10. NTPC Vindhyachal CII PPT 2018 - Green Business Centre...10. NTPC Vindhyachal CII PPT 2018 -...

NTPC Vindhyachal Welcomes YouVindhyachal

NTPC Vindhyachal Super Thermal Power StationS Banerjee (AGM EEMG ), Manas Kapoor (Manager EEMG)

Vindhyachal

Presentation for “Excellence in Energy Management” –2018

Vindhyachal

4 Click to edit Master title style

Copyright © 2016 Your Company All Rights Reserved. 4

Welcome to the Largest Power Station of India

Capacity Stage-1 = 210MW X 6 (1988- 92)Stage-2 = 500MW X 2 (2000)Stage-3 = 500MW X 2 (2006-07)Stage-4 = 500MW X 2 (2013-14)Stage-5 = 500MW X 1 (2015)Total capacity= 4760 MW

Renewables 569 kw commissioned

Land 5800 Acres including ash dyke

Water Source Discharge canal from NTPC Singrauli

Coal Source Nighai, Dudhichua Coal Mines of NCL

Beneficiaries Madhya Pradesh, Maharashtra, Chattisgarh, Gujrat, Goa , Daman and Diu, Dadra, Nagar Haweli



Company ProfileTechnology: Unit capacity

6X 210 MW unit And 7X500 MW units are sub critical boiler technology

210 MW units are having 2021 Kcal/kwh and stage V is having 1932 Kcal/kwh of GTCH

FGD (Wet Flue Gas Desulphurisation)

210 MW X6 Boiler: Dry bottom, corner fired, balanced draft, convective reheat, direct fired tilting burner typeTurbine: Impulse reaction, reheat, closed cycle with regenerative blending type Generator: 210 MW, OFAF cooling, self excited

500 MWX7 Boiler: Controlled circulation, refilled tubing, dry bottom, top supported, radiant heat single drum balanced draft, tilting tangential type Turbine: KWU, 3 cylinder, reaction, reheat closed cycle typeGenerator & Aux: 500 MW, OFAF cooling, self excitedVindhyachal FGD is limestone based WFGD plant supplied by M/S GE spread over 20,000 square Meter

• PAT Cycle 1 :Target Achieved by 9 Kcal/Kwhr & earned 30,000 escerts

• PAT Cycle 2: Target 2518 Kcal/Kwh ,More than 40 Kcal/Kwhrthan normative NHR



Sp. Energy Consumption in last 3 years

25422598

2541

2374

2424

2382

79 77

90

6.61 6.71 6.28

0

10

20

30

40

50

60

70

80

90

100

2250

2300

2350

2400

2450

2500

2550

2600

2650

2015-16 2016-17 2017-18

Net heat Rate

Heat rate

PLF

APC

Net Heat rate high due to less scheduling on account of Grid

Complete stoppage of Imported coal procurement, Action Plan implemented for ECR reduction , third party sampling Both at mine end and Plant end

PLF increased as our merit Order improved

APC Guidance Software introduced to reduce APC at part load

APC reduced through online monitoring and real time guidance from software

In consistent Trend of specific energy consumption is due to Varying Loading Factor



Sp. Energy Consumption in last 3 years (Breakup)

2542

2598

2541

21.7

17.2 16.8

25.6

15.719.9

16.3

14.2 12.3

10.9

5.77.5

16.2

12.6 11.5

2510

2520

2530

2540

2550

2560

2570

2580

2590

2600

2610

0

5

10

15

20

25

30

2015-16 2016-17 2017-18

Net Heat rate

DRY flue gass loss

Condenser loss

RH spray loss

CT loss

HP /ip turbineefficiency loss

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Major Initiatives Taken to Improve Specific Energy Consumption

