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Ratnagiri Gas & Power Pvt Ltd
Vision: To emerge as significant player in energy sector
Abdul Saleem, Dy GM (Energy Efficiency)
Aman Kaul, Manager (Energy Efficiency)
Mukul Sharma, Manager (Technical Services)
21st National Award for Excellence in Energy Management
RGPPL Overview
RGPPL Snapshot
Dabhol Power Company was set up as one of the first projects with major FDI after liberalization in India.
DPC envisaged to set-up an integrated power generation and LNG regasification facility.
RGPPL was formed in 2005 as a SPV under aegis of Empowered Group of Minister of GoI to take over & revive assets of DPC.
Joint venture of NTPC, GAIL, MSEB & FIs
COD: 19.05.2009
Power & LNG businesses demerged in 2018.
Beneficiaries: Maharashtra, DD, DNH, Goa, Railways.
ISO 14001 & ISO 45001 certified plant.
No fatal accident in power plant since take-over.
3
25.5
25.5
13.5
35.5
Shareholding
NTPC
GAIL
MSEB
IFIs
RGPPL Overview
4
India’s Largest Gas-based Power Plant at 1967.08 MW
Block Capacity - 640 / 663.54 / 663.54 MW
All blocks in multi-shaft combined cycle configuration
Each Block with
• 2 GTs (GE 9FA/9FA+)
• 2 HRSGs (Vogt/Kawasaki)
• 1 ST (GE D11)
Single shaft CTG with 18 stage compressor & 3-stage GT
Dry Low NOx Burners (DLN 2.0/DLN 2+)
Condenser cooling through sea water (Arabian Sea)
Sweet water supply through 50-km long pipeline
No diverted damper for open cycle operation
Power evacuation through four 400 KV lines
MH, 68%
DD, 2%
DNH, 2%
Goa, 1%
Railways, 27%
Power Allocation
1967.08
MW
Energy Consumption & Benchmarking
Total Energy Consumption FY 2019-20
6
Gross Generation4264 Million kWh
366,638 TOE
Sale to Customers4179 Million kWh
359,329 TOE
Township Power Consump.2.42 Million kWh
208 TOE
Aux. Power Consumption81.76 Million kWh
7,030 TOE
PLF 24.68 %APC 1.918
%
Raw Water consumption1,54,000 KL
DM Water consumption38,466 KL
7
1843 1840 1833
1840
26.5
26.1
25.9
24.7
24.0
25.0
26.0
27.0
1800
1820
1840
1860
FY17 FY18 FY19 FY20
Heat Rate
Heat Rate PLF
Specific Energy Consumption
2.01.8 1.9 1.91
26.5
26.1
25.9
24.7
24.0
25.0
26.0
27.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
FY17 FY18 FY19 FY20*
APC
APC PLF
41.4% 37.6%36.6% 34.0%
On-bar Availability
Activities for Reduction of SEC
Single block operation to reduce APC & Heat Rate
Timely overhauling of GT (CI, HGPI) and ST (Minor, Major)
Compressor: inlet air filter replacement, online/offline water wash, online efficiency monitoring
Condenser: high pressure jet cleaning, helium leak test for vacuum improvement
Maintaining COC & chemical dosing for better heat transfer in condenser through cooling water
Cooling Tower: fills replacement, blade angle adjustment
Replacement with LEDs in plant
Optimization of plant auxiliaries operation
Use of thermal cameras for insulation survey in HRSGs
8
9
2075 2100 2000 1975 2050 2040
1820
22122301
21332020 2068
2140
1840
0
500
1000
1500
2000
2500
Anta Auraiya Dadri Faridabad Kawas Gandhar RGPPL
Heat Rate in kcal / kWh
Target Actual
Benchmarking: Heat Rate in 2019-20
Best Heat Rate
10
2.75 2.75 2.75 2.75 2.75 2.75 2.75
6.73
4.213.76
3.38 3.30
4.36
1.92
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
Anta Auraiya Dadri Faridabad Kawas Gandhar RGPPL
APC in %
Target Actual
Benchmarking: APC in 2019-20
Lowest APC
PAT Targets
118/31/2020
Parameter 2019-20 2018-19 2017-18 2016-17
Gross Heat Rate (kCal/kwh) 1820.0 1832.8 1839.9 1842.8
APC (%) 2.75 1.94 1.74 1.93
Net Heat Rate (kCal/kwh) 1876.14 1869.1 1872.5 1879.1
RGPPL is covered under PAT Cycle 3. Net Heat Rate of 1876.14 is achieved against PAT target of 1873.12 kcal/kwh for assessment FY 2019-20.
