WATER CONSERVATION & QUALITY IMPROVEMENT INITIATIVES H.S.BAGGA VINOD RATAN PRAG SOOD

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1 WATER CONSERVATION & QUALITY IMPROVEMENT INITIATIVES H.S.BAGGA VINOD RATAN PRAG SOOD

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3 From Industrial prospective, High cost, strict environmental regulations & poor availability of fresh water has emerged as one of the big challenges and driven the industries towards Reduce, Reuse and Recycle of the precious natural resource.

4 Kawas Gas Power Project An ISO 9001:2008; 14001:2004;OHSAS 18001:2007;SA 8000 :2008 Plant overview

5 NTPC Kawas (Stage - I) An ISO 9001:2008; 14001:2004; OHSAS 18001:2007; SA 8000 :2008 Location Installed Capacity Type Gas Turbines Steam Turbines Fuels Source of Water Evacuation Beneficiaries Hazira-Surat-Gujarat Stage-I 656.2MW (2 CC Modules) Combined Cycle Gas Power Plant 4 Nos. GE 9001 E 106 MW 2 Nos. Alsthom Rateau 116.1MW Natural Gas: RLNG: Naphtha: HSD River Tapti. Pump House at Variav Thru 220 KV Transmission lines Gujarat, MP, Maharashtra,DNH Chhattisgarh, Daman & Diu

6 SOURCE OF WATER Since commissioning of the plant in Raw water for the project was sourced through irrigation canal of river tapi flowing very near of the plant In 1996 Gujarat Government intimated its inability to continue the supply of water from the irrigation canal to the project due to rapid industrialization in the Surat region NTPC, Kawas along with other industries of Hazira belt and Surat Municipal Corporation constructed a weir at Siganpore Weir in 1996 (around 18 km away from the project) Since then Water is drawn from Siganpore Weir ( Upstream of River Tapi) at Variav through 16 KM pipeline having pumping capacity of 1500 Cu. M/Hr. Raw Water fed through Intake channel up to Two Reservoirs of Capacity approx Lac Cu.M, with Water distribution in the ratio of 1:4. Reservoir Capacity ( Lacs CuM) at 3.9 meters depth Capacity ( Lacs CuM) at normal operational [ 2.5 m] Retention Time ( Days) Live days Dead days

7 NTPC KAWAS Variav Pump House

8 WATER USAGE AREA AT PLANT 50 M3/hr 45 M3/hr DM Water Drinking Water (For cycle & non cycle makeup) (plant & township) 45 M3/hr Service Water Make up to Cooling water system 680 M3/hr Average Daily water usage of M3/Day when plant runs at full load

9 Year WATER CONSUMPTION PATTERN Total Water Consumption (M3) Generation (MU) Specific water consumption [L/KWhr] Specific water consumption [L/KWhr]

10 WATER CHARGES AT KAWAS WATER CHARGES CALCULATION Particular As on Jan 2013 Anticipated by FY charges for water drawn through VARIAV pump house, Ave per Rs per M3 Chemical 1.23 per 1.23 per M3 Water 0.05 per 0.05 per M3 Pumping & Maint cost & Variav pump 3.70 per 3.70 per M3 Ave. Rs 20 Lac/Month Industrial water cost to per per M3 Process water cost inclusive of per per M3 This incremental 10 % in water charges is likely to get Rs / CuM from next FY as per recent proposal put up in front of state government after exhaustive survey & deliberation done during a study carried out by a reputed institute.

11 IMPACT OF WATER CHARGES ON PROFITIBILITY NTPC KAWAS Financial figures of last 3 yrs (in Crores) YEAR O&M Cost Station overheads Water charges % of Overheads % % % Profit of Project = FIXED COST RECOVERY +MARGINAL GAIN-EXPENSES O&M Cost Is the Major Component of EXPENSES WATER CHARGES plays a significant role in the profitability of project Decrease in WATER CHARGES can increase the profit of plant

12 INITIATIVES TAKEN TO REDUCE WATER CONSUMPTION WATER CONSERVATION THROUGH INCREASE IN COC FROM 1.65 TO 5.0 SWAS RECYCLE USAGE OF CW BLOWDOWN FOR HORTICULTURE PURPOSE CHECKING OF WHRB V/V PASSING DURING SHUTDOWN

