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19th National award for

CII “EXCELLENCE IN ENERGY MANAGEMENT-2018”


30th to 31th AUGUST, 2018: HICC, HYDERABAD

NTPC Limited

‘TO BE THE WORLD’S LEADING POWER COMPANY, ENERGIZING INDIA’S GROWTH’


NTPC Ltd Growth Plan
% Mix
Genrn source 30.06.2018 By 2032 Presented By:
53.651 GW Exp 130 GW
Coal 87.54 65.4
Gas 8.71 4.6 Manoj K Jha (DGM-EEMG)
Hydro 1.74 3.8 Sathish Chandra (Sr.Mgr- BMD)
Solar 1.90 23.2
Other RE (wind) 0.11 1.5
Ashwin Raja (Mgr-EEMG)
Nuclear 1.5
Total 100.00 100

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


NTPC Ramagundam

o NTPC & RSTPS Profile

o Production Process

o SEC (heat rate and APC ) trend

o Energy Saving Projects (2015- 2018)

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

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


NTPC PROFILE

Listed on indian 2013

First 200 MW Unit Stock Exchange : NTPC into


Commissioned GOI Holding 89.5% Wind and
Solar
1982 2004

1975 1997 2010


Became a 2018
NTPC Became a
Incorporated Navratna Maharatna First 800 MW
company Company commissioned

Today 2032
53.65 GW 130 GW

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Consistent recognition of NTPC
excellence
th
12 Largest Power Generator
in the world
Pan India presence
rd
3 Largest coal based power
generating company in the
world

nd
Ranked 2 in terms of PLF
rd
and 3 in terms of availability

Great Place
To work
by Economic
Times

“Corporate Plan 2032”.


• 30 GW Solar by 2032
• 30% No-fossil based
capacity by 2032.
PLATTS TOP 250
GLOBAL ENERGY
COMPANY 2018
Ranked 39

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


RSTPS Profile

NTPC - Ramagundam Vision


“To be a World Class Power Station actualizing NTPC Vision”

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


RSTPS Profile

NTPC-RAMAGUNDAM

LOCATED IN

PEDDAPALLI DISTRICT
OF TELANGANA

2600MW

(3x200 + 3x500 + 1x500 ) +


10 MW Solar

TeSTTP Planned 800 MWx5


Under Construction : 2 Units of 1600 MW

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


NTPC Ramagundam Profile
Power Generation Process

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


NTPC Ramagundam
Pattern in specific Energy Consumption

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


CO2 Emission Avoided through the Years
CO2 Emission avoided due to Performance Improvement through Years (LMT)
Cumulative 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

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Energy conservation projects 2015-16

Total Savings for 2015-16


Slno Activities In Energy
Rs in Lacs
(MU)
1 Corrocoating in stage-I CW pump 2& 6 3.10 74.42

2 Conversion of lighting to LED 0.13 3.15

3 MDBFP-1A/C and 2B/C Cartridge Replacement 4.32 103.68

Use of Energy Efficient Motors in Ash slurry pump house in


4 0.65 15.55
stage-I
Use of Energy Efficient Motors in Ash slurry pump house in
5 1.22 29.28
stage-II
Stage-1 ESP hopper heater cut-in cut-off optimised with
6 2.25 54.00
incorporation of timers
7 Stage-1 DAETP Energy efficient compressors 0.29 6.91

Total 11.96 287.00

Indicates without investment

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Energy conservation projects 2016-17

RSTPS Energy Savings on account of specific efforts towards Energy


Sr No Activities Total Savings for 2016-17
In Energy (MU) Rs in Lacs
1 Corrocoating in stage-III CW pump 7B nad CW pump 6 of Stg I 1.24 29.82
2 Conversion of lighting to LED 1.26 30.24
3 U7 OH and APH complete basket replacement 8.64 207.36
4 U5 APH OH duct repair 1.73 41.47
5 U6 APH OH duct repair 0.73 17.42
6 Use of Energy Efficient Motors in CT Fans in stage-I 0.31 7.33
Use of Energy Efficient Motors in Ash slurry pump house in stage-II
7 0.97 23.33
(contnd from previous year)
Stage-1 ESP hopper heater cut-in cut-off optimised with incorporation of
8 4.14 99.36
timers
9 Stage-1 DAETP Energy efficient compressors 0.40 9.68
Total Saving 19.42 466.00

