
APC (%)
* Block loading and Joint exercise results used to calculate the weighted Avg HR/APC for site
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Benchmarking : Heat Rate for FY 17-18
2075 2100 1990 1975 2040 20501850
2132 22162099
19832077 2037
1840
0
500
1000
1500
2000
2500
Anta Auraiya Dadri Faridabad Gandhar Kawas RGPPL
Traget Heat Rate
Actual Heat Rate
Kawas #2
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Benchmarking: APC for FY 17-18
2.5 2.5 2.5 2.5 2.5 2.5 2.5
4.13
4.69
3.22.99
2.53 2.63
1.74
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Anta Auraiya Dadri Faridabad Gandhar Kawas RGPPL
Target APC
Actual APC
Kawas # 3
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Benchmarking: Specific Water Consumption for FY 17-18
2.98
1.34
2.41
1.911.73
0
0.5
1
1.5
2
2.5
3
3.5
Auraiya Dadri Faridabad Gandhar Kawas
Specific Water Consumtion
Kawas # 2
* Anta operated in Open cycle and RGPPL data was unavailable for FY 17-18, so not show in the graph
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Energy Conservation Projects in 2015-16
Sr. Activity Energy Savings (MU)
Energy Savings (INR-in lakhs)
1Energy Efficiency Coating of CW 1CCRF201 pump
0.021 0.540
2 Inlet Air filters replacement in GT – 1A 1.097 28.300
3 Inlet Air filters replacement in GT – 1B 1.292 33.34
4Installation of Solar powered light poles in Reservoir area
0.018 0.47
5Online Compressor Washing in Gas Turbine
4.351 112.24
6Bullet cleaning of Condenser Tubes in Steam Turbine#1C & 2C
0.383 9.88
7 Retrofitting of VFDs in Raw Water Pumps 0.200 5.16
Total 7.362 189.93
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Energy Conservation Projects in 2016-17
Sr. Activity Energy Savings
(MU)
Energy Savings (INR-
in lakhs)
1 Online compressor washing of Gas Turbine 4.695 99.00
2 Retrofitting of VFDs with Raw Water Pumps 0.352 7.43
3Installation of Solar powered light poles in reservoir area
0.018 0.386
4 Installation of LED 0.010 0.210
5Energy Efficient Coating in CW pump 1CCRF101PO
0.050 10.45
Total 5.571 117.476
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Energy Conservation Projects in 2017-18
Sr. Activity Energy Savings
(MU)
Energy Savings
(INR-lakhs)
Investment(INR in Lakhs)
Payback (Yrs)
1 Energy Efficient Light Fittings 0.0320 0.70 1.39 2
2 Installation of Occupancy sensor 0.0233 0.51 2.92 3.4
3 COC increased from 5.0 to 5.60 0.1294 2.82 2.2 1
4Energy Efficient Coating CW Pump 2CCRF101PO & OCCRF001PO
0.3468 7.56 4.16 1
5 VFD drive in Raw water Pump's 0.0756 1.65 -- --
6 Destaging of HP BFP 0.4113 8.97 36 1.9
7 Compressor Washing 5.5826 121.70 -- --
8Installation of 52.5 KW roof top solar at admin building
0.0052 0.11 35 10
Total 6.601 144.07
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Projects With Zero Investment
Intake Water Pump Off Peak Hour Operation • Savings : 3.64 Lakhs INR
Hot Side Blow Down For Cooling Towers• Savings : 3.74 Lakhs INR (Annual Water Savings: 16000 m3)
APC Reduction Techniques • Switching off 3 Fin Fans in Winters Savings : 3.58 Lakhs INR• Minimizing Transformer losses by isolating parallel source
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Projects With Zero Investment
Rain Water Harvesting•Savings: 640000 m3 water recycled
equivalent to 1.51Cr (Rate : 23.58 INR/m3 )
CW Blow-down used in horticulture
Live
Dead Reservoir
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Proximity Sensor & Energy Efficient Light Replacement
Energy Efficient Lighting• 635 No installed (36W Tube lights replaced by 18W LED lights)• Total Savings : 0.032 Mus• Investment : 1.39 Lakhs Rs• Payback Period : 2Yrs• 11000+ Energy efficient fitting to be installed by October 2018
Proximity Sensor Fitting• 150 Sensors installed• Total Savings : 0.0233 Mus• Investment : 2.92 Lakhs Rs• Payback Period : 3.4Yrs
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De-staging of Boiler Feed Pump
Major HT Drive (750 KW)•25-30 % of the APC is consumed by Boiler Feed Pump• 5 Pumps de-staging done in FY 2017-18 & 1 done in Mar’17
Destaging Details• 1 Stage removed out of 11 stages• Pressure Reduction from 110 Bar to 90 Bar • 75 KW/hr per pump savings
Economics•Investment :- 48 Lakh Rs (For 6 pumps )• Payback Period : 1.9 yrs
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COC Improvement
COC: Conductivity of CW Water---------------------------------------------------------Conductivity of Make-up Water
CW Flow: 24000 m3/hr and ER: 1.75%
COC Improved from 5 to 5.6
Blow Down Reduction: 13.69 m3/hr
Total Water Savings: 136247 m3
Savings in Pumping Power: 0.1294MUs
Energy Savings in INR : 2.82 Lakhs
Total Savings in INR: 32.14 Lakhs
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Innovative Ideas Implemented
QR Coding
Safety Park
CLIMS
PRADIP
QR Codes at CCR Vertigo Structure at Safety Park
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Innovation Details: QR Coding & Safety ParkQ
R Co
ding
Instant access to crucial and relevant information on site itself
Easy to makeCost effective-Saves paper 360 degrees readability
Durable, Dirt and Damage Resistant
Safe
ty P
ark Vertigo Test
Work at Height TrainingHot Work Training
Confined Space TrainingScaffolding DemoFire Safety DemoChemical Handling Demo