APH seal replacement from soft to Hard seal

Total duct revamping in unit 1 , 6,4

APH basket replacement and global modification in unit 10

Boiler modification with BHEL under Global settlement of unit 8, 9,10

BFP cartage replacement in stage 1

Complete conventional light replacement with LED

Dry flue gas reduced from in stage 1 form 12.3 kcal/kwh to 8.3 kcal/kwh

APH Seal leakages reduced from 25% to 18% on an average

RH spray reduced on average 10 to 15 ton,And Reliabilityof RH metal surface increased

1.25 KW/mw improvement in Draft power

0.4 KW/mw BFP power improved



Major Initiatives Taken to Improve Specific Energy Consumption

Polymer coating in all CW pumps of stage 1 units

Introduction of Online condenser monitoring sheet for daily monitoring of condenser loss under different head

and taking action accordingly

Capital Overhauling of Unit 3 , I and unit 8 in July 2018

CT fills cleaning & replacement , flow adjustment depending upon capability and flow distribution

Blade angle increase from 12 to 17 deg in all CT fans of stage 4

Chemical Cleaning of condenser of unit 11 & 12

10 % efficiency improvement, 1100 to 1000 ton flow increased and 30 to 40 KW power improved

Air flow increased by 40 m3/hr in individual cell, CT loss improved by 2 kcal/kwh as compared to 2015-16

10 to 15 Kcal improvement in condenser

Unit 8 HP turbine efficiency improved by 5%



BEST POWER STATIONS IN THE COUNTRY

BEST POWER STATIONS IN THE COUNTRY BEST POWER STATIONS IN THE COUNTRY

APR - JULY'2017 APR - JULY'2018

STATION Capacity Rank PLF (%) STATION Capacity Rank PLF (%)BUDGE BUDGE TPS 750 1 100.08 BUDGE BUDGE TPS 750 1 98.07TALCHER (OLD) TPS 460 2 95.74

KORBA STPS 2600 3 91.38 TALCHER (OLD) TPS 460 3 93.42AMARKANTAK EXT TPS 210 4 91.30 HALDIA TPP 600 4 93.21

SIPAT STPS 2980 5 89.86 KASAIPALLI TPP 270 5 91.87BHILAI TPS 500 6 89.55 DAHANU TPS 500 6 91.49

PAINAMPURAM TPP 1320 7 89.44 SANTALDIH TPS 500 7 90.86IB VALLEY TPS 420 8 88.72 PATHADI TPP 600 8 90.76

DAHANU TPS 500 10 86.90 KORBA STPS 2600 10 90.22PATHADI TPP 600 11 86.33 SIPAT STPS 2980 11 89.21

KAKATIYA TPS 1100 12 89.13

KORBA-WEST TPS 1340 13 85.87 PAINAMPURAM TPP 1320 13 89.05



Merit order on the basis of Variable cost

Success Factor•Pit head location•Sound Corporate governance •Low cost producer•Highly talented team of committed professionals•Excellent relationship with suppliers and partners•Excellent relationships with statutory and regulatory bodies



Road Map to Achieve Benchmark/National/Global BestHEAD VSTPS NTPC Best Road Map to achieve Global Best

Generation Nation BEST Coal and Outage planning ( Implementation of Forced outage action plan )

Availability NTPC BEST Coal and AOH Planning

Plant load factor 89.92% 93.82% Talcher thermal (Second best)

Keep ECR low, ECR Reduction Plan

DC 93.15 % 93.41 Talcher thermal ( Second Best)

Monitoring 105% Capability and action plan Gap analysis

Sp Oil 0.16 (ml/kwh)

0.14% (ml/kwh)Rihand ( Second Best)

Following Best operational practices

Boiler tube Leakages

0.46 % 0.28 % Dadri Coal(Third Best in NTPC)

Monitoring of operational aberration, 100% Radiography of joints, Deploying Qualified welders and procedure

Forced Outage 1.19 % 0.85% Dadri Coal Monitoring of aberration parameter

Planned Outage 4.56 % 4.39% Ramagundam Gap Finding through performance analysis

Aux power 6.28 % 6.01% Korba Part load optimization of equipment ( Equipment wise specific energy optimization)