Indicates without investment

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Energy conservation projects 2017-18
RSTPS Energy Savings through Energy Conservation activities 2017-18
Type of
Activities Total Savings for 2017-18
Sr No Energy
Mus MT coal Rs in lakh
1 Corrocoating in stage-I CW pumps Electrical 1.58 37.95
2 U7 OH APH complete Basket Replacement (sustained from 2016-17) Electrical 15.77 378.43
3 U5 APH OH based on trending of DPs (sustained from 2016-17) Electrical 1.84 44.15
4 U6 APH OH (sustained from 2016-17) Electrical 1.10 26.49
5 Use of Energy Efficient Motors in CT Fans Stg I/II (under EC Electrical 1.05 25.23
Capital Budget)
6 Use of Energy Efficient Motors in CHP (sustained from 2016-17) Electrical 1.31 31.54
(under EC Capital Budget)
7 Stage-1 ESP hopper heater cut-in cut-off optimised with incorporation of timers Electrical 2.63 63.07
(sustained from 2016-17)
8 Saving due to Lighting conversion Electrical 5.69 136.66
9 Stage-1 DAETP Energy efficient compressors Electrical 0.35 8.41
10 U1/2/3 BFP cartridge replacement based on trending (two pumps in each 5.18 124.42
units in 2016-17)
11 U5 SCAPH Jet cleaning in opportunity 0.43 10.37
12 U4 APH Complete Basket replacement 1.30 31.10
13 U6 Condenser Jet cleaning during Opportunity based on HR deterioration 3840.00 126.72
trending
14 U5 Condenser Opportunity CLEANING based on HR deterioration trending 1920.00 63.36
15 U4 28% Economiser Coil Addition (System modification based performance 6000.00 198.00
monitoring)
16 U6 28% Economiser Coil Addition (System modification based performance 19466.67 642.40
monitoring) sustained from 2016-17
17 Stage II CT renovations (all 6 units) based on performance assessments 22000.00 726.00
Indicates without investment 31.33 53226.67 2700.21

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


GHG Inventory

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 Mus and 53250 MT tons of coal 2700

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Road Map for Heat Rate Improvement
Road Map for Heat Rate Improvement
Expected Unit Station HR Target Completion year
Heatrate improvement
Action Plan Proposed
improvement
(Kcal/Kwhr)
expected
(Kcal/Kwhr)
2018-19 2019-20 2020-21
U#6 LPT OH Completed in July
2018
10 1.92
Heat Rate imptoved
by 16 Kcal
28% additional Economiser
20 3.85 Oct-Nov 2018
Coil Addition in Unit-5 Boiler
Unit 5 Complete Air Heater
5 0.96 Oct – Nov 2018
Basket replacement
U#7 HPT/IPT OH 25 4.81 July-Aug 2018
U#3 Mega R&M (Turbine
70 5.58 April-May 2019
upgradation)
U#2 Mega R&M (Turbine
70 5.58 July-Sept 2019
upgradation)
U#1 Mega R&M (Turbine Sept-Nov 2019
upgradation) 70 5.58

Unit 4 HPT turbine OH 8 1.54 01-Mar-2020


Unit 6 BLR. & LPT annual OH 18 3.46 June - July 2020
Unit 5 BLR. & UNIT AUX.
annual OH
8 1.54 August 2020
Unit 7 BLR. & UNIT AUX.
annual OH
8 1.54 Nov – Dec 2020
Total 252 36.36

