1

17TH National award for CII “EXCELLENCE IN ENERGY MANAGEMENT-2016”

22nd to 24th AUGUST, 2016: HICC, HYDERABAD

NTPC Overview

India’s largest energy conglomerate, planted roots in 1975

The total installed capacity of the company is 47,178 MW (including JVs) with 18 coal based, 7 gas based stations and 1 Hydro based station. 9 Joint Venture stations are coal based and 9 renewable energy projects

400th rank in2016, Forbes 2000 world’s biggest companies

Became a Maharatna PSU in 2010

Generating 24% power with 17.73% of the total national installed capacity

2

NTPC Performance

NTPC - Ramagundam

Installed capacity of the Station : 2600MW (3x200+4x500)+ 10 MW Solar PV Plant

3

RSTPS: Sustainable performance over the years

Parameter 2013-14 2014-15 2015-16

Generation (MU) 19746 20443 20250

PLF(%) 86.7 89.76 88.67

Heat rate (Kcal/Kwh) 2368 2361 2362

APC (%) 6.01 5.86 6.12

Sp. Oil consumption (ml/Kwh) 0.252 0.23 0.181

NTPC Ramagundam achieved Net Heatrate of 2485.5 kCal/kWh (normalised) againstPAT-1 cycle target of 2498 kCal/kWh (Base line was 2520 kcal/kWh)

Specific Energy Consumption Trend

Gross Heatrate in kCal/kWh Auxiliary Power Cons in %

Net Heatrate in kCal/kWh

Reason for increase in APC in 2015-16 is due to

• change in CT loading of Export lines (Attended) and

• Unit-7 PAPH fouling (Planned in ensuing Unit Overhaul)

4

0.59 1.12 1.87 2.68 3.37 3.61 3.65 3.57 3.79 4.727.29

10.27

13.64

16.9018.48

21.62

24.77

28.02

31.40

35.31

39.14

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

45.00

Apr.

96 -

Mar

. 97

Apr.

97 -

Mar

. 98

Apr.

98 -

Mar

. 99

Apr.

99 -

Mar

. 00

Apr.

00 -

Mar

01

Apr.

01 -

Sep.

01

Oct

. 01

- Sep

02

Oct

. 02

- Sep

03

Oct

. 03

- Sep

04

Oct

. 04

- Sep

05

Oct

. 05

- Sep

06

Oct

. 06

- Sep

07

Oct

. 07

- Sep

08

Oct

. 08

- Sep

09

Oct

'09

to M

ar'1

0

Apr'1

0 to

Mar

'11

Apr 1

1 to

Mar

' 12

Apr'

12 to

Mar

' 13

Apr'

13 to

Mar

' 14

Apr'

14 to

Mar

' 15

Apr'

15 to

Mar

' 16

Com

mul

ativ

eCO

2 Av

oide

d La

khTo

nsCommulative CO2 Avoided due to Efficiency Improvement

from 1996 to 2016

CO2 EMISSION REDUCTION

Energy Management Policy

5

Efficiency Monitorin

g

Parameters

HeatrateAPCVacuumMake upTemp/Pr

Testing

Online& Off-line testing ofBoiler,Turbine,Condenser,APH etc

Audit

Draft audit,waterbalnance ,Insulationaudit etc.

Assessment

Pre and postoverhaul/Maint jobsgainsassessment

MIS

Daily,Monthly andYearly MISStatutoryReportingEnergyreturns

Efficiency monitoring

Energy Savings Trend

MU Rs in Lakh2013-14 9.83 196.502014-15 10.734 257.622015-16 11.96 287.00

Year ANNUAL SAVING

196.5

257.62287

0

50100150200250300350

2013-14 2014-15 2015-16

ANNUAL SAVINGS (Lakhs)