Heat rate 2382 Kcal/kwh 2305 Kcal/Kwh Korba Filling efficiency related gap at regular interval ( Optimization through Thermal Loss Analysis Software )



Energy Saving projects implemented in FY 2015-16

Investment(Lakhs)

Saving (Million)

Payback period

(Months)

2015-2016

(MUS)

Methodology (New Technology adoption)

LT Drives VFD in HFO stage ii & iii

47 2.1 30 1.40 Mus Hourly running hour

Lighting ( street + Plant)

45 3.43 18 2.28 Mus 20 W saving as compared to Incandescent lighting

Polymer coating ( 4B and 6B)

6 1.77 52 1.18 Mus 1000 Ton flow increases , 10 % efficiency improves, 15 Kcal improvement in Condenser

Flue Gas duct modification stage 1

200 4 .0 Million

45 2.8 Mus Monthly Monitoring by O2 and Pressure survey,

Cartridge replacement of BFP ( 2A and 5A)

20 6.39 Millions

7 4.25 Mus Efficiency Monitoring of BFP Pump




Investment(Lakhs)

Saving (Million)

Payback period

(Months)

2016-2017(MUS) /

tons of coal

Methodology

New initiatives ( APC optimization software installed)

0 7.4 0 22 Part Load characteristic of past performance data

Unit 8 Boiler Modification

22 49.6 6 22550 Tons of coal

Boiler temp and pressure mapping , and PG test short fall analysis

CT 7 A fills replacement

200 6.8 52 3129 Tons of coal

Cooling tower performance characteristic and shortfall

Unit 9 Boiler global settlement

22 20.7 13 9410 Tons of coal




Energy Saving projects implemented in FY 2016-17Investment(Lakhs)

Saving (Million)

Payback period

(Months)

2016-2017(MUS)

Methodology

LT Drives VFD CT fan &

30 1.58 19 1.05 In CT fan Depending upon CT fan characteristic and FOPH on running hour basis

Lighting 135 1.19 136 0.788 20 W saving as compared to Incandescent lighting

Polymer coating 3 0.69 2.3 0.46 Mus 1000 Ton flow increases , 10 % efficiency improves, 15 Kcal improvement in Condenser

Solar power 290 0.44 40 0.292 Mus

Learning operation & maintenance of solar power

Flue Gas duct modification

200 2.0 Million


Cartridge replacement of BFP (1C and 6C)

20 3.3 1 2.2 Mus Efficiency Monitoring of BFP Pump




Investment(Lakhs)

Saving (Million)

Payback period

(Months)

2017-2018

(MUS)

Methodology

New initiatives ( FD fan put in Low speed

0 9.07 0 6.04 Statistical study of O2 , Air flow and Bottom ash

Lighting (33500 lights replaced)

559 1.52 72 3.058 20 W saving as compared to Incandescent lighting

Polymer coating (3A,3B,5A,6B)

15 2.43 52 1.62 1000 Ton flow increases , 10 % efficiency improves, 15 Kcal improvement in Condenser

Roof top Solar power

16.4 0.87 23 0.623 All Lighting Load of Plant is replaced with Renewable Lighting

Flue Gas duct modification

200 2.0 Million





Investment(Lakhs)

Saving (Million)

Payback period

(Months)

2017-2018

(MUS)

Methodology

Cartridge replacement of BFP ( 3A, 5C)