Safety Kiosk
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Innovation Details: CLIMS & PRADIP CL
IMS Automates Contractor’s
Labour Information Management System
Enhances Statutory Compliances, labour laws and labour welfare
Labour can enter the plant only after the requisite safety training and medical clearance and EIC checks
Biometric System is used for all the labours
PRAD
IP
Proactive and Digitital Initiative to become Paperless at workplaceConversion of Physical Documents to DigitalStorage of document at secure locationHighly Secure through Access ManagementEasier Access & Retrieval
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Utilization of Renewable Energy Sources (Solar)
30 KW Solar PV Roof Top at ITI Olpad. (FY 16-17)
30KW The Akshay Patra Foundation Solar Roof Top PV (FY 17-18)
52.5KW Solar Roof Top at Admin Building (FY 17-18)
Street Light Solar (FY 15-16)
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Utilization of Renewable Energy Sources (Solar)
Admin Building Roof Top
•Capacity: 52.5 kW•Installed: Jan’ 2018•Generation: 23596 kWhr•Total CO2 Savings: 16 Ton•Investment : 35 Lacs•Unit Price : 3 INR•Pay Back : 10 yrs
Akshay PatraRoof Top
• Capacity: 30 kW• Installed: Jan’ 2018• Investment : 17.83 Lacs• Unit Price : 6 INR• Pay Back : 6.5 Yrs
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Rojmal Wind Power Station (2MW * 25 turbines)
1st Wind Turbine Commissioned on : 31st March 2017
Capacity : 50 MW
Location: Rojmal, Rajkot District, Gujarat
Investment : 323.35 Cr.
FY 17-18 Cumulative Generation: 41.86 MUs
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Renewable Energy Sources (E-Vehicle Charging Point)
E-Vehicle charging point
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Future Projects/ Road Ahead
Under Implementation
• 1 MW Floating Solar PV over Reservoir
• 65 MW Solar PV Plant in Stage-II area.
• Paper Recycling Machine• All Office Building Roof
Rain Water Harvesting
Proposed
• 173 KW Solar PV floating over pond in Simulator
• Implementation of ISO 50001/ Green Co/ IGBC Certification
• VFD installations in CEPs• New Lower Rating Feed
Water Pump Installation
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Utilization of Waste Material as fuel : Bio-Methanation Plant
For FY 2017-18• Total Waste Collected: 15.685 TPA• Total Gas Generated: 1214 M3• 1M3 Bio-methane Gas: 0.45 kg of LPG• LPG Equivalent Generated: 310 Kg• No. of LPG cylinders saved: 22 Nos
Bio Methanation Plant Capacity -100kg/Day.Substrate to be used – Canteen Waste/Food waste/Vegetable Pulp /Organic WasteOutput: Gas having GCV 1750 Kcal/Kg
Saving2 LPG
Cylinders per
month
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Vermi Composting Unit
FY 2017-18 Produced: 1700 KgsSavings: INR 1.16 Lakhs
Current Financial year Produced: 8700 KgsSavings: INR 5.86 lakhs
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GHG Inventorisation
Year Generation (MU) Scope1 CO2 (MT) Scope2 CO2
(MT) Total CO2 (MT)
2017-18 2405 962338 487 962825
2016-17 1717 686817 361 687178
2015-16 1228 485569 306 485875
2014-15 1758 696620 286 696906
2013-14 1494 557960 495 56291
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Efforts towards Green Company
Procurement of Energy efficient Motors, LED Lights, etc
Procurement of server racks with efficient cooling systems
Plastic Ban in Township
PUC check of all vehicles done every 6 month
Township dry and wet-waste separation collection from homes
Tree Plantation: 2016-17 – 1000 No. 2017-18 - 2025 No.
Qty of Hazardous waste sold in last three years:• Resin: 3.99 MT• Used Lube Oil & Transformer Oil: 59.29 Ton for value of 15 Lakhs• E-Waste free: 1 lot for value of Rs 11.51 Lakhs
24370 E-scerts Earned in
PAT Cycle I1Escert = 10968 INR
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Team Work and Employee Involvement & Monitoring
Efficiency MAP Software
On Line Efficiency Monitoring System
Maintenance practices and real-time monitoring system ensure high availability and efficient operations
Daily and Monthly review system (ORT-Operation Review team) system ensures high level of performance
Periodic structured Technical Audits carried out for all units for identifying and correction of gaps
Start-up time optimization
5 QC Teams Won Awards at QCFI-Vadodara 2017
Awards and Accolades
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National Energy Conservation Awards – 2017, 2015, 2012
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CII Energy Efficiency Award 2017
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More Feathers in the Cap
SEEM Award For Sustainable Energy Performance & Energy Conservation
SGCCI Golden Jubilee Memorial Award For Excellence in Improving Productivity
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Employee State & National Awards
Presidents Award for Empowerment of Person with Disabilities to Shree Dilipbhai Patel
Gujarat Government Shram Bhushan Award to Shree Gunvant Shah
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Happy 25th Birthday to KawasIn Sync With Nature
Kawas Safety Park
Thank You
Address
NTPC Limited, KGPP,
Adityanagar, Surat – 394516 (India)
Phone
+91 261 2877000