presentation for 18th national award for excellence...

Presentation for 18th National Award for

Excellence in Energy Management-2017

KAWAS

31st August 2017

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Copyright © 2016 Your Company All Rights Reserved. 2

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Company Profile

Station Profile

Energy Conservation Projects

Roadmap For Energy Conservation

SEC Trend

Benchmarking

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GHG Inventorisation

9 SEC Monitoring Formats

Efforts Towards Green Company

10 Best Practices

Contents

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12 Awards & Accolades

Renewable and waste utilization



Location Hazira, Surat (Gujarat, India)

Installed Capacity Stage-I 656.2MW (2 Identical blocks, each block consisting of 2 GTs and 1 ST)

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, HSD

Source of Water River Tapti: Pump House at Variav

Power Evacuation Thru’ 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

Mah 31.14%

GUJARAT (28.5%)

MP 21.36%

DNH 12.38%

D&D 4.73%

GOA 1.89%

J&K 0.01%

MW Share % Share

656.2 MW

POWER ALLOCATION

Station Profile

Copyright © 2016 Your Company All Rights Reserved.


5

S.

No.

Title of Project Annual

Saving (Rs

Lakhs)

Investment

Made (Rs

Lakhs)

Payback

(Months)

Remarks

1 De-staging of HP BFP in Block-I

(Benefits as per one Pump).

6.98 5.55 9.45 02 No completed in 2016-17.

04 No planned in 2017-18.

2 Jet cleaning of Condenser Tubes in

Steam Turbine #1C & 2C.

9.88 4 4.85 ST#2C - Feb’ 2017

3 Online Compressor Washing of Gas

turbine.

72 91.75 15 Recovery of lost power output.

Prolonged sustained operation.

4 Replacement of 70 W HPMV Bollard

with 18 W Energy efficient

Bollard and LED tube light.

1.5 3.19 25 60 No. Bollard; 700 No. LED

Tubelights.

FY 17-18 – 4500 No

FY 18-19 – 10500 No.

Energy Conservation Projects in last 3 years



6

S. No. Title of Project Annual

Saving (Rs

Lakh)

Investment

Made (Rs

Lakh)

Payback

(Months)

Remarks

5 Replacement of air filters cartridges

in all Gas Turbine

15 17.5 14 FY 16-17: 02 GT’s filters

replaced.

6 Application of Energy Efficient

Coating in Circulating Water Pump

10.45 9.4 10.8 CW Pumps – all 5

completed.

Make up water pumps – 2

No.

7 Retrofitting of VFDs in Raw Water

Pumps

5.16 15.58 36

Energy Conservation Projects in last 3 years



25-30 % of the APC is consumed by Boiler Feed Pump.

2 working + 1 standby BFP’s in 1 block.

BFP Discharge Pressure – 98 Kg; Required Pressure – 87 Kg.

Hydraulic power requirement is low as compared to actual conditions.

Total stages in the BFP – 11 stages.

After De-staging – 10 stages

Yearly Electrical Savings – 2 Lakhs

Investment of INR 5.5 lakh gives simple payback of 9.45 Months.

De-staging of Boiler Feed Pump



Description Before De-staging After De-staging

Discharge Pressure (Kg) 97.79 84

Discharge flow(T/hr) 175.95 179

Power consumption(kw) 751.68 kw 675.74 kw (@0.85p.f)

Power savings (kW) (10% power

savings) 75.94

Saving in kWh yearly (PLF=30%) 199570

Rs/kWh 2.58

Saving in Rs. (Lakhs) 6.98

Investment in Rs. (Lakhs) 5.5

Payback period in months 9.45

De-staging of Boiler Feed Pump



The efficiency of the compressor depends on the inlet air temperature & fouling on the blades.

Gas turbine compressors consume approximately 60% of the overall cycle energy during operation.

Online washing is being performed while the gas turbine is in operation and at load.

The basic objectives of online cleaning are to maintain the cleanliness of a compressor after offline washing and to

extend the operating period between shutdowns required for offline (crank) washing.

Kawas has installed the GT Compressor

Online Washing System in all the 4 GTs and

simple payback period 15 Months. The

improvement in gas turbine power output after

utilization of compressor online water wash

system helps in restoring the lost power

and GT will run for prolonged duration.