23 5.51 3 3.672 BFP power improvement and Better low load performance

CT 7 B Fills replacement

200 4.59 52 10250 Tons of coal

Cooling tower performance characteristic and shortfall

Unit 10 Boiler modification

22 20.7 13 9410 Tons of coal


Unit 11 Condenser chemical cleaning

50 22.5 3 10250 tons of coal

Chemistry and condenser performance analysis



Innovative Projects of 2017-18

Online condenser performance sheet

Polymer Coating of Stage 1 CW pumps

ECO AC Installation in stage 2

Eco AC installation

Investment: 4.56 crore Saving : 0.22 Crore/yr

Polymer Coating In stage 1 CW pump

Investment: 24 Lakhs Saving :0.48 Crore/yr

Online Condenser Performance Sheet

Investment: 0 Saving :4.7 Crore /yr




-15.00

-10.00

-5.00

0.00

5.00

10.00

15.00

20.00

25.00

30.00

Deviation due toCW Inlet tempKcal/Kwh

Deviation due toCW Dirty tubes /Air IngressKcal/Kwh

Deviation due toCW Flow / HeatLoad Kcal/Kwh

Source of Idea is seasonal variation in condenser Losses Under Different head

Online data is collected through PI

Data analysis Is done on the basis of Condenser performance Method in EXCEL

Action Plan is prepared on the basis of gap in Performance sheet.

Through Monitoring Daily activity major activity leading to Air ingresses or choking can be identified and further deterioration can be avoided .

Replication ( Methodology is replication of earlier developed APC guidance software )

Can be implemented in •Cement Industry•Steel Industry•Medical science•Automobile industry•Manufacturing industry




0.0

5.0

10.0

15.0

20.0

25.0

Apr

il

May

June July

Aug Se

p

Oct

Nov Dec Jan

Feb

Mar

2014-15

2015-16

2016-17

2017-18

Source of Idea: Irrespective of Condenser cleaning not major improvement is seen condenser loss due to Flow in 2014-15

New technology Intervention: Polymer coating

1000 Ton flow increases , 10 % pump efficiency improves, 30 to 40 kw power reduces with average life of 3 to 4 years

Replication ( Methodology can be replicated in Pumps where Clarified water is used and erosion rate is high)

Can be implemented in •Raw water pumps•Ash water recirculation pump•Service water pumps•ECW & ACW pumps



ECO AC Installation in stage 2

Basic advantage is efficiency improvement from 15 to 16 kw/100cfm in reciprocating chiller to 18-19 kw/100 cfm screw chiller

Source of Idea from : Stage 3 combination of VAM and Screw chiller pump

Major changes required in converting reciprocating chiller to Screw Chiller is very less.It is cost effective, less maintenance and spare availability advantage.

Interdependency of OEM for Spare is reduced

No additional Input in manpower training is required

170 Kw of additional saving in Power

Replication:Model is the replication of Stage 3 AC system



Utilisation of Renewable Energy Sources

Roof Top Solar Generation Of VSTPSLocation CAPACITY (KW) Generation (kwh) Yearly PLF%

Stage 5 ASH handling Building 145 178993 14.09

Stage 5 TG building 265 293646 13.9

Stage 5 PT plant 44 56571 15.7

Stage 3 Service building (Comm. in Aug-17)

20 11256 18.18

DPS school (Comm. in Aug-17) 20 10825 9.28

NH3 shopping complex 30 14815 16.59

D Paul school (Comm. in Aug-17) 20 17249 14.79

SWYD (Comm. in Nov-17)