Reason for higher Heat Rate:
Higher percentage of negative RRAS & lower PLF.
Lockdown in last fortnight of FY 19-20 also contributed to higher heat rate due to drastically reduction of load.
Activities for Achieving PAT Target:
Installation of 260 KW of LED in Power Plant & Colony.
Conversion of Duel Fuel Nozzle to Single Fuel Nozzle in Gas Turbine leading to saving of 51,048 MMBTU of Thermal Energy per annum
Installation of VFDs in DM makeup pumps
Most Efficient Power Plants
Nishi Nagoya Power Station, Japan
• 1188 MW installed capacity
• 63.08% efficiency (NCV) on 22.01.2018
• 3 GE 7HA GTs with 1 Toshiba ST
Bouchain Power Station, France
• 605 MW installed capacity
• 62.22 % efficiency (NCV) on 28.04.2016
• 1 GE 9HA GT with 1 GE D650 ST
RGPPL
• 55.62 % efficiency (NCV) on 21.07.2010
• Neat Heat Rate 1744 kcal/kWh
• 2 GE 9FA GTs with GE D11 ST
12
Torrent Sugen Surat - 1590
Torrent Unosugen Surat - 1599
Torrent Dgen Dahej – 1606
Siemen’s SGT5 4000F GT
OTPC Tripura – 1699
GE 9FA GT
Global National
Energy Saving Projects
14
Energy Saving Projects: 2017-18
1.0
4.5
4.7
15.8
31.5
90.5
122.7
Installation of LEDs
Integrated Chiller Water System
Compressed Air Optimization
GT Compressor Water Washing
ST-2X Condenser Tube Cleaning
Single Block Operation (Heat Rate saving)
Single Block Operation (APC saving)
Savings in Rs Millions
34.08 MU
10.5 kcal/kWh
8.76 MU
4.38 MU
1.31 MU
1.24 MU
Energy Saving
0.26 MU
15
Energy Saving Projects: 2018-19
4.4
4.5
7.9
15.7
31.5
37.8
90.2
172.4
Installation of LEDs
Integrated Chiller Water System
GT-3A Inlet Air Filter Replacement
GT Compressor Water Washing
ST-3X Condenser Tube Cleaning
ST Helium Leak Test for Vacuum Imp.
Single Block Operation (APC saving)
Single Block Operation (Heat Rate saving)
Savings in Rs Millions
20 kcal/kWh
25.05 MU
10.51 MU
8.76 MU
4.38 MU
2.19 MU
1.24 MU
1.23 MU
Energy Saving
16
Energy Saving Projects: 2019-20
4.1
4.5
7.9
15.8
31.5
127.7
Installation of LEDs
Integrated Chiller Water System
GT-3A Inlet Air Filter Replacement
GT Compressor Water Washing
Condenser Tube Cleaning
Single Block Operation (APC saving)
Savings in Rs Millions
35.47 MU
8.76 MU
4.38 MU
2.19 MU
1.24 MU
1.14 MU
Energy Saving
Energy Saving Projects (Planned) FY 20-21
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Conversion of dual fuel nozzles to single fuel firing (Competed in 2 Gas Turbine)
Electric vehicles for use inside plant area
Ground mound Solar panel of 100 KW as pilot project
Solar water heaters in township
Turbo-ventilators in place of motorized fans for TG hall and warehouses
Installation of light tubes in warehouse & conference halls
Energy Saving Projects (Planned in FY2020-21)
Existing BFP is 9 stage centrifugal pump, driven by 2660 kW / 6.6 kV electric motor.
Modification proposed for removal of two stages of pump impeller for pressure reduction from 177 kg/cm2.
Destaged BFP will provide 130 kg/cm2 pressure, which is sufficient for part load operation.
After modification, power consumption will be 1766 kW, thereby saving 607 kW per BFP.
Annual power saving per BFP @ 185 days running will be 2.70 million units.
18
Destaging of Boiler Feed Pump
Environment Management- Water
Environment Management- Water
20
DM water Consumption of Plant (Unit - %)
FY 2017-18
0.52 %
FY 2019-20
0.61%
FY 2018-19
0.58 %
Raw water Consumption of Plant (Unit – M^3/MW)
FY 2017-18
320 M^3/MWFY 2018-19
318 M^3/MWFY 2019-20
317 M^3/MW
Zero Liquid Discharge (ZLD) is not applicable for coastal power plant which are using sea water for condenser cooling.