Online Compressor Washing of Gas Turbines

http://www.google.co.in/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwi_yra2utHUAhXGLo8KHVnRCugQjRwIBw&url=http://entropyte.com/_gas-turbine-axial-compressor-washing.htm&psig=AFQjCNG56NYQVhzmALXI0iteEeHnOAPKVQ&ust=1498220994372608



Test Results of Online Compressor Wash

Test period (GT#2B) 01.04.2016 to 31.03.2017

No. of Offline Wash Performed 6 No

No. of Online Wash Performed 40 No. Every 3rd Day

No. of Days operation 157 days

Average power output increase after an off line wash 1.325 MW Average=1.25%

Average power recovery during an online wash 0.93 MW

Production Profitability due to Online Wash 2.81232 MU's

In terms of Rs. (Lakhs) 72.557856

The operating and maintenance cost of the systems are not considered.

Online and offline cleaning are complementary.



Energy Efficient Coatings on Pump Internals

The purpose of the circulating water system is to cool the condenser and condense the steam into water. Circulating

water is cooled in cooling towers.

There are 5 pumps which are driven by 6.6 KV, 930 kW motor.

Pump efficiency deteriorated due to scaling and corrosion.

Due to irregular surface area and resistance to flow, there may be

reduction in pump efficiency and increase in Power consumption.

Coating helps in gaining Pump efficiency by approximately 8%.

Energy Efficient Coating on Circulating Water Pumps



Description Before Coating After Coating

Power consumption(kw) 845.67 kw 886.45 kw

Total Head Developed (m) 26.5 26.5

Measured Average Flow (m3/hr) 9000 10635.93

Pump Output (kW) 649.9 752.42

Motor Input (kW) 845.67 886.45

Calculated Pump Efficiency

(assumed motor efficiency as 95%) 80.89 89.34

Gain in Efficiency (%) 8

Saving in kWh yearly (PLF=30%) 495500

Rs/kWh 2.58

Saving in Rs. (Lakhs) 10.45

Investment in Rs. (Lakhs) 9.4

Payback period in months 10.8

Energy Efficient Coating on CW Pumps



Replacement of Air Filters in Gas Turbines

Compressor sucks huge quantity of atmospheric air through paper filters.

These paper filters become clogged with dust, moisture and other impurities causing reduction in air flow and

high differential pressure.

The higher the clogging, lesser amount of air flow leading to low Gas Turbine power output.

Earlier filters were replaced when DP reaches at 1200 Pa.

Replacement being done at 700 Pa.

Losses due to high DP across filters is recovered as

improved GT output.

Simple Payback is 14 Months.

Replacement of Air Filters



As per our efficiency reports, losses in generation due to clogged filters: 0.83 MW.

Operating Hours of GT = 24 X 365 X 0.3 (PLF = 30%) = 2628 Hours

Average Energy Saved = 0.83/2 X 2628 = 1.454 MU’s

Gain due to early replacement of filters (Earlier we were replacing it in 15 months but now every 9

months-6months early replacement)

= 40% period gain X 1.454 = 0.5816 MU’s

Energy Tariff = Rs 2.58 per KWhr

Energy saved in money terms = 2.58 X 0.5816 = Rs 1.50 Million

Investment Made = Rs 1.75 Million

Payback Period = (1.75 X 12)/1.5 = 14 Months

Gain through Replacement of Air Filters



The hard scales which gets deposited on

condensers tubes of the Steam Turbines

affecting their heat transfer effectiveness

adversely and thus affecting the vacuum of

the system as well.

These hard scales are removed through jet

cleaning during Stream Turbine (ST) shutdown.

As per the capacity reports, after removal of

scales from the condensers, the vacuum

improved by 3.82/1.5 mbar in ST1C & ST2C

respectively resulting in corresponding saving of

0.382 MW/0.15MW power which remain effective

for minimum 60 days.

Total savings of INR 9.88 Lakhs

Jet Cleaning of Condensers



As per our efficiency reports, average gain in generation due to improved vacuum: 0.382 MW (ST#1C) & 0.15 MW

(ST#2C)

Operating Hours of ST = 24 X 60 = 2880 Hours

Average Energy Saved = (0.382 +0.15)/2 X 1440 = 0.383 MU’s


Energy saved in money terms = 2.58 X 0.383 = Rs 0.988 Million


Payback Period = (0.4 X 12)/0.988 = 4.86 Months

Gain through Jet Cleaning of Condensers



Installation of Energy Efficient Lights

Total 60 nos of convention lights of 70 w replaced with EE light in reservoir area.