25 4754 2.17

VSTPS Total Roof top solar generation

569 588109 11.80



Utilisation of waste material as fuel

Installation of Bio Diesel Plant of 110 liter per day capacity

Installation of Bio gas Plant of 24KWh capacity

Installation Solid waste Compost Plant of 250 Kg capacity



GHG Inventorisation

Heat rate action Plan

APH basket replacement from 8Years to 4 years

Cooling fills replacement in 4 year

VFD Installation

LED light Replacement from Conventional replacement

Part Load APC Optimization

Renewables

Boiler global Modification

Condenser Chemical Cleaning

1009

988

95231.6 31.8

35.7

29.0

30.0

31.0

32.0

33.0

34.0

35.0

36.0

37.0

920

930

940

950

960

970

980

990

1000

1010

1020

15-16 16-17 17-18

GHG Inventorization

Tons of CO2/MUCo2 EmmisionC02 Ton emission



Green Supply Chain

PRADIP: PRo-Active and Digital Initiatives to become Paperless

Auto Rickshaw Charging Station installed at Main gate to Promote E vehicle Use

HR unified services for Paper less HR approval at NTPC

NOTE: E- Waste generated at NTPC Vindhyachal are returned / channelized through collection centre or dealer of electrical & electronic equipment producer or dismantler or recycler authorized by CPCB/SPCB In - order to ensure smooth disposal of e-waste as per rules, the clause of taking back the e-waste is incorporated in all purchase orders of NTPC Vindhyachal



Green Supply Chain

70000

75000

80000

85000

90000

2015-16 2016-17 2017-18

77000 77500

87000

Nos

Year

543173

1067700

1440700

17590001884000

2021500204650021215002213500

0

500000

1000000

1500000

2000000

2500000

1989-90 1994-95 1999-00 2004-05 2009-10 2014-15 2015-16 2016-17 2017-18

Nos

.

Cumulative Tree Plantation

VSTPS has taken following steps regarding tree plantation-•Agreement has been signed with M.P. Rajya Van Vikas Nigam for 05 lacs tree plantation in Madhya Pradesh in next 10 years.•50000 trees planted at Siddhi during 2017- 18. •NTPC Vindhyachal shall bear the entire cost of plantation.



Daily Energy Monitoring Methodoly

TLA ( Thermal Loss Analysis)• Live tracking Of Heat rate parameter• Kcal loss with trend

APC Optimization software• Real time monitoring of APC equipment wise• Even it provide Guidance to operator

Online condenser performance sheet• Real time monitoring of Condenser • Head loss under various category

Online Water Metering through Scada



DPM Presentation• Daily Financial Parameter• Aberration parameter

ORT Sheet • Efficiency sheet monitoring• Equipment performance with action plan

Part load Opportunity Utilization sheet

Mill running hour sheet

Daily Energy Monitoring Methodolgy



Employee Engagement and Team Work orientation at VSTPS

Responsibility: EIC

1) EEMG HOD

2) Shift Incharge

3)Unit controller

4) Maintenance person responsible

Company: VSTPP Department: EEMG(Testing & monitoring)Process Name: Efficiency Improvement

Activities in the process /Value Addition

Machine/Monitoring Equipment/ Measuring Instruments/Work Env.

Method/Criteria/External Document/CP/FMEA/Risk & opportunities

Effectiveness & Efficiency.

Man/Skill/Competency/Awareness

Input from Previous process:Efficiency gap & aberrations Output from Previous process:

Product/Service/Semi finished

TURTLE DIAGRAM :Process Approach Form

SUPPLIER:ORT report, EEMG deptOperation, maintenance Dept

GTCHR, Boiler efficiency, turbine efficiency , equipment performance, chemical aberration , capability shortfall

Ort report, TLA , APC sheet , Condenser sheet, EMS, etc

Efficiency Calculation, condenser performance , HP heater performance, BFP & CT performance etc

Maintenance related work, operation practices, Schedule planning. Shutdown, training input etc

Review at DPM, SMC, ORT and Long term planning AOH

Maintenance Plan Operation PracticesOptimization technique

CUSTOMER:Maintenance and operation



Energy Conservation

Year Budget Major Work

2015-2016 1.67 Crore VFD in stage 2 & 3 HFO

LED lightreplacement

Water balance study and meter installation

2016-2017 2 crore Solar roof panel Solar water Heater at D type qtr

LED light replacement

2017-2018 58.40 Crore 4 MW solar roof top

Led light replacement in plant and town ship

Solar water heater at guest house



Projects implemented through Kaizens

16 Projects were implemented through Kizen in the year 2017-18 ( 7 were efficiency oriented) 1) OPTIMISATION OF THE RUN HOURS AND

