Plant Performance Improvement by

Reduction In Auxiliary Power Consumption

Date: 27-05-2011

Presented By

Reliance Infrastructure Limited

Anirudha Asawa
Bhupesh Raut

Flow of Presentation

Company & Plant Profile

Plant Performance Indices

System Approach

Case Study

Results

Confidential

Slide 2

Company & Plant Profile

1800 mw for HPGCL Commissioned

600 mw for R-power commissioned
4400 mw for R-power under
commissioning
Confidential

Slide 3

Dahanu Thermal Power Station (2 x 250 Mw)

First 250 MW sets in the Country

Indigenous technology

Coastal power plant far away from

Coal Mines Annual requirements
Total Coal

Indian coal

Imported coal

2.75 Million tons

2.0 Million tons
0.75 Million tons

Sea Water Open Cycle cooling

system (M3/Hr.) 84,000

Nearby Surya River dam (32 kms).

Sweet Water (M3/Hr.)

Confidential

300

Slide

Plant Performance Indices

Plant Load Factor (%)

102.33

101.79
101.53

2006-07

Confidential

2007-08

101.00

100.99

2008-09

2009-10

2010-11

Slide

Plant Performance Indices

Plant Availability (%)

96.79

2006-07

Confidential

96.7

2007-08

96.31

2008-09

97.18

96.48

2009-10

2010-11

Slide

Plant Performance Indices

Heat Rate (Kcal/kwh)

2279
2300

2288

2008-09

2009-10

2278

2006-07

Confidential

2007-08

2282

2010-11

Slide

Dahanu Thermal Power Station (2 x 250 Mw)

Auxiliary Power Consumption (%)

7.64

7.67

7.71

7.6
7.38

2006-07

Confidential

2007-08

2008-09

2009-10

2010-11

Slide

System Approach
ISO 9001:2008

BS EN
16001:2009

ISO
14001:2004

DTPS
SA 8000
OHSAS
18001:2007

ISO
27001:2005
Continual improvement is ensured through improvement plans like
Quality Improvement Plan, Safety Improvement Plan
Environment Management Plan, Energy Management Plan
Confidential

Slide

Overall Plant Performance Indices

Turbine-Generator (TG) Heat Rate (Kcal/kwh)

Boiler Efficiency (%)

Auxiliary Power Consumption (%)

Confidential

Slide 10

Case Study On

Reduction In Auxiliary Power

Consumption

Confidential

Slide

Auxiliary Power Consuming Area

AHP
CHP
Compressors

ECO

CONDENSER
CWP

BFP

5.04 mw

9 mw

CEP
0.625 mw

SEA WATER CREEK

DEA

APH
4.70 mw

ESP

2.7 mw
FD Fan
Coal Mill
Confidential

PA Fan

1.45 mw

ID Fan 3.5 mw
Slide

Auxiliary Power Consumption at DTPS

Auxiliary Power Breakup at DTPS

LT Motor
Consumption
1.99 Mw
5.0%

HT Motor
Consumption
37.90 Mw
95.00%

Auxiliary Power Consumption 2009-2010 7.6%

Confidential

Slide 13

Auxiliary Power Consumption at DTPS

DTPS Net Generation Vs APC

DTPS APC Breakup

CHP 0.11%
AHP 0.11%
CWPH 0.78%
Net Generation
92.40%

APC 7.60%
Main Plant
6.43%

ESP
0.1%

Raw
water PH
0.09%

2009-2010
Confidential

Slide 14

Approach for Reduction in Auxiliary Power

Consumption
Conventional Practices
Quality Tools
Operational Control
Maintenance Control

