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Kawas Gas Power
Project
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CII National Award for Excellence
in Energy Management 2020
NTPC R&R Colony,
DarlipaliNTPC Bhadla
NTPC Koldam NTPC Kayamkulam
NTPC Kudgi
Presentation By: Mukund Meena, Manager (Operations)
Jayesh Behede, Manager (Operations)
5
2
3
4
1Company Profile /
Introduction
Energy Consumption
Overview
Sp. Energy Consumption in 3
Years
En Con Projects/ Savings
2
Contents
11-12
7
8
9-10
6 Innovative Projects
Renewable Energy Presence
Environment Management
Best Practices/Teamwork
ISO 50001/Long Term EE
vision
Benchmarking
3
1. Company & Station Profile
4
Kawas : A Brief Profile
MH31.14%
GUJARAT (28.5%)
MP21.36%
DNH12.38%
D&D4.73%
GOA1.89%
J&K0.01%
MW Share % Share
656.2 MW
Location Hazira, Surat (Gujarat, India)
Installed Capacity Stage-I 656.2MW (2 CC Modules)
Type Combined Cycle Gas Power Plant
Gas Turbines4 Nos. of GE 9001-E of 106 MW each
Steam Turbines 2 Nos. of Alsthom 116.1MW each
Fuels Natural Gas, Naphtha, HSD
Source of Water River Tapti: Pump House at Variav.
Renewable Energy
1MW Floating Solar Plant
ISO CertificationsISO 50001:2018, ISO 9001:2015, ISO 14001:2015, ISO 45001:2018
First Unit Commissioned
22.03.1992
Vision to Direct the Change Efforts
6
•NTPC to be a 130 GW
company by 2032 with
diversified fuel mix from current
capacity 58.15GW
•Share of RE (including
hydro) would be 28% by 2032
from current 3.5%, Thermal
based generating capacity
share would be 70%
•NTPC targets a market share
of 25% in ancillary services and
storage
•NTPC aims to achieve 10% of
the estimated market share for
supply of electricity in E-mobility
business
7
2. Energy ConsumptionOverview
8
S.N
O
Performance
Parameters
FY 2019-20 Target (FY 2019-20)
1 Annual Generation 1382.66 MU 2500 MU
2 PLF 23.99% 44.5%
3 Availability 94.30 % >85%
4 Gross Heat Rate 2068 Kcal/Kwh 2050 Kcal/Kwh
5 Auxiliary Power 3.30 % 2.75%
6 DM Water consumption 0.87 % 1%
7 Raw Water
Consumption
1.6 m3/MWh 3.5 m3/MWh
Energy Consumption Overview FY 2019-20
9
3. Sp. Energy ConsumptionLast Three Years
GROSS HEAT RATE, APC & PAF (2017-20)
2037
2070
2057
2020
2030
2040
2050
2060
2070
2080
2017-18 2018-19 2019-20
Gross Heat rate
2.63 2.753.3
0
1
2
3
4
5
2017-18 2018-19 2019-20
APC
99.2796.91
94.29
80
85
90
95
100
105
110
2017-18 2018-19 2019-20
PAF
11
Partial Load Study Done With WRPC
Due to decrease in Loading
factor, there is a increase in APC.
Around 42 % of
the total TB,
loading factor
was less than
75% when
machine was
running in closed
cycle mode
12
4. Benchmarking
13
1851.8
1382.66
555.14
302.13
444.76 436.55
00
200
400
600
800
1000
1200
1400
1600
1800
2000
DADRI KAWAS Faridabad ANTA AURAIYA GANDHAR RGCCPP
Genera
tion M
U
NTPC GAS POWER PROJECTS
Cumulative Generation for the year FY 19-20
KAWAS #
13
Benchmarking- Cumulative Generation FY’19-20
14
21332068
2020
22122301
2140
0
19902050
19752075 2100
2040
1850
0
500
1000
1500
2000
2500
DADRI KAWAS Faridabad ANTA AURAIYA GANDHAR RGCCPP
GH
R K
cal/K
wh
NTPC GAS POWER PROJECTS
Gross Heat Rate and normative heat rate for the year FY 19-20
KAWAS is
closest to its
normative HR
KAWAS #
2
14
Benchmarking- Gross Heat Rate FY’19-20
15
3.76
3.3 3.38
6.73
4.21 4.36
00
1
2
3
4
5
6
7
8
DADRI KAWAS Faridabad ANTA AURAIYA GANDHAR RGCCPP
Genera
tion M
U
NTPC GAS POWER PROJECTS
Auxiliary power consumption for the year FY 19-20
KAWAS #
15
Benchmarking-Auxiliary power consumption FY19-20
16
3
1.611.68
3.013.14
3.03
0
0.5
1
1.5
2
2.5
3
3.5
DADRI KAWAS Faridabad ANTA AURAIYA GANDHAR
Sp.