INCREASING THE LIFE OF ME WASH PUMP2) TO PROVIDE THE SOLUTION FOR PASSING

DETECTION IN LP BYPASS SYSTEM 3) FREQUENT BREAKDOWN PROBLEM IN VERTICAL

PUMPS OF ZERO DISCHARGE SYSTEM4) POOR INSTRUMENT AIR/PLANT AIR DUE TO

LEAKAGES IN AIR COMPRESSORS5) HIGH COAL REJECTION IN MILLS OF STAGE-1

BOILER UNITS AT VSTPS6) FREQUENT TRIPPING OF BOILER FEED PUMP

MOTORS7) REDUCTION IN BOILER TUBE LEAKAGES DUE TO

FLUE GAS EROSION IN 210 MW



Energy efficiency / awareness training program

100 % Enrolment of all employee through GPIlearn training program with separate module for efficiency improvement

O&M conference meet ( for capturing New ideas)

Energy managers meet Compulsory energy auditor nomination

minimum 2 employee one from EEMG each year

Operation general meeting with efficiency improvement practices

EEMG HOD meet



New initiatives Future course of Action

Initiatives Status Saving

VFD in CEP Under study 200 Kw

VFD in Raw water pumps to regulate drawl during part load

Under study 600 kw

Regulating ESP outlet damper of stage 1 ESP pass as per CFD modelling to distribute flow in 5 passes

Study already donewith BHEL in unit 5 and planed activity in the month of August-sept

1 kw/mw in one unit

Under performing Cooling tower improvement through additional FRP cells in stage 4

Paharpur consulted to study the feasibility of proposed plan

1 deg improvement in CToutlet temp

Nano technology in Lubricants to reduce Friction loss by 15% and in-turn reduce power by 10%

Developed by NETRA under procurement

20 KW improvement in Power

Additives in coal to improve Unburnt C % & RH spray

Result of one of our PIP . Forwarded for approval



APC Guidance software installed in all units of VSTPS



Initiative towards Zero Liquid Discharge

Stage-3 Stage-2 Stage-1 Stage-4

South-West PitPump: 5 Nos :5x50m3/hr

LWTP: 300m3/h.Pump: 3x100 m3/h (Use for service water)

Drain to Surya Nala Drain to Labour gate

LWTP: 200m3/h.Pump: 2x100 m3/h

Raw water intake stage –III

2x 100 m3/h

Drain to RTO Barrier

DRN near watch tower-8

Clarifloculater

Construction of pit for collection

Collectionsump

p/pTo effluent Mixing Chamber

P/p

OAC St-IOAC St-I

P/p

Stage-5

2x300

30000 m3/day

37



Latest Technology Introduction: FGD in Stage 5

SO2 Emission <200mg/Nm3 (As per MOEF)

Vindhyachal FGD is limestone based WFGD (Wet Flue Gas Desulphurisation) plant supplied by M/S GE spread over 20,000 square Meter.

• The plant is designed for

(1) Treatment of 100 % flue gas.

(2) Maximum sulphur in coal: 0.49 %

(3) SOx removal efficiency > 90.6 %

(4) SOx content in stack < 200mg/Nm3

(5) limestone consumption : 6.25 T/Hr (4500 MT/month )

(6) Gypsum production : 11.31 T/Hr ( 8000 MT/month )

• System byproduct is chemical Gypsum having

(i) Purity > 90%

(ii) Moisture < 10%

(iii) Chlorides < 100 PPM



Aberration data Sheet



Golden Peacock National Quality Award 2017



42

18 th National Award For Energy Efficient Unit by CII

42



43

D.L.Shah Gold Award for project ( APC Monitoring and Guidance Software)

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Par excellence award Winner at NCQC

Thank You

10. NTPC Vindhyachal CII PPT 2018 - Green Business Centre...10. NTPC Vindhyachal CII PPT 2018 -...

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