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Roadmap for APC Reduction

Roadmap for APC Reduction


Expected APC Reduction
Action Plan Proposed Implementation Years
(MU)
2018-19 2019-20
IE3 motors stg I&II CT (60 nos of 67 kw) 0.683 Feb-19
Conversion of EE Lighting 0.200 Feb-19
Conversion of EE Lighting 0.200 Aug-19
Plant and Township street lighting through EESL 3.100 Mar-19
Plant and Township street lighting through EESL 1.280 Aug-19
U3 BFP Cartridge replacement/refurbishment 3.154 April - May 2019
July-Sept 2019
U2 BFP Cartridge replacement/refurbishment 3.154
Sept-Nov 2019
U1 BFP Cartridge replacement/refurbishment 3.154
VFD for ID Fan of one unit of Stg II 3.154 Aug-19
Conversion of Admin building into Net Zero building 4.468 Mar-20
Total 22.547
In addition to above Structured APC Reduction plan has been made and being followed wherein
equipment running optimizations based on performance are done

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Innovative Projects

Innovative Project :1
Performance Improvements through ESP GD Screen modifications in U4, 500 MW

APC reduction upto 3.72 MU/Year and saving upto 90 lakh/Year

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Innovative Projects

Innovative Project :2
CHP Coal conveyor idle running reduction by Monitoring SEC

APC reduction upto 0.6 Kwh/Ton


Coal Handled in Fy. 2018-19 (Till 13 Aug 18) :41142524 MT CO2 Reduction :2152 Tons
Power Saved : 2.48 MU Monitory savings : 60 Lakhs

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Innovative Projects
Innovative Project :3
CW channel screen and Unit 6 Condenser Jet cleaning in opportunity Shutdown

•• Condenser Vacuum
Condenser Vacuum
improved by
improved by255 Kcal/Kwhr
mmHg
• Monitory gain Per day: HR
Heat Rate
•improved by 30 Kcal/Kwhr
improvement by 9
Kcal/Kwhr
• Gain at Full load: Rs 3.3
Lakh per day
• Gain at Full load: Rs 3
• Monthly
Lakh CO2 Emission
per day
reduction by 3.7 MT
• Monthly CO2
Emission reduction by
3.4 MT

Source of idea:
Through Monitoring &
Analysis

Before After Replication potential:


Yes, can be done
NTPC Ramagundam
Capital Project :1
Heat Rate Improvement through 28% Extra Eco coil Addition U#4, 500 MW in March 18

 Total cost incurred each unit: Rs 10 Cr Heat Rate Improved by 15 Kcal/Kwhr

 Annual Benefit due to coal saving: Rs 9.6 Cr. PAY BACK PERIOD:10 Months
Renewable Energy Installed

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


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

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Utilization of Waste Material as Fuel
Solid 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

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Utilization of Waste Material as Fuel

Township- 200kg/ Waste Per day: Saving 4 LPG Cylinders/Month


Plant Canteen - 50 kg/ Waste per day - Saving 1 LPG Cylinders/Month
Per Month Saving 500 Kg of Coal equivalent
National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018
Green Supply Chain : PRADIP- Paperless Office

Paper Consumption in RSTPS - NTPC (in


Year 2017):
1,297,500 A4 Sheets

Trees Saved : 157


CO2 Emission Reduced: 24806 Kg/Year
(One Ream = 500 A4 Sheets
One Tree Yields 16.5 Ream*)

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Green Supply Chain : Storm Water Separation
& Zero Liquid Discharge

• Process water effluent separation for Specific water


Specific Water
reduction.
reduction expected
• Separation of Rain water from common plant channel
by 0.3 l/kwhr
• Proposal Under Implementation

 One Lakh Tree Planted in Year 2017-18 Ash bricks use for
 Ash Utilization for last two consecutive year is more than 100% Telangana projects

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


RSTPS: Elements of Energy Management System
Evaluation &
Dissemination

Accurate Gap
Assessment
Retrofits and Analysis

Modus-
Operandi

PIPs Action Plans

Implementation Resource
Mobilization

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


RSTPS: Elements of Energy Management System

• Yearly three Internal audit of different system are being carried Energy Auditor

• MEA is being carried out every three years as per Gazette notification of GOI

Action plans are devised as per Audit findings and notified for corrections

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Team work, Employee Involvement & Monitoring
Daily monitoring system
• Online Heat Rate (HR) Monitoring through PI,TLA(Thermal Loss Analysis
System),and real time DDCMIS data.