13 INCREASE IN COC FROM 1.65 TO 5.0 As per the design COC of 1.65 the water requirement 2000 m3/hr In the year 1996 the water source is shifted to Singpaur Weir at 18km It forced to think on reduce the plant make up by operating the Circulating water system at a higher Cycles of Concentration (COC) Site filtration skid to for continuous filtration of 1.25% of CW Water (1050 M3/hr) & Dedicated CW Chemical Treatment plant was commissioned to maintain the water quality COC was increased to 5.0 from design of 1.65 WATER SAVING = 1000 M3/HR (50% of Original consumption)

14 Recycling of SWAS Drains Original Header of SWAS Drains New Header of SWAS Drains WATER SAVING 20 M3/DAY

15 TAPPING TAKEN FROM CW BLOW DOWN LINE FOR HORTICULTURE USAGE WATER SAVING 45 M3/DAY

16 CW WATER USED FOR HORTICULTURE USING WATER SPRINKLERS

17 IDENTIFICATION OF V/V PASSING

18 INITIATIVES TAKEN FOR IMPROVEMENT IN WATER QUALITY ISOLATION OF DEAD RESERVOIR SEPARTAION OF CLARRIFER ULTRA FILTRATION SYSTEM IN TOWNSHIP. REPLACEMENT OF DRINKING WATER/SERVICE WATER PIPELINES

19 PROBLEM OF DEAD RESERVOIR WATER QUALITY Deterioration in Raw Water Quality Increased industrialization Non release of water to Tapti river. Increased C0C to 5 from Design value of 1.65 Increased stagnation time in reservoir due to low water requirement Plant Water requirement ~ 1000 M3/Hr from design Carry over of High Organics present in raw water and that originated from casurina trees to Dead reservoir. Due to High Retention Time ( > 30 days) in dead reservoir, Concentration of Organics are getting multiplicated.

20 Earlier water quality at Dead Reservoir

21 After water quality at Dead Reservoir

22 Impact of Dead Reservoir Water on the Plant Process & Other Systems Red Worms Problems Drinking Water DM Plant Deterioration in MB o/l Quality. Difficult to achieve Cond < 0.3 us/cm Reduction in OBR of DM Plant from 600 to 250 M3. Specific Consumption of Chemicals increased. Disturbance in boiler chemistry due to carry over of organics to drums. Difficult to maintain ACC < 0.3 us/cm Boiler Cycle CW System Severe Foaming in CW Forbay. Organic fouling / deposits in condenser tubes

23 Various steps done to improve water quality Joint Committee of M/s NETRA and Site representatives did a comprehensive study It has been decided to Isolate Dead reservoir & fresh water to be taken through live reservoir only. Dead Reservoir has been isolated since Jan Improvement observed in the various processes.

24 Benchmarks achieved in Quality of Water in 2012 MB Outlet conductivity of us/cm DM Storage Tank Outlet conductivity of 0.22 us/cm. After Cation Conductivity (ACC) of 0.09 us/cm in SWAS system

25 SEPARATION OF CLARIFIER Better Organic & Turbidity Control Common outlet channel of two clarifiers has been separated. One clarifier is used for DM & Potable Water % design flow to increase retention time thereby improving the clarification process Other clarifier is used for make up to CW system.

26 Separation of clarifiers New outlet line Laid for Clarifier -02 This modification of isolation of clarifiers has resulted in significant improvement in the DM water quality and maintaining ACC in the boilers.

27 1 st in any NTPC Station Specifically dedicated for drinking water purpose Consist of Carbon filter, micro filter, UF Skid & storage tanks

28 ULTRA FILTERATION PLANT OPERATIONAL & PERFORMANCE REPORT OF JAN-2013

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30 SCHEME OF EFFLUENT DISCHARGE AT JHANOR Year Effluent discharged (M3) DM Water Consumption (M3) DM water consumption as % of Effluent disposed % % %

31 PILOT UNIT PIL SCHEME A pilot study was conducted at site by M/s Pall Filtrations with MF+RO combination skid to treat CW blow down water, which is the major constituent of the combined effluent.