9.8310.734

11.96

02468

101214

2013-14 2014-15 2015-16

MU

6

ENERGY CONSERVATION PROJECTS 2013-14

Energy (MU) Rs in Lacs

1 Replacement of FTS s with CFL/LEDs (12-13) 0.55 11.0

2 Replacement of EC ceiling fans and lights with energy efficient eqpt

1.13 22.6

3 Savings due to Solar power 0.02 0.4

4 stoppage of one stage-2 raw water p/p by operating inter connection v/vs

1.58 31.6

5 Corrocoat of CW p/p-3 0.13 2.7

6 Unit-1 & Unit-2 BFP savings 1.03 20.5

7 Energy saving on the account of Mill PA flow optimisation in Unit-5 2.76 55.2

8 Optimisation of CW pumps running hrs in Stage-1 during winter & partial load condition

1.94 38.8

9 Optimisation of CT Fans in Stage-2 and 3 during winter & partial load condition 0.69 13.8

Total 9.83 196.5

Total Savings S.No Activities

ENERGY CONSERVATION PROJECTS 2014-15

In Energy (MU) Rs in Lacs

1 Mill PA flow optimisation in stage-II units 1.296 31.10

2 Corrocoating in stage-I CW pumps 0.864 20.74

3 Diverting CW stg-I system water to Stage-II&III t 1.620 38.88

4 Use of Energy Efficient Motors in Ash slurry pump house in stage-II

2.400 57.60

5 Stage-1 ESP hopper heater cut-in cut-off optimisation 1.800 43.20

6 Lighting - CHP Crusher House 0.010 0.25

7 MDBFP-3A & B Cartridge Replacement in U-3 2.744 65.85

Total 10.734 257.62

Total SavingsS.No Activities

7

ENERGY CONSERVATION PROJECTS 2015-16

In Energy (MU) Rs in Lacs

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

4 Use of Energy Efficient Motors in Ash slurry pump house in stage-I 0.65 15.55

5 Use of Energy Efficient Motors in Ash slurry pump house in stage-II 1.22 29.28

6 Stage-1 ESP hopper heater cut-in cut-off optimised with incorporation of timers 2.25 54.00

7 Stage-1 DAETP Energy efficient compressors 0.29 6.91

Total 11.96 287.00

Slno ActivitiesTotal Savings for 2015-16

Major enablers towards Energy conservation

• A system for Energy and Efficiency Management– Regular performance and diagnostic testing of capital equipment– High accuracy performance testing instruments– Regular monitoring – Periodic Energy audits (by Teams from Energy Auditors in the station /

Within NTPC / External system experts)• Installation of OLEMS (Online Energy Management System) covering all

the Electrical motors of 100 kW and above rating• Use of tools like PI (Process Information) system for performance

monitoring (real time & trends of performance indices from LAN connected PCs). Development of applications based on PI data like SEED (System Energy Efficiency Display) on NTPC level and numerous monitoring screen on individual/departmental level for Specific Energy Monitoring

8

Major ENCON Projects

Lighting – Conversion from Conventional to LED

Motors – Replacement of conventional motors with IE3 motors

Raw water modification – Interconnection between stages

Ash slurry pumps – Replacement with energy efficient pumps

DAETP Compressors- Replacement with energy efficient compressors

ESP hopper modification- Auto operation of ESP hopper heaters

Solar energy- Substitution of thermal with renewable energy

Innovative Technology – Light Pipes / Solar Car parking

Waste Heat Recovery - Installation of 100TR VAM for Stage-II ESP units

ENCON Projects – Lighting conversion

Sl. No. Location Tube Light

Load (Watts)

Present LED Load

(Watts)

Net Reduction in Watts

Net Energy Saving in %ge

(Achieved)1 Unit # 1 UCB & Others 20400 2640 17760 87.06%2 Unit # 2 UCB 4400 640 3760 85.45%3 Unit # 4 UCB & 8.5Mtr (DAS Panel) 16560 4840 11720 70.77%4 U#5 UCB & Others 9360 2528 6832 72.99%5 U#6 UCB & Network Room 9600 2880 6720 70.00%6 Service Building 8560 2440 6120 71.50%7 Switchyard & Switchyard Other Areas 16160 3000 13160 81.44%8 Other Areas 18800 6680 12120 64.47%

Total 103840 25648 78192 75.30%

1A. REPLACEMENTOF CONVENTIONAL TUBE LIGHT FITTING (2X40W) WITH 40W LED RECESS FITTING

Sl. No. Location Tube Light

Load (Watts)

Present LED Tube Rod Load

(Watts)

Net Reduction in Watts

Net Energy Saving in %ge

(Achieved)

1 Unit # 1, U#2 & U#3 Cable Gallery 13200 6300 6900 52.27%2 Unit # 5 Switchgear Rooms & Others 19280 5490 13790 71.52%3 Unit # 6 Switchgear Rooms & Others 28880 9252 19628 67.96%4 U#7 UCB & Others 48480 11898 36582 75.46%5 Service Building 720 360 360 50.00%

Total 110560 33300 77260 69.88%

Sl. No. Location

High Bay Lighting

Load (Watts)

Present LED Load

(Watts)

Net Reduction in Watts

Net Energy Saving in %ge

(Achieved)1 Unit # 4 TG Hall 21175 13860 7315 34.55%2 Unit # 5 TG Hall 17325 11340 5985 34.55%3 Unit # 6 TG Hall 21175 13860 7315 34.55%4 Unit # 7 TG Hall 17600 9600 8000 45.45%5 Unit # 7 HP Heater Area 7975 3960 4015 50.34%