Energy Saved = (70 -18)/1000 X 60 No. X (12) hrs per day X 365 day = 18396 KWhr per year

Total 700 nos of 36W tube lights replaced with 18 W LED.

Energy Saved = (36 -18)/1000 X 700 No. X (12) hrs X 365 day = 40068 KWhr per year


Energy saved in money terms = 2.58 X (18396 + 40068) = Rs 150,837/-

Investment Made = Rs 119000 + 200000 = 319,000

Payback Period = (319000 X 12)/150837 = 25 Months

In year 2018-18 15000 no. conventional light(covering complete plant and township) will be replaced by EE

LED lighting.

Installation of Energy Efficient Lights



VFD Installation in Raw Water Pumps

Gas plant operated at partial loading due to grid and gas availability constraints.

If, motor is allowed to continuous operate at full speed and uses electric energy at the full-load rate, even

though it was performing less useful work. In the process, it wasted a great deal of energy.

Incorporating variable frequency drives into applications such as fans, pumps, etc reduce energy use up to

50 percent at partial loads by matching motor speed to the changing load and system requirements.

Various drives have been converted to VFD’s like raw water pump, etc. On part loading operation of the

pump energy saving to the tune of 50 kW is achieved.

In 12 Month period, energy saved: 0.2008 MU’s

Energy Tariff: Rs 2.58

Energy saved in money terms = 2.58 X (0.2008) = Rs 0.516/- Million


Payback Period = (1.558 X 12)/0.516 = 36 Months.

Retrofitting of Variable Frequency Drive’s



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Energy Efficient Coating of continuously running pumps

like ARCW pump, service water, DM water and potable

water pump. (Investment 60000; Savings-32000,

payback 23 months)

Switching off one of transformers and both sections

bus charging through tie breaker to reduce transformer

losses.

Increasing COC from present level of 5 to 5.5 keeping

LSI & RSI within limits. (Rs 2.2 lakh)

Hot blow down in place of cold blow down for NDCT to

decrease to reduce evaporation losses and heat load

to NDCT. (Rs 2.61 lakh)

Replacement of all the lights with energy efficient LEDs.

Replacement of chillers of central HVAC with new

chillers units.

Optimizing operation

Reducing open cycle generation during start-up. (Electrical

saving per start up – 23414 KWh)

GT configuration as per fuel and schedule availability.

Switching off one set of fin fans in both GT and Gen cooling

in winters. (Saving – INR 3.06 lakh)

Single CW pump with one unit. (Saving-Rs 17.27 Lakh/year)

Stopping T/G of ST after 72hours (Earlier we were not doing

this because of vibration hiccup issues) (88 KW saving)

Water makeup pump operations only during night hours ( off

peak hour tariff ) and capacitor bank to avoid P.F penalty.

All HPBFP de-staging. (Savings – INR 7 Lakh/year)

Stopping of ARCW Pumps (35 KW)

Roadmap for Energy conservations



20

Year Thermal SEC

(Kcal/Kwh)

Electrical SEC (%) Target Gross Heat

Rate (Kcal/Kwh)

2014-15 2043 2.54 2050

2015-16 2064 2.9 2040

2016-17 2013 2.49 2020

Specific Energy Consumption-Trends

Target Electrical SEC: 2.5%



21

Station Heat Rate

(Kcal/Kwh)

APC (%)

Kawas 2013 2.49

Dadri 2039 2.69

Faridabad 1993 2.8

Jhanor 2089 2.79

Road map to achieve benchmark

De-staging of all boiler feed pumps.

Energy Efficient Coating on high

consumption pumps.

Increasing COC from present level of 5 to

5.5 keeping LSI & RSI within limits

Replacement of all lights with energy

efficient LEDs.

Replacement of chillers of central HVAC

with new chillers units.