For reuse of sewage water, RGPPL has planned to installed 0.5 MLD STP based on MBR technology in place of existing STP.
Environment Management- Water
Rainwater Harvesting:
RGPPL is self sufficient in term of sweet water from Rain Water Harvesting. RGPPL has harvested 304 m^3 rain water against requirement of 219 m^3 for power plant & colony for FY 21.
Chiller Coil Condensate Use:
RGPPL was envisaged as an integrated energy complex with a power plant and an LNG regasification facility. In this energy exchange process, heat energy of condenser cooling water from power plant is utilized for regasification of LNG and cold of LNG is utilized in power plant for inlet air chilling & circulating water cooling. When power plant units operate at base load condition, chiller coils are taken into service to enhance efficiency and also because the condensate formed on inlet air chiller coils. This condensate provides water at the rate of 10m3/hour per gas turbine, which is then re‐used as process water for plant activities.
21
Best Practices in water Management
Environment Management- Water
Auxiliary Make‐up: Auxiliary cooling towers are operated in closed loop so that the evaporation loss is null. This has helped in saving considerable quantity of clarified water.
HRSG Blowdown, quench water and Sample Loss: Water collected in blowdown tanks are treated for using in demineralization process, thereby reducing requirement of fresh water for process
STP Water Re-use: RGPPL has also planned to upgrade its existing sewage treatment at township with Membrane Bioreactor (MBR) technology based STP
22
Best Practices in water Management
Innovative Projects
Innovative Projects
Naphtha storage tanks converted as water storage tanks (3 X 40,000 m3)
Check dams & bunds constructed
Dewatering pumps installed in all storm water drains of plant
Diversion of gravity flow channels for sending rainwater to EWR
Supply of excess rainwater to nearby villages
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224 220 219
170196
304
0
50
100
150
200
250
300
350
FY19 FY20 FY21
Tho
usa
nd
s
Sweet WaterRequirement
RainwaterHarvesting
Water quantities in cubic meters
Actual data for FY19 , FY20 & FY21
Further enhancement in FY 21
Repair of primary reservoir (120,000 m3) & use of fourth fuel tank for water storage (40,000 m3)
Water Positive in
FY21
Rainwater Harvesting
Innovative Projects
LNG is stored cryogenically at –160 oC.
Chilled water (DM water + 12% MEG) carries heat from condenser cooling water to LNG process area for regasification.
Cold energy of LNG is utilized in power plant for inlet air cooling and condenser cooling.
25
Use of chiller coil condensate water as process water (10m3/hr per GT)
Use of gravity for water supply from Tanks (139 m) to plant (105 m) & colony (120 m)
Chilled Water System
Other Projects
Utilization of Waste Material
Paper recycling machine of 20 kg capacityinstalled to effectively & sustainablyrecycle used papers.
Recycled paper is being used to makedrawing sheets & other small items suchas note pads, bags, files, folders, etc.
26
Waste Paper Recycling MachineHydro-pulper Paper-lifter
Screw-pressCalendaring
STP Water Re-useFinished Products
Re-use of treated water from Sewage Treatment Plant for horticulture
Green Supply Chain
27
Disposal of e-waste through OEM collection centers or MPCB authorized recyclers.
Installation of electric vehicle charging station
Procurement of energy efficient lighting, ACs & fans through BEE certified agencies
21% reduction in use of paper in last three years
Ban on plastic & tobacco.
Distribution of jute & recycle paper bags.
Reduction in township water consumption by 100 m3 per day by provision of individual tanks and replacement of taps & fittings.
Activity Planned
Relocation of weigh-bridge to reduce travel distance of vehicles by 1100 meter one-way, thereby saving fuel & emissions
Green Initiatives
Best Practices in the Plant
Best Practices in the Plant
Safety• 100% Safety induction training is imparted to all workers at the time of issue or renewal of
gate-pass.
• Pre-work briefing (tool box talk) is provided to contract workers before start of works under hot work and confined space permits.
• Cross Line marking in back Panel of SWGR to avoid accidental maintenance activity on live panels.
29
Flexibilization
• Smart blending of Fuel –RLNG,NAPM and Spot Gas
• USP in Electricity sales- LTA,TAM,DAM,RTM
Best Practices in the Plant
30
Maintenance and reliability
• Real time Compressor Blade health monitoring of compressor for early detection of abnormality
• Critical Analog inputs were shifted to TMR (Triple Modular Redundancy) channels to improve system reliability
• Control / power cable conduits, Hand Rail replacement by PVC/FRP to counter corrosion due to airborne salinity
• To increase insulation resistance of breakers under saline atmospheric conditions, RTV coating for generator breakers in 400 KV switchyard has been done.