32 OUTCOME OF PILOT PIL STUDY AT JHANOR The quality of output from MF+RO skid w.r.t chemical parameters is such that it can be directly used as inlet to DM Plant for polishing and further use. It can reduced water consumption by 60% Recycling the effluents, in this manner, will fetch benefits in terms of reduced chemical consumption in DM plant, lower power consumption in the effluent disposal system and a big leap towards zero discharge. On similar lines, NTPC Kawas has also initiated proposal for recycling the CW Blow Down M3/Hr and utilizing the same in CW system as make up, which will reduce the fresh water consumption of the plant by ~ 20 % and effluent generation will be reduced by ~ 75 %.

33 VARIOUS STUDIES DONE TO CONSERVE WATER RAIN WATER HARVESTING IN YEAR WATER BALANCE STUDY WITH THE HELP OF THERMAX STUDY OF BTF LEAKAGE PROBLEM THROUGH CMI, BELGIUM IN YEAR CANAL TOP SOLAR PROJECT FOR RAW WATER CANAL YR

34 RAIN WATER HARVESTING STUDY Study being carried through M/s Furaat Earth Pvt ltd, Ahedabad to assess the potential of rain water harvesting at NTPC Kawas Report envisages that with average rainfall of 1300 coefficient of 60 %, there is potential to harvest approx 18 lacs M3 of rain water considering the entire plant area of 560 acres. Report has identified following three potential points from where the rain water can be harvested. COOLING BAY OPEN INTAKE CHANNEL ROOF TOP RAIN WATER FROM BUILDING

35 RAIN WATER HARVESTING STUDY

36 MODULAR SYSTEM FOR ROOF TOP WATER HARVESTING

37 WATER BALANCE STUDY BY THERMAX A comprehensive Water Balance Study was carried out in by M/s Thermax To assess the gaps in the various process water consumption / usage pattern To identify the areas for recycling of the effluents To improve the overall efficiency of the plant through installation of energy efficient devices, wherever applicable.

38 STUDY OF BTF LEAKAGE PROBLEM THROUGH CMI, BELGIUM OEM of WHRB, M/s CMI, Belgium was awarded to study the boiler tube leakage problem at Kawas. CMI representative visited site for study & assessment of problem. Observation of Comprehensive Report:- HP2 SHT Inlet Header to be relocated to be modified for complete draining during shut downs. Provision of extra drain valves before & after Desuperheating temperature control valves.

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41 FEASIBILITY STUDY OF CANAL TOP SOLAR PROJECT AT NTPC KAWAS Canal Top Solar project has been identified as S.D. Project of Kawas. Site Feasibility survey has been completed by M/s Sunedison (I) Ltd [ Party who has carried out India s 1st Canal Top Solar Project]. Feasibility Report Canal Top solar project is feasible. Expected cost of project = Rs 4 Crores Expected Solar Output of project = 0.3 MW Installation Time = 6-8 months from LOA

42 PAY BACK PERIOD OF VARIOUS INITIATIVES Initiative Running at higher COC of 5 compare to design of 1.65 Recycling of cooling water blow down water for horticulture purposes Actual/anticipated water saving /yr Approx. Initial Cost 87.6 Lacs M3 2.5 Crores Pay Back period 6 months Lacs M3 0.5 Lacs 2 months Recycling of SWAS drains Lacs M3 0.5 Lacs 4 months Rain water Harvesting 6 Lacs M Lacs 2 months Recycling of CW Blow down to achieve ZERO EFFLUENT DISCHARGE 14 Lac M3 21 Crores 7 years

43 Thank you! TOGETHER WE CAN TOGETHER WE WILL MAKE THE DIFFERENCE

44 Comparison of Water Charges in Western Region State Project name Water Charges ( Rs / CuM) Madhya Pradesh Vindhyachal 4.00 Chhattisgarh Korba, Sipat 7.24 Gujarat Kawas, Jhanor This incremental 10 % in water charges is likely to get Rs / CuM from next FY as per recent proposal put up in front of state government after exhaustive survey & deliberation done during a study carried out by a reputed institute.