• Auxiliary Power Consumption (APC) monitoring through OLEMS (Online


Energy Energy Management System.

• Equipment wise Specific Energy Consumption monitoring through SEED


(System Energy Efficiency Display), developed In-house

Practices adopted for energy performance


• Performance review by management through Daily Planning Meeting, Monthly Through ORT
meeting and ROPR half yearly.
• Corrective actions generated from monitoring & review meetings implemented in Operational
and Maintenance Practices.
• Performance improvement without Investment by operational optimisations and practices
• Performance Improvement with investment by System modifications and R&M of equipment

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Performance Monitoring tools
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

5. Efficiency Awareness amongst


Operation and Maintenance people

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Performance: Remote monitoring through TLA tool

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


NTPC Ramagundam
HEAT RATE Monitoring Through PI and PI Tools
Avg HR Dev
Monitory
Parameter Unit Value (Kcal/kWh)
loss
Cumulat
(Lakh rs)
Design Daily Daily ive
Load MW 500 459.2 18.9 26.3
Main steam Temp
536.0
before ESV °C 537 0.7 1.3 0.02
Hot Reheat Temp
534.7
before IV °C 537 1.5 0.4 0.05
Superheat
25.8
Attemperation t/hr 0 1.2 1.6
Reheat Attemperation t/hr 0 18.5 7.2 6.7 0.26
mm
62.6
Condenser Vacuum Hg 76.0
Cond Vac (Corrected for mm
73.5
CW I/L temp) Hg 76.0 -4.7 -2.7 -0.17
CW inlet temperature °C 32.2 29.5 -20.9 -24.5 -0.75
Makeup Water * t/hr 0 14.63 21.5 12.0 0.77
FW temperature at HPH
253.3
O/L °C 253.7 -3.9 2.0 -0.14
Dry Flue Gas loss (DFG)
1) Oxygen at Eco
4.65
Outlet % 3.50 12.1 12.8 0.44
2) APH Exit temperature ° C 125 141.3
APH Exit
temperature 140.0
(Corrected) °C 125 19.7 16.6 0.71
Combustibles in Bottom
ash % 1.30 1.42 0.4 0.0 0.02
Combustibles in Fly ash % 0.40 0.33 -0.9 -0.7 -0.03

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


NTPC Ramagundam
Real Time Monitory Calculations Corresponding to HR deviations using DDCMIS data

