Transforming lives

RAMAGUNDAM

“Economizer Modification–A focused perspective(A Case Study on Project Management)

A Team effort by

Balaram Reddy TSatish Chandra VNaresh Raju PPavan M

Presentation Outline …

Present scenario at NTPC

PLF trend over the years…

Source: NTPC Annual Report 2015

Ramagundam PLF

“My flight should fly”

- Sh. Aditya Ghosh, CEO, Indigo

Boiler

Boiler Efficiency Losses

First time in India by handling 1200MT in a running plant

Economiser modification at U#6

Reduction in Flue gas Exit temperature

Improvement in Boiler EfficiencyReduction in Flue gas velocity thereby erosion

reduction in economizer

SH spray reduction

Environmental benefits

Improvement in ESP collection efficiency.Emission reduction (CO/CO2 / SOx / Nox)

Targeted Benefits

Project Approvals

Corporate Centre OEM Statutory Bodies Budget

Project PlanningContract Awarding

Preparatory works

Interim Change of plans

Safety plans

Logistics PlanningMaterial Procurement In house designAlternate vendor

development Awarding of Service contract Split contracts Additional resources

In House Design of Hanger Bends

Designed with the help of NETRA, Exactly suitable at site

Contract Awarding

Works divided among two agencies on 50-50% basis

Preparation

Best Man power chosen, to avoid re-work

Eco coil shifting

Shifted from stores 1 week before OH

Eco coil shortening

Shortening works started 15 days before OH

Interim Change of Plans

Coil Removal

Per day coil removal raised to 43 against 24

Coil Placement

Removed 20 sets and inserted 15 sets.

Safety Plans

Safety PlansWorkers safety training T&P Testing Safety monitoring Safe material handling

Time

Actual coil placement completed in 15 days against 25 days planned

RAMAGUNDAM

SYNCHRONISATION

BOILER SAFETY VALVE FLOATING

BOILER LIGHT UP

BOILER HYDRO TEST

RESTORATION

RADIOGRAPHY

WELDING WORKS

COIL INSERTION

COIL REMOVAL

PREPARATORY WORKS FOR COIL REMOVAL

ACTIVITY Vs. DAY WISE PLAN

MILE STONE CHART NTPC

9

TARGET

STARTED ON 22.07.2016

3 12 3315 18 216

END DATE 22.08.2016

24 27 30

ACTUAL

ECONOMISER MODIFICATION WORKS IN U#6 OH

34 & 35 DAYS

Performance Achievement

Benefits achieved Flue Gas exit temperature reduction: 15 deg.C Heat Rate Improved by 15 K.cal/Kw.Hr Boiler efficiency improved by 0.75% Annual coal consumption reduced by 16000MTPAT benefits SH attemperation reduction APC reduction Variable Cost Reduction

APC REDUCTION

Benefits in Physical parameters

Description

Before modif. HT Surface

( 12833sq.M) in economiser

After modif. HT Surface

( 16426sq.M) in economiser

Feed water Eco. i/l Temp

254 254

Feed water Eco. o/l Temp

317 321

FGT at Eco i/l 438/477 442/484FGT at Eco o/l 375 333

Monetary Benefits Cost of the project:

Material cost: Rs 8.5 Cr ( 2existing +1 new bank)Services cost: Rs 1.5 CrTotal cost incurred Rs10Cr

Monetary Benefits achieved:

Benefit due to coal saving: Rs 4.8 Cr.Energy Certificates earning in PAT cycle-II(PAY BACK PERIOD: 10 Months)

Performance 1 Reduction in Flue Gas Exit

temperature 15 deg C

2 Corresponding Heatrate reduction 15 kCal/kWhr

3 Per annum Energy savings 59130 Million Kcal

4 Energy equivalent of coal 15561 MT of coal

5 Saving in Rs Cr / year 4.67 Rs Cr

6 Pay back in years (incl two existing banks) 2.4 Years

7 Pay back in years (additional bank) 10.0 Months

Towards Environment Gains Emission reduction of CO2 by 19650MT Reduction in CO, SOx, Nox Enhanced ESP efficiency thereby reduction in SPM Future FGD investment cost reduction Reduction in ash handling

Replication of the project

R&M Budget Proposal i/p for Implementation at other units-4 & 5 of NTPC-Ramagundam

A detailed study report beingsent to CC for the projectimplementation at similar units of NTPC

Installing VFD Motors in ID, FD, PA Fans

R&M of Air Pre Heaters

LP Coil Pre Heating

Energy efficient equipments – IE coded motors for CT

Installation of FGD

Our other smart ideas

The difference between what we do and what we are capable of doing would suffice to solve most of the problems.