ENERGY AUDIT REPORT National Thermal Power Corporation Limited Dadri Name and Address of the Energy Audit

t Firm Enercon Systems Pvt Ltd 44 P Electronic City Phase II Hosur Road Bangalore 560 100 Phone:- 91 80 51189726 Fax:- 91 80 51189729 Email:- contact@enercon.co.in Website :- www.enercon.co.in National Thermal power Corporation (NTPC) Dadri Thermal Power Plant Contact Person Mr. R K Jain DGM (O&E EC) National Capital Power Plant Dadri P O Vidyut Nagar Distt: Gautam Budh Nagar 201 008 Email:Phone:-0120-4671284 Feed Water system of Boilers Compressed Air Systems Electro Static Precipitators Draft system Air Pre-heaters Township Power Consumption Sectionwise data not available Instruments Used are enclosed at Annexure-I

Name of the organization where the energy audit was carried out

Details of Equipments for which Audit was undertaken: 1) Boiler 2) Electrical Systems 3) Steam Systems 4) Furnaces 5) Insulation & Refractors 6) Electric Motors 7) Compressors 8) Compressed Air System 9) HVAC and Refrigeration 10) Cooling Towers 11) Fans & Pumps 12) Lighting Systems 13) Diesel Generating Systems 14) Others Quantified benefits to the industry

Energy

Identified annual recurring savings of Rs. 46.9 milion. to the Refer Executive Summary at Annexure-II Refer Executive Summary at Annexure-II

List of industry

suggested

equipments

Overall recommendations to the industry

Annexure-1 List of Instruments Please find below the list of instruments available with us for carrying out various measurements.

S. No

Instrument

Make

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17

AR 5 Network Analyser Clip on Meter Demand Recorder Liquid Flow Meter (Ultrasonic) Temperature Indicator Infra Red Temperature Flue Gas Analyser RH & WBT Recorder RH Recorder RH Meter Anemometer Pressure Meter Temperature Probes Pitot Tube Lux Meter TDS Meter / pH Meters Non Contact Tachometer

CIRCUITOR Spain METRA CLIP - Germany ENERCON - India Greyline USA Testo Taiwan TES KANE MAY UK AIRFLOW USA AIRFLOW USA KANE MAY UK LUTRON Taiwan COMARK OMEGA USA AIRFLOW USA LUTRON Taiwan MILWAUKEE BELTRONICS

ANNEXURE - II EXECUTIVE SUMMARY - NTPC The summary of the observations and recommendations evolved out of the energy audit study of National Capital Power Station, NTPC, Dadri, Ghaziabad, UP, is as follows:-

2.1

The combined efficiency of Boiler Feed Water Pumps (4A, 4B and 4C) in Unit IV is 61.5%, 60.1% and 60.2% respectively. The specific power consumption (kW/TPH) is 8.05, 8.22 and 8.21 respectively. The Feed Water Pumps 3A and 3B are operating at lower efficiency having higher specific power consumption. Replacing the cartridges of these pumps will lead to a saving of about Rs. 1.83 million per annum, with return on investment of about 14 months. Variable Frequency drives could be installed on Condensate Extraction Pumps to operate on variable speed to reduce the pressure drop across the control valve. Use of VFD with these pumps will lead to a saving of about Rs. 6.9 million per annum, with investment pay back of about 3 years. Reducing the operating voltage in the township to about 410 volts is estimated to save about Rs. 23.3 lakhs, as shown in Annexure-1, with no capital investment. In addition to the reduction in energy consumption, the failure rate of appliances is estimated to reduce substantially, leading to considerable monetary savings due to reduced inventory cost. EIL standards recommend 150 and 70 watt lights for street lighting. Eliminating the use of 250 watt lamps for street lighting is estimated to save about Rs. 5.25 lakhs per annum, as shown in Annexure-2, with return on investment of about 16 months. The overgrown trees along the lamp poles may be trimmed or replanted at the other side of the road. Use of lighting energy savers or voltage stabilizers to reduce the operating voltage of the street lighting and central park lighting is estimated to save about Rs. 4.16 lakhs per annum, as shown in Annexure-3, with return on investment of about 21 months. Switching off alternative street lights and switching off the lights in the small parks after midnight is estimated to save about Rs. 2.5 lakhs per annum, as shown in Annexure-4, with return on investment of about 15 months. It is desirable to replace the existing GLS lamps with CFLs of adequate wattage in the township in a phased manner, to start with common area lighting. The return on investment is about 9 months and as per available records, the potential of savings could be as high as Rs. 32 lakhs per annum. There are 14 air compressors installed in the plant, 5 for instrument air with capacities of 20 3 3 M /min. each, 4 for plant air with capacities of 20 M/min. each, 3 for AHP with capacities of 14 3 3 3 M /min each and 2 additional compressors of capacities 10 M /min. and 20 M /min. the capacity of the identified air compressors to about 90% of the rated capacity is estimated to save about Rs. 12.2 lakhs per annum, as shown in Annexure-1, the capital cost is the investment required for overhauling the compressors. is estimated that the management can save about Rs. 31.28 lakhs per annum, as shown in Annexure-2, by opting for centrifugal compressors for base load operations. management may consider replacing the time based drain valves by moisture based drain valves to optimize the energy use efficiency and to prevent any possibility of moisture carry over to the user ends, protecting the critical controls of the plant from damages. Usually, the return on investment will be within 2 years. use of high pressure air at the lagoon may be avoided by use of a root blower considering the requirement of pressure, length of pipe line and associated pressure drop etc. which will lead to an estimated annual saving of about Rs. 4.27 lakhs per annum, as shown in Annexure3.

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2.10 Regaining

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dust collection efficiency has been estimated as 99.2% in Unit I , 99.5% in Unit II, 99.5% in Unit III and 99.4% in Unit IV. power consumption of heaters and wrapping motors was found to be 175 kW in Unit I, 155 kW in Unit II, 158 kW in Unit III and 241 kW in Unit IV. air ingress from the ESP flange joints, isolating gates and from ash conveyer as well as seals of AHP should be minimized. fluctuation of current in the different fields was observed, which could be due to increased deposits on electrodes. In these cases rapping cycles may be increased to maintain an optimum and stable V-I characteristics, at a higher secondary voltage. is desirable to use feedback signal from opacity meter and boiler load signal to optimise the power consumption in ESP. Variable Speed Couplings of PA Fans in all the units could be replaced with Variable Frequency Drives as a long-term measure to save the inherent power loss in Variable Speed Couplings, amounting to about Rs. 17.2 million per annum, with return on investment of about 4.5 years. The Variable Speed Couplings of ID Fans in Unit I & II could be replaced with Variable Frequency Drives as a long-term measure to save the inherent power loss in Variable Speed Couplings, amounting to about Rs. 9.95 million per annum, with investment pay back of about 5.4 years.

2.16 The 2.17 The

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