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


NTPC Ramagundam
APC monitoring through PI/SEED/OLEMS
Monitoring of :U7 POWER Consumption T rends (Systemwise)
Values at
13-01-18 18:33
Draft System M illing System Condensate System Circulating Water System
Equipment Units Power Equipment Units Power Equipment Units Power Equipment Units Power
ID FAN-A(Ch-1) kW 1007.5 Mill -A kW 362.7 CEP-A kW 766 CW Pump A kW 2307.7
ID FAN-A(Ch-2) kW 1006.8 Mill -B kW 406.7 CEP-B kW 0 CW Pump B kW 2339.6
ID FAN-B(Ch-1) kW 975.0 Mill -C kW 0 CEP-C kW 772.2 CW Pump C kW 0.0
ID FAN-B(Ch-2) kW 949.1 Mill -D kW 410.6 Total Power kW 1538.2 Total CW Pumps Power
kW 4647.3
FD FAN-A kW 546.7 Mill -E kW 417.6 Total Condenser Flow
T/h 1337 Circulating Water Flow
T/h 61662.2
FD FAN-B kW 484.8 Mill -F kW 351.5 SEC kWh/T 1.15 SEC kWh/T 13.27
PA FAN-A kW 1175.0 Mill -G kW 443.5 Unit Load MW 492.4 Unit Load MW 492.4
Energy Consumion Energy Consumion
PA FAN-B kW 1327.3 Mill -H kW 0 Index kW/MW 3.12 Index kW/MW 9.44
Total Power kW 7472.2 Mill -J kW 0
Mill -K kW 385 ECW System Compreesed air System
Power of ID FAN-A kW 2014.3 Total Power kW 2777.6 Equipment Units Power Equipment Units Power
SEC of ID FAN-AkW/MW 4.09 Total Coal Flow T/Hr 364.8 ECW PP-7A (SG) kW 0 Instrument Air Compresure-1
kW 294.25
Power of ID FAN-B kW 1924.2 SEC kWh/T 7.61 ECW PP-7A (TG) kW 110 Plant Air Compresure-1
kW 50.1
SEC of ID FAN-BkW/MW 3.91 Unit Load MW 492.4 ECW PP-7B (SG) kW 68.78 Total Power kW 344.3
Energy
Total Power of ID FANS
kW 3938.5 Consumion Index kW/MW 5.64 ECW PP-7B (TG) kW 109.2 Unit Load MW 492.4
Energy Consumion
SEC of ID FANS kW/MW 8.00 Individual M ill SEC ECW PP-7c (TG) kW 0 Index kW/MW 0.70
Sp
Equipment Units Power Total Power kW 288.0
FD Fan Disch. T/h 1644.3669 Mill -A kWh/T 9.03 Unit Load MW 492.4 Ash handling System
Energy Consumion
SEC of FD FANS kWh/T 0.63 Mill -B kWh/T 7.52 Index kW/MW 0.59 Equipment Units Power
Mill -C kWh/T - Ash Slurry Pump A1
MW 175.45
PA Fan Disch. T/h 677.60303 Mill -D kWh/T 7.47 M DBFP Ash Slurry Pump A2
MW 130.36
SEC of PAFANS kWh/T 1.52 Mill -E kWh/T 8.00 Equipment Units Power Ash Slurry Pump A3
MW 134.96
Mill -F kWh/T 6.59 MDBFP 7C kW 0 Ash Slurry Pump A4
MW 134.57
Unit Load MW 492.35309 Mill -G kWh/T 8.52 Unit Load MW 492.4 Ash Slurry Pump B1
MW 0
Energy Consumion
Mill -H kWh/T - Index kW/MW 0.00 Ash Slurry Pump B2
MW 0
Energy Consumion
Index kW/MW 15.18 Mill -J kWh/T - Ash Slurry Pump B3
MW 0
Mill -K kWh/T 6.74 Ash Slurry Pump B4
MW 0
Ash Slurry Pump C1
MW 0
Unit Load 492 Ash Slurry Pump C2
MW 0
Unit Export 470 Ash Slurry Pump C3
MW 0
APC (MW) 23 Ash Slurry Pump C4
MW 0
APC (%) 4.60 Total Power kW 575.34
Unit Load MW 492.3531
Energy Consumion
Index kW/MW 1.17

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


NTPC Ramagundam
Auxiliary Power Consumption: Consumption Pattern
Auxiliary Power Consumption Pattern
BFP
Mills
10.86 %
8.28%
CEP
CW 5.46%
12.86 % ESP
3.00%

APC CHP
Draft 1.91%
6.02 % 35.20 %
Net ECW
1.75%
Genrn Comp.Ai
93.98 % r
1.95%
AHP
1.73%
Lighting Others CCpps
6.15% 9.22% 1.64%

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


NTPC Ramagundam
Equipment wise Specific Energy Consumption monitoring through SEED

Mill Outlet Temp FA ratio on Line Monitoring through SEED

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


NTPC Ramagundam
Heat Rate Improvement due to OH correction
UNIT 4 HR Improvements after OH - 2017-18
Boiler (Eco coil addition, APH Baskets replacements & LP Turbine, TG
TYPE OF O/H
Aux OH)
OVERHAUL PERIOD 20/12/17 to 25/01/18 (35 Days)
PARAMETER UNITS Design PRE O/H POST O/H
BOILER EFFICIENCY % 87.28 86.01 87.19
TURBINE HR KCAL/KWHR 1988 2074.1 2045.7
UNIT HR KCAL/KWHR 2277.7 2411.46 2346.26
APH Leakage (SAPH A/SAPHB/PAPH A/PAPH B) % 5.2/20.8 13.4/14.1/28.8/36.9 4.9/5.2/21.4/21.9
GAIN IN UNIT HR KCAL/KWHR 65.2
Loss due to CW inlet temp from Pre-O/H to Post-O/H KCAL/KWHR -1.2
TOTAL GAIN IN UNIT HR DUE TO O/H KCAL/KWHR 66.4
BENEFIT - HR reduction Lakh Rs/Month 169.92
ID Fan power Cons reduciton Lakh Rs/Month 8.65
Total Benefit after OH (Approx) Lakh Rs/Month 178.57
EXPENDITURE Lakh Rs 2300.00
PAYBACK Months 12.88