Wate
r consum
ption ltr
/kw
h
NTPC GAS POWER PROJECTS
Specific water consumption for the year FY 19-20
KAWAS #
16
Benchmarking-Specific Water consumption FY19-20
17
5. Energy Savings For Last Three Years
Energy Conservation Projects in 2017-18
18
Sr. Activity Energy Savings
(MU)
Energy Savings
(INR-in Mn)
1 De-staging of HP Feed water pump 0.41300 0.897
2 GT online Compressor Washing 5.582 12.17
3 VFD drive in Raw water Pump's 0.0756 1.65
4 Energy Efficient Coating CW Pump 0.3468 7.56
5Installation of 150 proximity sensor at all plant and common
building0.0238 0.051
6 Water saving through COC improved from 5.0 to 5.60 0.129 0.282
7Replacement of 36 W HPMV light fittings with 18 W Energy
efficient light fittings in township and plant0.0320 0.07
Total 6.601 14.391
19
Sr. Activity Energy Savings
(MU)
Energy Savings
(INR-in Mn)
1 De-staging of HP BFP 1.789 4.115
2 Variable frequency drive in raw Water Pumps 0.170 0.392
3 Energy efficient coating in CW pump 0.039 0.091
4 Energy Efficient Fittings in Plant 0.342 0.789
5 Occupancy Sensors 0.0473 0.109
Total 2.38 5.496
Energy Conservation Projects in 2018-19
20
Sr. Activity Energy Savings
(MU)
Energy Savings
(INR-in lakhs)
1 Energy efficient light fittings 1.87 5.82
2 Installation of 150 Proximity sensor 0.0168 0.052
3 2C Bullet Cleaning 1.142 3.49
4 Energy efficient coating in CW pumps 0.297 0.922
5 De-staging of HP BFP 0.544508 1.688
6 Electrical saving due to increasing COC 0.02510 0.078
7 Optimization of Aux raw cooling water pumps 0.058245 0.181
8 Optimisation of GT/Gen fin fans 0.18530 0.575
9 Optimization of service air compressor 0.1208 0.374
Total 4.2589 13.099
Energy Conservation Projects in 2019-20
21
Major Energy Conservation Projects
Energy Conservation
Projects
Capital Intensive Project
HP BFP De-staging
(0.5445 MU)
ST Condenser bullet cleaning
(1.142 MU)
Energy Efficient Coating of CW Pump (0.297
MU)
Zero Investment
Projects
Service Air Compressor Optimisation (0.1208 MU)
ARCW Pump Running
Optimisation (0.0582 MU)
Fin Fans Running
Optimisation (0.1853 MU)
22
Energy saving budget/target/Planned projects for FY20-21
1 1
2.38
4.25
0.54
1.3
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
FY 2018-19 FY 2019-20
Energy Savings Comparison
Target (MU) Electrical Savings (MU) Savings (Crore Rs)
Financial Year 2017-18 2018-19 2019-20
EC Budget
(Lacs)
39.40 21.30 7.80
Sr. Planned projects for FY 2020-21
1 Condenser Bullet cleaning of ST#1C
2
Conversion of air detection deluge system for
generator transformer to water detection deluge
system
3 Energy Efficient coating in make up water pumps
4 Optimum utilisation of HP BFP
5Installation of Energy efficient cassette air
conditioner
23
6. Innovative Projects Implemented
Salient Features• Higher Operation Efficiency
• In-house Floaters have been patented
• Generation till now: 1.08 MUs
• CO2 Avoided : 861.45 T
• Water and Land Conservation
• Water Savings : 15000
CbMtr/MW/Year
• Reduction in Algae Growth in Water
Bodies
24
1MWp Floating Solar Plant
•Blow Mould Improved
•60 kg/KWp
•1 Cr/MW
•Dec 2018
•Blow Mould (HDPE)
•230 Kg/Kwp
•4.3 Cr/MW
•March 2017
•Rota Mould (LDPE)
•230 Kg/KWp
•8Cr/MW
•March 2016
25
Waste To Energy
Karsada Waste Management Plant, Varanasi, Uttar
Pradesh
• 700 TPD Waste Will Be Recycled
• Land Area : 19 Acres
• 14.9 MW Power Output