Benchmarking



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0

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'07-08 '08-09 '09-10 '10-11 '11-12 '12-13 '13-14 '14-15 '15-16 '16-17 17-18

Kawas

Performance Trend of Kawas in NTPC Gas Stations

Source: PEM ranking of NTPC



23

GHG Inventorisation

Year Generation

(MU)

Scope1 CO2

(MT)

Scope2 CO2

(MT)

Total CO2 (MT)

2013-14 1388 557960 495 56291

2014-15 1741.2 696620 286 696906

2015-16 1212 485569 306.44 485875

2016-17 1717 686817 361 687178

1. NOx reduction through water spray system.

2. Replacement of Halon Fire fighting system with

Inergen based FF system.

3. Massive tree plantation.

4. Modification of Combustor components like

nozzles, liner, transition piece, etc.

5. Reduction in purchased electricity through

EE Coating on make-up water pumps.



24

Energy Conservation projects and % investment

EnCon Project Budget allocation %

Total turnover of the company/plant FY 2016-17 (Rs. Million): 9734.6

Amount invested in EnCon Projects FY 2016-17 (Rs. Million): 39.1

Investment as % of turnover: 0.391

Status of Energy Conservation Projects of FY 2016-17

S. No. Description Status

1 HP BFP Destaging (02 No) Implemented

2 Energy Efficient Coating on CW Pump Implemented

3 Replacement of CFL & HPMV with LED Implemented

4 Online Compressor Washing Implemented



25

Efforts towards Green Company

Projects Implemented

Procurement of Energy efficient Motors, LED Lights, solar lights, etc

Installation of RO Plant. Settling pit for conservation of water.

Jute Bag Distribution to Township.

Tree Plantation: 2016-17 – 1000 No. 2017-18* - 2025 No.

Green Vendors

Contract for collection of Bio medical waste is awarded to agency which is accredited and authorized by Gujarat

Pollution Control Board. Only valid licence holders from GPCB are considered for tendering/award.

Contract for collection of Electronic & Hazardous waste is awarded to agency which is accredited and

authorized by MSTC Ltd.

Benefits Achieved

Replacement of Halon Fire Fighting system with environmental friendly Inert gas based fire protection system.

Qty of Hazardous waste sold in last three years:

Resin: 3.99 MT

Used Lube Oil: 12.55 KL

Transformer Oil: 30KL

E-Waste free.



26

SEC Monitoring and Reporting Formats

OLEMS Reports.

SAP generated reports for APC.

SMC

ORT

Mobile message

EMAP

Energy efficiency measures

implementation.

Monitoring of Auxiliary power consumption.

Coordinating & conducting Energy audits

of different systems.



Best Practices

Air Scoring Line

Manual handling of chemical process has been removed.

Saving of time, APC & manpower.

Exact measuring of quantity leading to no wastage/over

usage of chemicals.

Investment of INR 45,000/- gives simple payback of 1

Months.

• Zero Investment project.

• Reduces evaporative & drift loss leading to

saving of Rs 2.61 Lakh per annum (Pumping cost &

water saving).

Hot Water Blow Down



28

OPEN CYCLE TIME REDUCTION PLAN

• Typical efficiency of Brayton cycle is 32% in open cycle

mode and 49% in combined cycle mode.

• Open Cycle Thermal SEC- 3010 Kcal/Kwh whereas

Combined Cycle it is 2050 Kcal/KWh.

• Cold Start Up Time is 330 Minutes.

• By reducing open cycle time, thermal specific energy

consumption will decrease for the station.

• Electrical Saving – 23414 KWh per start-up.

• Saving in terms of Rs. 60000/- per start-up.



Projects implemented through Kaizen

Air scoring Line for neutralization of De-Mineralization plant effluent. (Payback - 1 Months)

Replacement of old obsolete motorized actuators with new indigenous actuators. (INR 1.5 Lakh/actuator)

Steps towards zero discharge: Boiler drain pit water reuse, etc

Roof rain water harvesting.

Settling Pit for water conservation.

Energy conservation week is celebrated every year.

Various quizzes, competition and training are imparted to employees & their families on energy

conservation awareness.



Renewable Energy Sources and Utilization of Waste

Presence in Renewables

30 KW SOLAR PV AT ITI OLPAD.

Solar lights in reservoir and Damka Village under CSR.

Future Projects in Renewables

35 KW ADMIN BUILING SOLAR PV ROOF TOP.

E-Vehicle charging point.