Standard
O&M
Practices

Energy Management

Technology

Confidential

Slide 15

Auxiliary Power Reduction Through Operational

Control
F-Grade Coal

Cooling water

Wash Coal

pump

Coal

ACW pump
Compressors

Equipment

Blending

Running

Mgt

Hours

@4000kcal/kg

Imported Coal
High/Medium GCV

Excess Air
Excess air
optimization
Air ingress
measurement at

various location
Confidential

control &

Maximizing

air ingress

Generation

monitoring

Current limit= < 9800

MS flow = <775 TPh

MS pressure = < 155
Kg/cm2
MS Temp = < 540C
Slide

Optimization of Equipment running Hours

Condens
er Unit #
1

Condens
er Unit #
2

20750 m3/hr each

Cooling channel

1.8 km duct

2.6 mtr duct

4th CW pumps running hours / day
104.99

17.98

105.30
104.86

11.21

Sea
Water
Creek

Loading Factor
104.68

Tide
Level
Varies
from
-0.5 to
5.5 mtr

9.49
4.1

Running of 4th CW pump is

optimized as per Tide Level,

2007 2008
Confidential

2008 2009

2009 2010

2010 2011

Sea water temperature

Slide

Operational Control
Condens
er Unit #
1

Condens
er Unit #
2

20750 m3/hr
Cooling channel

TC
T+2
@T C

2.6 mtr - 1.8 km duct

Sea
Water
Creek
Tide
Level
1.8 mtr

After filling the sea water above the duct area the rise in temperature

due to solar heat in summer prevented

Confidential

Slide

Optimization of Coal Quality

Auxiliary power reduction through Operational Controls

Boiler Auxiliaries Current

Optimization of Coal Blending

GCV kcal/kg

950

Ratio (@ 4000 kcal/kg)

4300

42004200
900

4100

920

4000

4000

850

Boiler Auxiliaries
Coal Mills, ID Fans, PA Fans, FD Fans

3900

860
3800

800
750

3600

3800
3700

820

3600

780

3500
3400

700

3300

Optimization of Grinding media in coal mills as per the coal Quality

Ball charging are optimized from 100 Mt to 80 Mt, without compromising coal

fineness & required output

Confidential

Slide

Maintenance Control
Performance based

Performance

based Boiler feed

Liner

pump cartridge

reversal, grinding

replacement

Boiler

Coal

Feed
Pump

Duct leakages of
Air and Flue gas

Mill

media segregation.
Liner replacement done

from Manganese to Hichrome

Duct

Boiler

Leakages

Maint

Arresting Steam
leakages online

arrested in every

HVOF Coating

opportunity

LFET

Confidential

Slide

Maintenance Control

Auxiliary power reduction Through BFP cartridge Replacement

Maintenance Control

Saving Achieved
BFP-1A = 461 kwh
BFP-2A = 656 Kwh
BFP-1B = 347 Kwh

Performance Based BFP cartridge

Replacement (serviced cartridge)

0.19 %

BFP Cartridge Replacement

Before (Kw)

After (Kw)

7568
7404

7264
7057
6803

BFP-1B

Confidential

BFP-1A

6912

BFP-2A

Slide 21

Maintenance Control

APC reduction Through Replacement of Manganese liners by Hi-chrome

liners & ball charging optimization

Mn Liner

1478

1472
1185

1196

MILL -1AB

MILL -1CD

Hi-Cr Liner

1398

1430

1395

1135

1162

1113

MILL -1EF

MILL -2CD

MILL -2EF

APC Reduced = 0.26% approx

Confidential

Slide 22

Maintenance Control
APC reduction Through Arresting Air
& Flue gas Duct Leakages during
Every Opportunity

Befor Overhaul

After Overhaul

1517
1290
914

670
283

ID Fan

PA Fan

260

FD Fan

APC Reduced = 0.18% approx

Confidential

Slide 23

Maintenance Control
Reduction In Forced Outages
through

1 BTL = 1.125 (Mus) APC Loss

(0.023%)

HVOF coating

Reliability improvement of

Tube Thickness survey in

Done at Leak

boiler tubes by carrying out

every opportunity by In-

Prone Area

corrosion mapping (LFET)

house Cross functional team

From Overhaul to Overhaul average Boiler tube leakage per Unit is 2

Radiography of old erection joints 20% completed
Confidential

Slide 24

Adoption of Energy Conservation Technology

14 Nos of hybrid

Total 8 Nos of VFD are

wind ventilator (TG

installed

floor)

ID Fan VFD installation

30 Nos natural
wind ventilator

Wind
ventilators

Solar lighting (1050

W)
Solar water heaters

(1100 Liters/day)