Unit#4 Draft Power Improvement due to OH


Observations: HR
PRE OH POST OH
08-Dec-17 08-Feb-18
improvement due to OH : 66.4
11:38:00 hr 11:12:00 hr Kcal/kwhr
PARAMETER UNITS
ID Fan-A Power consumption kW 3275 3056.0 Gain per month: Rs 178 lakh
ID Fan-B Power consumption kW 3352 3178.0
FD Fan-A Power kW 586 484.0
FD Fan-B Power kW 586 480 OH Expenditure : Rs 23 crore
Draft Power Reduction after OH (KW)
compensated to total air and coal flow KW 601
Pre and Post OH
Pay back : 12.88 months
NTPC Ramagundam
Heat Rate Improvement
Without Investment

Summary of actions without additional investments


• Improvement in loading factor
• Operational Optimization ( listing in separate slide)
• Condenser loss reduction –
• Restoration of COLTS, regular & effective operation of COLTS
• Installation of additional screens at the intake channel for removal of
debris;
• Regular and opportunity cleaning of condenser
• Attending Air ingress reduction in FG ducts
• Opportunity SCAPH Cleaning
• FW temp at inlet to Economiser: HPH to be kept in service

37
National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018
NTPC Ramagundam
PERFORMANCE IMPROVEMENT PROJECTS WITH NO INVESTMENT
Opportunity Cleaning of SCAPH to save Power and increase Air flow

U5 SCAPH Cleaning Effects


Pre Cleaning Post Cleaning
More than 50 out
PAPAH A Air side DP of range 45
PAPAH A Air side DP 6 22
PAPAH A Gas side DP 90 82
PAPAH B Gas side DP 107 100
PAPAH A FGET 62 123
PAPAH B FGET 232 170
PAPAH A Air out Temp 194 283
PAPAH B Air out Temp 311 311

PA Fan Total Power 3169 2329


Total PA power saving
(Kw) 840

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


NTPC Ramagundam
Opportunity U4 Condenser Cleaning (with no investment)

100 100 100 525 35 100 10M AVG VAC.Average 100 100 100 510 33.2 10M AVG VAC.Average
101.921 85.4098
90 90

EXP 10M AVG VAC.Average EXP 10M AVG VAC.Average


80 80
79.4597 77.9172

70 70
VAC LOSS.Average VAC LOSS.Average
22.4612 7.49261
60 60

G4_MW G4_MW
50 50
485.51761 479.85690
MW MW
40 40
4TAG0285 4TAG0285
33.27017 33.07436
30 30
degC degC
VAC LOSS.Value VAC LOSS.Value
20 20
21.8567

10 10

0 0 0 0 31 0 0 0 0 420 31.2
17-04-2017 00:00:00 24.00 hours 18-04-2017 00:00:00 23-04-2017 00:00:00 24.00 hours 24-04-2017 00:00:00
10m Avg Vac 10m Avg Vac
Exp Vac 10m Avg Exp Vac 10m Avg
Condenser Vac Loss Condenser Vac Loss
G4_Gross Meter_ Total Active Pow er G4_Gross Meter_ Total Active Pow er
CW INLET TEMP LEFT CW INLET TEMP LEFT
Condenser Vac Loss

Gain: Before cleaning condenser vacuum loss was 22 mmHg and after cleaning reduces to 8
mm Hg thus 20 Kcal/kwhr Improvement in HR loss found corresponding to saving of Rs 2
lakh monitory gain daily and reduction of CO2 emission 2230 Tons monthly

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Budget for Energy Conservation 2017-18
Energy efficiency & awareness training program

