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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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Copyright © 2016 Your Company All Rights Reserved. 2

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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



Installed Cap : 53651 MW

Under Construction : 14000+ MW

RE :928 MW



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

Copyright © 2016 Your Company All Rights Reserved.


5

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



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



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



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



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



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



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



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



13

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



14


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



15


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



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



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



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



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



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



Innovative Ideas Implemented

QR Coding

Safety Park

CLIMS

PRADIP

QR Codes at CCR Vertigo Structure at Safety Park



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



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



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)



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



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



Renewable Energy Sources (E-Vehicle Charging Point)

E-Vehicle charging point



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



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



Vermi Composting Unit

FY 2017-18 Produced: 1700 KgsSavings: INR 1.16 Lakhs

Current Financial year Produced: 8700 KgsSavings: INR 5.86 lakhs



31

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



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



35

National Energy Conservation Awards – 2017, 2015, 2012

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CII Energy Efficiency Award 2017



More Feathers in the Cap

SEEM Award For Sustainable Energy Performance & Energy Conservation

SGCCI Golden Jubilee Memorial Award For Excellence in Improving Productivity



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



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

Email

[email protected]

[email protected]

[email protected]