Variable

is under study

Frequency
Drive

Solar lights

IFC air

& water

controller at

heaters,

service air

LED lights

compressor

Intelligent Flow

Control for demand

side air control
IFC for instrument air
is under study

Confidential

Slide

Innovative Project CEP VFD

CD-60

OCST
PT
PT TT

PT

TT

LPH - 1
CD-31

CD-33

CD-36
CD-35

CD-32

Saving Achieved
= 2 x 148 kwh

DRAIN
COOLER

CD-29

CD-14
CD-17

100%

0%

CD-53

DM-4

CONDENSER

TT

LPH - 2

PT

TT

TT

PT

MIN. RECIRCULATION

PT

LPH - 3

DM-2

CD-30

CD-34

CD-37

TO O/H SURGE TANK

TO DEAERATOR

CD-58

PT

TT
PT

TT

CEP-B
VA-6

CEP-A

PT

VA-5

CD-21

TO HP
FLASH TANK
SPRAY

CD-4
CD-23
CD-25

CD-19

CD-3
FT
TT
PT

CD-27
FT

GSC
CPU

Confidential

TO LPBP

Condensate System Overview

Slide 26

IFC Air controller for Service Air System

Saving Achieved =
807 kwh per day

Confidential

Slide 27

Adoption Of Energy Conservation Technology

Sr. No.

Application

Population

Running
Drives

Energy
cons.
without
VFD

Energy
cons
with
VFD

Energy
saving

Cost of
Drive

Nos

Nos

kwh

kwh

kwh

Rs in Lakhs

Coal Mill Seal Air Fan

12

473

222

251

30.55

CEP-1B

583

435

148

106.09

CEP-2A

583

435

148

90.50

ACW Pump

75

44

31

4.50

Ash SILO

68

42

26

6.50

LDO Pump

10

2.00

CDWP

40

24

16

5.00

Sevice Water Pump

16

10

2.00

1847

1219

622

247

0.11% reduction in APC

Confidential

Slide 28

Approach for Reduction in Auxiliary Power

Consumption
Conventional Approach

Auxiliary Power Consumption (%)

Quality Tools

Operational Control
7.64

7.67

Maintenance Control

7.71

Standard
7.6
O&M 7.38
Practices

Energy Management
2006-07

2007-08

2008-09

2009-10

Online
Energy
Monitoring
system

2010-11

Technology
Improvement plans / CA / PA

MIS

Continual Process
Confidential

Slide 29

Online Energy Monitoring System

PCR-1
Process parameter

FGD

PCR-2
Process parameter

Compressor
Room
Process parameter

Process parameter

4-20 mA

4-20 mA
24+16 channel

4-20 mA
16 channel

24+16 channel

SCANNER

SCANNER

4-20 mA
16 channel
SCANNER

SCANNER

RS485

RS485
RS485

RS485

ELAN
VIEW

ELAN
SERVER
LAN

Continual Improvement
ELAN
VIEW

RS485

RS485

Single Login

6.6 KV Swgr
U-1
Confidential

Total 161 New meters

installed (HT)

6.6 KV Swgr
U-2
Slide

Features of Energy Monitoring System

Online monitoring.

Elimination of human error

Measurable outputs

Compares and identifies the efficient processes & equipment

Different type of reports like daily, monthly, quarterly or yearly can

be generated automatically

Report generation and archiving is possible.

Confidential

Slide

Online Energy Monitoring System

Confidential

32

Slide 32

Online Energy Monitoring System

Confidential

33

Slide 33

Online Reports

Feeder name

Confidential

Slide 34

Standardization with Energy Monitoring

System
With Installation of Online monitoring system ,the Energy

consumption of the equipments are classified in to following

Base value (PG test / Design)

Operating value (Process variation from 1 yrs data)

Operational Control

Maintenance Control

Equipment

Boiler Feed
Pump
Confidential

Base value

Operating
Value

Operational
Control

Maintenance
Control

Kwh

kwh

kwh

Kwh

7100

< 7350

7350 - 7450

> 7450

Slide

Daily Reports - MIS

Confidential

Slide 36

System Approach
Energy deviated for three

Equipment wise
standardization of

consecutive days above

Operating & Control

control limit, FIR to be raised

limits
Review of report in
Daily Plant Meeting

Online / Offline
Maintenance work will
be carried out against
FIR

Daily

FIR

Energy

Against

Deviation

Energy

Report

Deviation

Maintenanc

Operational

Study & rectification of

e Control

Control

the problem & process

by O&E dept through SAP on

respective department.

optimization
Any defect observed
notification is raised
through SAP

Confidential

Slide

EMS based O&M Practices

Standardization of O&M
Practices through Energy
Monitoring

Scheduled changeover
of Equipments as per

energy deviation

Most energy efficient

Predictive maintenance

equipment run for

maximum time

Confidential

Slide

Equipment Changeover Condition Based

BFP Changeover
37
25
21

18 19
13 12

Unit-1
Unit-2

11 10

APC Loss per BFP

changeover = 2.7 Mw
(Approx.)