 Workshop on Energy Cost Optimisation was


arranged in March 2017 in which participants from
all NTPC stations and SR beneficiaries attend. The
press release is attached

 Energy Conservation slogans competition arranged


in 2017-18 for employees, school Children

 Display of Energy conservations hoardings in Plant


and Township

 Energy efficiency at Fingertips Display


Boards/Hoardings inside plant area

 Efficiency Awareness training module through


training Centre
Projects implemented through Kaizens
( Workers and Supervisor level)

• The ash slurry sump level high alarm


to be given so that corrective actions
can be taken to avoid the overflow.
• Status: Implemented
• Idle running of slurry system
minimized
• APC reduction of 400 Units per day

Safety Related:
1. Unit-1 3rd floor opp.C&I room hand rails r weak.
2. Unit-1 Lamp cover hanging opp. burner S.
3. Cable tray cover hanging near burner-E in Unit-1.
4. Stage-1 Bottom Ash grinder flushing v/v location is unsafe.
ISO 50001

In process of
certification, document
writing in progress.

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


NTPC Ltd. – Finance : Profit After Tax up by 10.21%

NTPC Ltd TOP and BOTTOM line growth:

• For FY 2017-18, NTPC Ltd. generated 265.80 Billion Units against 250.31 Billion Units
generated in the previous year, registering an increase of 6.19%.

• For FY 2017-18, Audited Total Income is Rs. 85,207.95 crore, registering an increase of
7.39% over the previous year Audited Total Income of Rs. 79,342.30 crore

• Audited Profit After Tax for FY 2017-18 is Rs. 10,343.17 crore as compared to Rs.
9,385.26 crore in the previous year, registering a growth of 10.21%.

NTPC Ramgundam TOP and BOTTOM line growth:


Revenue earning in 2017-18 was Rs 5620.55 CR in comparison to Rs 5559.02 in 2016-17

Profit in 2017-18 was Rs 715.22 CR in comparison to Rs 736.49 CR in 2016-17

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Operating Challenges and Mitigations

Challenges:
(Maintaining the performance level)

• Operation at New Technical minimum 55%: Frequent backing down


• Uncertain renewable energy injection in Southern Grid
• RRAS down regulations
• Equipment degradation due to Flexible operation

Mitigations:
• Training to O&M personal for Flexible Efficient Operation
• Load reduction in Units based on Unit Heat Rate Merit Order
• Structured APC Reduction plan implementation
• VFD in LT and HT drives in a big way
• Capital Investment for Equipment upgradation
• Daily Monitoring of ECR
• Maintaining less ECR amongst the beneficiaries for better merit position

Introduction of Pooled Tariff across the nation by competent authority


National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018
Awards & Accolades Received during 2017-18

1. Ramagundam Received Golden Peacock


Award for Excellence in Energy
Management Organized by Institute of
Directors on 7 July 2018.

2. NTPC,Ramagundam Received Apex


India Energy Efficiency Award 2018.

3. Ramagundam declared Winner in CSR-


CD & Runner-up in Productivity in
Swarn Shakti Award.

4. Greentech Safety Gold Award 2017


(received on December 14,2017 at
Goa)

5. 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).

6. Techno Galaxy 2018 Runner up Award


SR Region

7. Awarded Second in PEM matrix


evaluation across NTPC.

National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018


Station Highlights during calendar year 2017
Other Achievements:
 Station has recorded highest ever daily Generation of 64.401 MU on 29.03.2017 with a PLF of
103.21 % (Previous best figure Is 64.395 MU on 29.03.2009) Since Inception.

 Unit 3 recorded 114 days continuous run during the calendar year.

 Unit 6 recorded 123 days continuous run during the calendar year.

 Unit 7 recorded 203 days continuous run during the calendar year.

 NTPC RSTPS GOT 26000 ECERTS IN PAT CYCLE I

Major Activities In Pipeline:


• Conversion of Admin Building in Net Zero Building: Potential saving is 600 KW in 2019-20
• CW Channel Solar PV 125 KW in 2018-19
• Floating solar on water reservoir: 200 MW by 2021-22

Celebrating
40 Years
Of Excellence
National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2018

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