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

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2 RAMAGUNDAM Transforming lives Economizer Modification A focused perspective (A Case Study on Project Management) A Team effort by Balaram Reddy T Satish Chandra V Naresh Raju P Pavan M

3 Presentation Outline

4 Present scenario at NTPC

5 PLF trend over the years Source: NTPC Annual Report 2015

6 Ramagundam PLF

7 My flight should fly - Sh. Aditya Ghosh, CEO, Indigo

8 Boiler

9 Boiler Efficiency Losses

10 Economiser modification at U#6 First time in India by handling 1200MT in a running plant

11 Targeted Benefits Reduction in Flue gas Exit temperature Improvement in Boiler Efficiency Reduction in Flue gas velocity thereby erosion reduction in economizer SH spray reduction Environmental benefits Improvement in ESP collection efficiency. Emission reduction (CO/CO 2 / SO x / No x )

12 Project Approvals Corporate Centre OEM Statutory Bodies Budget

13 Project Planning Contract Awarding Preparatory works Interim Change of plans Safety plans

14 Logistics Planning Material Procurement In house design Alternate vendor development Awarding of Service contract Split contracts Additional resources

15 In House Design of Hanger Bends Designed with the help of NETRA, Exactly suitable at site

16 Contract Awarding Works divided among two agencies on 50-50% basis

17 Preparation Best Man power chosen, to avoid re-work

18 Eco coil shifting Shifted from stores 1 week before OH

19 Eco coil shortening Shortening works started 15 days before OH

20 Interim Change of Plans

21 Coil Removal Per day coil removal raised to 43 against 24

22 Coil Placement Removed 20 sets and inserted 15 sets.

23 Safety Plans

24 Safety Plans Workers safety training T&P Testing Safety monitoring Safe material handling

25 Time NTPC STARTED ON MILE STONE CHART ECONOMISER MODIFICATION WORKS IN U#6 OH RAMAGUNDAM END DATE ACTIVITY Vs. DAY WISE PLAN PREPARATORY WORKS FOR COIL REMOVAL COIL REMOVAL COIL INSERTION WELDING WORKS RADIOGRAPHY RESTORATION BOILER HYDRO TEST BOILER LIGHT UP BOILER SAFETY VALVE FLOATING SYNCHRONISATION & 35 DAYS TARGET ACTUAL Actual coil placement completed in 15 days against 25 days planned

26 Performance Achievement

27 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 16000MT PAT benefits SH attemperation reduction APC reduction Variable Cost Reduction

28 APC REDUCTION

29 Benefits in Physical parameters Description Feed water Eco. i/l Temp Feed water Eco. o/l Temp Before modif. HT Surface ( 12833sq.M) in economiser After modif. HT Surface ( 16426sq.M) in economiser FGT at Eco i/l 438/ /484 FGT at Eco o/l

30 Monetary Benefits Cost of the project: Material cost: Rs 8.5 Cr ( 2existing +1 new bank) Services cost: Rs 1.5 Cr Total 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)

31 Performance 1 Reduction in Flue Gas Exit temperature 15 deg C 2 Corresponding Heatrate reduction 15 kcal/kwhr 3 Per annum Energy savings Million Kcal 4 Energy equivalent of coal 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

32 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

33 Replication of the project R&M Budget Proposal i/p for Implementation at other units- 4 & 5 of NTPC-Ramagundam A detailed study report being sent to CC for the project implementation at similar units of NTPC

34 Our other smart ideas 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

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