Station

2008-09

2009-10

2010-11

Linear
(Station)

Mill Changeover
55

Unit-1

33

Unit-2

33
24

22

15

18

14

Station

10

APC Loss per Mill

changeover = 1.5 Mw &
Generation Loss =11 Mw
(Approx.)

Linear
(Station)
2008-09

Confidential

2009-10

2010-11

Slide 39

Enhancement of Energy Efficient Equipment

Operation
Sr. No.

Auxiliary

Running Average Power

+ Stand consumption
By
(kw)

Energy
Efficient
Rating

BFP-1B

CEP-1A

7010

7200

555

1+1

1+1
4

CEP-1B

440

ECW-1A

299

ECW-1B

310

ECW-1C

308

COAL MILL-1AB

1149

COAL MILL-1CD

1213

10

COAL MILL-1EF

1252

Confidential

2+1

2+1

can Reduced by
0.19 %

BFP-1A

Increased Running Hour of EE

Equipment

APC

Unit-1

Slide

Benefits

Auxiliary wise Benchmarking energy consumption

Reduction in specific energy consumption

Energy resource planning

Eliminating in-efficient energy operation

Predictive maintenance

Root cause analysis

Measurement and verification

Confidential

Slide 41

Use of Renewable resources

Wind Ventilator at TG Roof

Solar Water Heater 1100 LPD

3.7 kw replaced with 116 watt =

saving 3.6 kwh per ventilator

Saving : 16 Mwh per year

Total Saving : 441
Mwh per year

Solar Street lighting

48 Nos = 1056 watts

Total Installation : 14 Nos

Saving : 3.1 Mwh per year

Confidential

Slide 42

Results
Auxiliary Power Consumption (%)

7.64

7.67

2006-07

7.71

2007-08

7.6

2008-09

2009-10

DTPS APC (%) 2010-11

7.39 7.52 7.45 7.41 7.43 7.51

7.69

6.20
7.11

Apr/10

6.31 6.30 6.31 6.29 6.31

6.24

6.42

6.04

6.07

7.24 7.29

Jun/10

Aug/10
APC (%)

Confidential

2010-11

DTPS Main Plant APC (%) 2010-11

7.25

7.31

7.38

Oct/10

Dec/10
Average

Feb/11

Apr/10

Jun/10

Aug/10

Oct/10

Main Plant APC (%)

Dec/10

6.17 6.16

Feb/11

Average

Slide 43

Mission
Auxiliary Power consumption %
7.64

7.67

7.71

7.6

7.38

Target

2006-07

2007-08

2008-09

2009-10

2010-11

Forward Path

100 Mw Solar Power

ID Fan VFD

LT consumption metering & monitoring

Confidential

Slide 44

DTPS Journey..
1998 ISO 9001

IMS
ISO 27001

1999 ISO 14001

1999 QIP/SIP/EMP
6-I
Mercer,
CII

2000 RAMCO ERP Package implmentation

2001 ISO Up gradation

2003 SAP & ESS implementation

BSC

2004 British Safety Council Audit

SAP
ESS
ISO
Upgrade

RAMCO
ISO 14001
ISO 9001

6-II
OHSAS

RBNQA
Performa
nce

BS EN
16001

SA8000

2005 Benchmarking CII

2005 Six Sigma drive I

2005 Mercer HR study
2006 OHSAS 18001
2007 SA 8000
2008 Integrated Management system
2008 ISO 27001
2009 SAP in place of RAMCO
2010 BS EN 16001

1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Confidential

Slide 45

Energy Conservation Is Cheaper Than

Generation

1 Unit Saved

Confidential

3 Units Generated

Slide

Think Bigger Think

Better.

Thank you
Date: 27-05-2011

Journey Towards Excellence

Continues