Total 85250 52620 32630 38.28%

1B. REPLACEMENT OF CONVENTIONAL 40W TUBE LIGHTS WITH 18W LED TUBE RODS

1C. REPLACEMENT OF HPSV HIGHBAY FITTINGS WITH LED HIGHBAY FITTINGS

9

Sl. No. Location

Tube Light / High Bay /

Street Light Present Load

(Watts)

LED Load (Watts)

Net Reduction in Watts

Net Energy Saving in %ge

(Expected)

1 Control Rooms / Office Rooms Etc.. 85000 32400 52600 61.88%2 High Bay Lighting 129000 71640 57360 44.47%34

Total 414000 190040 223960 54.10%Street Lighting 200000 86000 114000 57.00%

Sl. No. Location

Tube Light / High Bay /

Street Light Present Load

(Watts)

LED Load (Watts)

Net Reduction in Watts

Net Energy Saving in %ge

(Expected)

1 Switch Yard & Offsite Area Lighting 200000 48000 152000 76.00%2 All Offsite Pump Houses 62500 30000 32500 52.00%3 All MCC's 260000 60000 200000 76.92%4 All Offsite Areas 14000 8000 6000 42.86%5 Office Corridors 10800 3000 7800 72.22%6 Office Rooms 56000 8000 48000 85.71%7 Street Light 75000 36000 39000 52.00%

Total 678300 193000 485300 71.55%

ENCON Projects – Lighting conversion

2. ON GOING WORKS COMPLETION BY OCT-2016

3. PROPOSED WORKS IN 2016-17 EC BUDGET

ENCON Projects – Lighting conversion

10

Activity Status Investment (Lakhs)

Saving (Watts)

Payback Period(yrs)

Replacement of Conventional tube light fitting (2x40W)with 40W LED recess fitting

Completed 38.2 78192 2.97

Replacement of conventional 40W tube light with 18W LED tube rods

Completed 38.5 77260 3.4

Replacement of HPSV high bay fittings with LED high bay fittings

Completed 46.51 32630 >4

Works in progress Ongoing 53.56 223960 2.0

Future works Proposed 100 485300 1.89

ENCON Projects – Lighting conversion

ENCON Projects – Motors replacement

Year No. of Motors

replaced

Investment (Lakhs)

Gain(kW)

Payback Period (yrs)

2014-15 17 68 25.4 / Motor 2.4

2015-16 21 43.02 14.3 / Motor 1.8

2016-17 (Proposed

83 125.94 8.4 / Motor 2.1

11

ENCON Projects – Raw water interconnection

Stage-1 CW Blow down line is interconnected with Stage-2&3 CW make up line.Resulted in stopping of one raw water pump for Stage-.Annual energy saving is 1.58MU.

Utilization of Waste Heat from Flue Gas for Air Conditioning as aproof of Concept Pilot Plant (100TR) at Unit-4 Ramagundam STPS

Ø Waste heat is used to generate hot water which drive a Vapour Absorptionmachine (VAM)

Ø Chilled water generated from VAM is distributed to different locations (ESP Controlrooms of Unit-4, 5 & 6) for Air conditioning

Objective -

Technique

Benefits Ø Air conditioning using Waste heat instead of Electricity or Auxiliary steam.Ø Auxiliary Power saving 0.49 million units per annum.Ø Reduction in CO2 emissions (312 Tons/year)Ø Free from ozone depletion substances (R12/R22)Ø Step toward 100% phase out of HCFC, as VAM system is free from Green House GasesØ Scale-up potential is good

ENCON Projects – Waste Heat for Air Conditioning

12

ENCON Projects

4.14MU Energy /year saving is achieved by providing timers for Auto cut-in and cut-out of heaters in Stage-1 ESP hoppers.

ESP Heaters auto operation

NTPC Ramagundam has installed and commissioned 10 MW Solar PV Plant to add Green Power to its Portfolio

10 MW Solar PV Plant

25 kW Solar PV on roof top is installed in Sep 2013 and Generated around 95,000 Units of Green Power

25 kW Solar PV on Roof Top

A Patented technology of Light Pipes used in Stores to harness Solar lightInnovative Solar Light Pipes

Car parking shed is converted to Green Shed with 100 kW Solar panels as Car shed roof100 kW Solar Car Parking

Substitution of Thermal with Solar energy

DAY LIGHT optimisers (Light pipes)

10 MW Solar PV View 25KW roof top solar panels

13

Towards Sustainable Environment

• Installation of AAQMS (Ambient Air Quality Monitoring System)

• Monitoring Stack Emissions through Video cameras• Installation of CEMS (Continuous Emissions Monitoring

System)• Up-gradation of ESP Rappers Control System to reduce

emissions• Development and usage of ESP Rappers timing algorithm• 100% ash utilisation• Recirculation of Storm Water• Recovery of Ash Pond Water

People’s involvement

Celebration of world environment day Celebration of world Ozone day

14

/kU;oknThank you