• MoU signed with Surat Municipal
Corporation
26
• Floating Solar Technology 1MW• Rooftop Solar PV Technology
52.5KW• Wind Power Technology 50 MW
7. Renewable Energy
Utilisation
Rooftop Solar PV + Wind Energy
• 126 KWp Rooftop solar to be put up on
simulator building roof
• 52.5 KWp Administrative rooftop Solar
Catering 57% of the total load demand of
Admin Block
• 30 KWp Solar Roof top installation at Akshay
Patra, Surat (Under CSR)
FY Generation Target CUF(%)
2018-19 98 MU 94 MU 23
2019-20 96 MU* 100 MU 26
NTPC Rojmal (50 MW Wind Power
Station)
Future Expansion : Solar Energy (78 MWp)
29
8. Environmental Management
3030
Environment Management-Emission
Particulars UOM 2017-18 2018-19 2019-20
Current SOx Emissions at
Full Load*ppm 4.51 4.76 9.30
Current NOx Emissions at
Full Load*ppm 85.83 79.28 81.80
Particulate Matter * ppm 8.23 9.18 10.21
3131
GHG Inventorization
FY Generation
(MU)
SCOPE 1 CO2
(MT)
SCOPE 2 CO2
(MT)
Total CO2
(MT)
2019-20 1382 552994 280 553274
2018-19 2499 999951 506 1000457
2017-18 2405 962338 487 962825
2016-17 1717 686817 361 687178
1.9351.73 1.72 1.604
5
5.6
6.67
0
1
2
3
4
5
6
7
8
2016-17 2017-18 2018-19 2019-20
Sp Water (ltr/kwh)
COC
3219
1. Rain Water Harvesting
(Reservoir + Building
Roofs)
2. Zero Liquid ischarge
(Under Implementation,
Drain separation
completed)
3. Improvement in Cycle
of Concentration from 5
to 7
Water Conservation
Various measures taken
at Kawas
MoEF&CC norms : 3.5 ltr/kwh
3319
Water Conservation
CW Blow-down used in horticulture
Live
Dead
Reservoi
r
Rain Water Harvesting
Sr No DetailsFY 2016-
17
FY 2017-
18
FY 2018-
19
FY 2019-
20
1Avg Rain Fall
(mm)900 1435 1258 1644
2
Live
Reservoir
(m3)
102659 163653 143261 188735
3
Dead
Reservoir
(m3)
311886 494705 434327 569391
4
Water
Recycled
(m3)
402109 638607 560260 735382
5
Industrial
water Rate
(Guj)
23.58 23.58 23.58 28.53
6Amount of
Savings (Cr)0.948 1.506 1.32 2.10
Drain Separation : A Step Towards ZLD
34
Separation of Process Water from Storm
Water Drain
Process Water in Collection Pit
Water Diverted to Dead Reservoir for Floating
Solar
Separated Process
water
Process Water
Collection PitRO Plant
Recycling in Process
Current Flow Diagram of Drain
Separation
Proposed Flow Diagram of Drain
Separation
Waste disposal/Paper recycling/Tree plantation
We have tied up for proper disposal of
our domestic / Solid Municipal waste with
Surat Municipal Corporation through Hazira Notified Area.
Waste paper has been recycled to
make Isolation/Danger
Tags and Papers to print permits.
Around 184 trees planted inside plant
and township area in FY 2019-20
36
• Machine Reliability and Grid Stability
• SOP • O&M Cost Reduction• Digitisation• Manpower Optimisation
9. Best Practices
Preparedness for Grid Black Out- BSMD
37
Kawas successfully completed Western Region BSMD in Dec 2019
Stakeholders: NTPC Kawas, NTPC Jhanor, WRLDC, GETCO, MGVCL,DGVCL
None of the generators tripped due to abnormal parameters
Max frequency : 50.08 and minimum frequency at kawas: 50.00 Hz
The timing of creation of island and then reconnecting with grid has also improved from previous attempts
Boosted confidence and shown technical solidarity in case of grid black out.
Because of such preparedness,
Kawas was able to support during
PM’s 9 minute Lights OFF call by
using fast ramping capabilities of
Gas turbines.