1 MW FLOATING SOLAR PV OVER RESERVOIR.

173 KW SOLAR PV FLOATING OVER POND IN SIMULAOR.

65 MW SOLAR PV PLANT BESIDE STAGE-II.

Utilization of Wastes: Around 216 MT/year of household waste have been used in Bio-methanation plant

which produces gas having GCV 1750 Kcal/Kg. The heat value of 378 Million kcal/year have been

generated in the bio-methanation plant. Vermicompost plant at Plant.

Installation and Supply of 30 MLD Tertiary treated water from SMC (Bhesan Sewage Treatment Plant of

Surat Municipal Corporation) to NTPC Kawas.

Settling pit to utilize water from Clarifier & cooling tower sludge.

Awards and Accolades



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National Energy Conservation Award – 2012 & 2015



33

Station No of ESCerts Station No of Escerts

Singrauli 17610 Anta 1256

Rihand -16225 Auraiya 13931

Unchahar -7051 Dadri Gas 1112

Tanda -26086 Faridabad 7145

Dadri 33217 Kawas 24370

Badarpur -2610 Gandhar 8897

Korba -3395 Kayamkulam 1643

Vindhyachal 33729

Sipat 36443

Ramagundam 26947

Simhadri 11511

Farakka 24041

Kahalgaon 31197

Talcher Kaniha -49681

Talcher Thermal 1356

NTPC Coal Total 111003.23 NTPC Gas Total 58353

24370 ESCerts

issued to Kawas for

PAT CYCLE-1.

PAT Cycle-I performance



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SAFEE Global Energy Management Award for 2016

• Won SAFEE (South Asian Forum For

Energy Efficiency –World Energy

Council) First Global Energy

Management Award for 2016-17,in

the category Thermal Stations/Gas

Category for excellence in Energy

Efficient Performance dtd. 12/1/2017

.

Thank You

Address

NTPC Limited, KGPP,

Adityanagar, Surat – 394516 (India)

Phone

+91 261 2877000

Email

[email protected]

[email protected]

[email protected]

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mailto:[email protected]





GT 1A synchronized 24.05.1992

GT 1B synchronized 22.03.1992

GT 2A synchronized 27.08.1992

GT 2B synchronized 30.06.1992

ST 1C synchronized 23.02.1993

ST 2C synchronized 19.03.1993

Renovation and

Modernisation Milestones

Commercial Operation

Milestones

GT 1A synchronized 21/01/2013

GT 1B synchronized 27/08/2013

GT 2B synchronized 05/03/2014

GT 2A synchronized 22/08/2014

ST 1C Minor O/H 24/08/2013

ST 2C Major O/H 04/07/2014

NTPC Kawas (Stage - I)



Air Filters Replacement

SAVINGS DUE TO REPLACEMENT OF AIR FILTER CARTIDGES

SL.

NO. DATE

DIFFERENTIAL

PRESSURE IN

PASCALS

LOSS IN GENERATION DUE

TO HIGH DP AS PER

CAPACITY TEST in MW

REMARKS

1 06.04.2016 712 0.94 READINGS TAKEN BEFORE

REPLACEMENT OF AIR FILTERS

2 02.09.2016 219 0.16

READINGS TAKEN AFTER

REPLACEMENT OF AIR FILTERS IN JUL

2015

IMPROVEMENT 493 0.78 EXCESS GENERATION MADE POSSIBLE

WITH REPLACEMENT

SAVINGS in MU 1.097

SAVINGS Rs. (Lakhs) 28.30 AVG. RATE OF ENERGY IN KAWAS- @

RS. 2.58 PER UNIT

Note:- Replacement dates-

1A 01.05.2016

1B 01.06.2016



Power /Operation Conditions

Before Offline Wash

After Offline

Wash

Before Online

Wash

After Online

Wash

Ambient Temperature °C 30.589 33.549 27 25.071

Ambient air Pressure BARA 1.0047 1.0070 1.0119 1.0120

Ambient RH % 34.721 26.92 35.341 33.554

GT Gross power (measured) MW 111.97 111.03 119.84 118.08

Corrected power

(corrected to site condition ) MW 115.10 117.09 115.77 116.88

The improvement in gas turbine power output after utilization of compressor online water wash system helps in

continuous prolonged operation and recovery of lost power output.

Performance Improvement thru Online Compressor Washing

presentation for 18th national award for excellence...

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