• Monthly Hot washing of switchyard insulators to prevent deposit on insulators due to saline environment.
• Distributed emergency lighting system for all plant areas, staircases, switchgear rooms and control rooms.
Best Practices in the Plant
Asset Management• Dry Preservation of Pressure parts with N2 capping.
• Preservation of Gas turbine, Steam turbine and HRSG of units under long shut down with dry air using dehumidifier
31
Research
• Optimum Utilization of inlet air filter using ANN Model
• Compressor fouling identification using ANN regression & pattern recognition
Best Practices in the Plant
New Initiatives
• Upgradation of its existing sewage treatment at township with Membrane Bioreactor (MBR) technology based STP
• Replacement of conventional chlorine gas dosing system with Electro chlorinator.
• Installation of Condensed Aerosol based fire fighting system in Central control rooms and Local Control rooms
32
Team work, Involvement & Monitoring
Monitoring
Continuous & online monitoring of emissions through CEMS
Realtime monitoring of effluent quality through EQMS
Realtime ambient air quality monitoring through 4 AAQMS stations
Display of real-time emission parameters at plant main gate.
Daily monitoring of operational & commercial parameters including Heat Rate, APC, water consumption, etc in meeting chaired by HOP.
Monthly performance report of Gas /Steam Turbine & all critical equipment reviewed by HOP
Monthly Operation Review Team meeting chaired by HOP.
Annual technical audit for identification & correction of gaps.
Circulation of energy audit & equipment performance reports.
Real-time parameter monitoring through HMI (GT & ST) and DCS (HRSG & BOP)for immediate deviation identification.
34
Team Work & Employee Involvement
Interaction of HOP with all employees through Open Forum
Awareness & cleanliness drives in neighboring villages
Classes by executives in Township school on various subjects
Display of energy conservation slogans & posters in plant
Awareness amongst contract workers
Felicitation of workers & executives for safety & excellence
35
Suggestion Scheme – सुझाव
36
Suggestions Received
Suggestion scheme for executives & workers
Number of suggestion received in 2019-20: 83
Suggestions recommended for implementation: 56
Online portal developed for suggestions
Suggestion boxes installed at prominent locations
Installation of RTD pads for temperature measurement & indication in Control Room for immediate identification of passing in high energy drain valves.
Radar type level transmitters in Lube Oil tanks with alarm for quick identification of leakages.
Position feedback of valves of HRSG & condensate system in Control Room.
Auto-start of stand-by BFP based on feedwater flow (before tripping of running BFP) to avoid tripping of running turbines.
Long Term Vision on Energy Efficiency
Advance Gas Path modification in gas turbines for efficiency improvement and maintenance
optimization (approximate implementation cost Rs 250 Crore per GT)
Installation of MBR based Sewage Treatment Plant, for re-use of treated water as process water
Self-sufficiency in sweet water requirement through rainwater harvesting (Completed)
100% LED installation in plant & township (Completed)
Implementation of ISO 50001
Use of IOT for remote operation of equipments
37
Energy Conservation Budget
38
0.19 0.731.45
3.25
%, 0.04 %, 0.20
%, 0.36
%, 0.81
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
0
0.5
1
1.5
2
2.5
3
3.5
FY18 FY19 FY20 FY21
EnCon Investment as % of EBITDA
EnCon Investment %
Actual data for FY18 , FY19 , FY 20 & budgeted for FY21
EBITDA in Crore: 473 (FY18), 373 (FY19), 398 (FY20) ,403(FY21)
Investm
en
t in
Rs C
rore
FY21: Rs 2.80 Crores amount allocated for BFP de-staging
Awards & Accolades
XIII World Aqua Congress-2019
Awarded Aqua Foundation Excellence Award for 2019 under two category
Water Reuse Project & Sustainable Development in thermal power sector
40
20th National Award for Excellence in Energy Management
RGPPL received CII’s Energy Excellence Award 2019 for being ‘Energy Efficient Unit’
41
Best Gas Power Plant
RGPPL received NTPC’s Best Gas Station Award at O&M Conference IPS 2020
42
RGPPL recognized as ‘Safe Plant’ by NTPC for 2019-20
At Post Anjanvel, Taluka GuhagarDistrict Ratnagiri – 415703 (MH)
www.rgppl.com
Contact Us
Copyright 2018 @ RGPPL. All Rights Reserved.
02359 - 241146
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