Standard Operating Procedures
38
Total 64 Procedures are identified
Easy to Understand, Comprehensive & As per OEM Manual
P&ID Included in SOP
Equipment Pictures from Local Added and Tagged wherever Necessary
SOPs are made available Online
39
Repair & Maintenance
Cost
Counter Based PM
Predictive Maintenance
Contracts Clubbing
102
O&M Cost Reductions
Station Overhead
Manpower Optimization
Integrated Security System
Employee Cost
• Reduced
resource
consumption
• Over-
maintenance will
be avoided
• Reduction in
machine
failures &
downtime for
repairs
• CISF
Manpower
Optimisation
• Multiple layers
of security
• Repetition of
same process
for many
contracts will
reduce
• Reduction in
Man-MW ratio
• Utilization in
other
functions
40
New Teams/ Departments
Common Functional
Group (Expert
Group)
Digital
InitiativesBusiness
Development
Waste to Energy
- New Initiatives
Young Executives
GroupRenewable
Energy
Safety, LMI,
BE, IMS
Knowledge
Managemen
t & Sharing
Learning
Research &
Developme
nt
Innovate
Create
Compete
41
Manpower Optimisation
30.29
21.03
29.89
41.9
43.5
23.99
0
5
10
15
20
25
30
35
40
45
50
2014-15 2015-16 2016-17 2017-18 2018-19 2019-20
Plant Load Factor (%)
PLF (%)
114 10275
5641 42
133132
126
117
105 91
0
50
100
150
200
250
300
2014-15 2015-16 2016-17 2017-18 2018-19 2019-20
Manpower at Kawas
Executives Non-Executives
40
%
42
10. Team Work, Monitoring
Team Work, Involvement and Monitoring
43
Efficiency MAP Software
On Line Efficiency Monitoring System
Good Maintenance practices and Real-time monitoring system ensure high availability and efficient operations
Periodic structured Technical Audits carried out for all units for identifying and correction of gaps
Start-up time optimization
Quality Circle
44
Par Excellence Trophy at National Convention 2018
(Project on Tagging of Boiler Manual Valve &
Digitization)
Par Excellence Trophy at National Convention
2019
(Project on Difficulty in Venting of GT CW
Circuit)
45
• 6T Approach• Unique Energy Policy• Involvement of Stakeholders
11. ISO 50001 Implementation
4646
KAWAS: 1st NTPC GAS PLANT TO GET ISO 50001:2018 CERTIFIED
MoU between BEE and NTPC Kawas signed on
18th February 2019
ISO 50001 Certification Received on
28th November 2019
Timely Audits/MRMs
47
6-T
Approac
h
Technology (IOT)/
Digitisation
Trainings/Efficient
Communication
Top Management
Support
Team of Energy
Auditors/Managers
Technical
Understanding of
System/ ISO standards
6T Approach for Effective Implementation
48
Energy Policy & Communication
Comprehensive, Easy to understand and Site
specific
49
ISO 50001
TRAINING
For All the Employees
SUGGESTION
SCHEME
(0.36 MUs of Energy
Saved) ENERGY CONSERVATION WEEK
CELEBRATION
Slogans/ Quiz/Poster/Suggestion Competition
AWARENESS SESSION
For All the Contract
Labours
ENERGY CONSERVATION
MESSAGES
Pop-ups On All LAN Desktops
CONSERVATION POSTERS
At Various Location in Plant & Township
Trainings/ Awareness Programs
50
12. Long Term Vision on EE
•Long term vision
•Major areas of
concern
Vision on EE
51
Continual Improvement in Energy Savings
Following Global Best Practices
Developing Pool of Energy Auditors
Tapping Digitisation/ Smart Technologies
ISO 50001 Sustenance
5252
MAJOR
CONCER
NS
REDUCTION IN
TECHNICAL MINIMUM
LOADING
AVAILABILITY OF
CHEAP GAS
ENVIORNMENTAL
NORMS
RE INTEGRATION &
CYCLICAL LOADING
AGING UNITS
HEALTH OF DISCOMS
Major Areas of concern in terms of energy efficiency and reliability
53
13. Awards & Accolades
National Energy Conservation Awards
54
Year 2012 Year 2017 Year 2015
CII Energy Excellence Awards
55
Year 2017 Year 2018
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Migratory Birds at NTPC Reservoir
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