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Contents
Company Profile
DTPS at a glance
Approach
Maintenance Practices
Confidential
Slide
Contents
Confidential
Operation practices
Slide
Company Profile
Infrastructure
Generation
EPC
Transmission
Distribution
Trading
Confidential
Slide
About DTPS
Confidential
Slide
Confidential
Slide
About DTPS
The setting up of the Plant was
approved in 1989 for 2 x 250 MW
capacity.
First Synchronization
Unit I
- January 1995
Unit II
- March 1995
Slide
DTPS Journey..
1998 ISO 9001
IMS RBNQA
ISO
27001
BSC
SAP
ESS
ISO
Upgrade
RAMCO
ISO
14001
ISO
9001
6-I
Mercer,
CII
6-II SA8000
OHSAS
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
2011 ISO 50001:2011 (Energy Management
System)
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2013
Confidential
Slide
System Approach
First
Certification
by BVQI
ISO
9001:2008
ISO
14001:2004
ISO
50001:2011
OHSAS
18001:2007
SA
8000:2008
ISO/IEC
27001:2005
Slide
Process
Safe
Reliable
Sustainable
Efficient
M
O
N
I
T
O
R
Communication
Log-books
Confidential
Economical
O
P
T
I
M
I
S
E
C
O
N
T
R
O
L
Team Work
Environment
Clean
R
E
V
I
E
W
Standardisation
Systems
Slide
10
Stretch targets
Benchmarking
Resource optimisation
Energy conservation
Efficiency improvement
Legal requirement
Confidential
Slide
11
Brainstorming
D-logbooks
Event analysis
MIS reports
Technical
Validation
Data
Collection
Validation &
conversion
in reportable
format
GAP
Analysis
Probable
solutions
Pilot testing
Monitor
OEM data
Benchmarking
Other plant visit
Other site inputs
Slide
12
R&M
Online Energy
monitoring
System
Confidential
Fuel Switch
HFO to LDO
New technology
introduction
Modular
Scaffolding
APH Brush
Seals
Thermo-vision
applications
Optimisation
Innovative
approach
Equipment
running hours
VFD applications
Soot blowers
Standardization
PROMT
maintenance
Coal Blending
Slide
13
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
6.6 KV Swgr
U-2
Slide
14
Operating Value:
Operational
Control:
It includes
Base
theValue:
Maintenance
Control:
Is Decided
Based On Average
Effect
OfIt
Coal
Quality Variation,
It Includes
This Condenser
control
includes
Value
of 1 Condition,
Year Data
Vacuum
Un-optimized
Detail
Analysis
Of Problems
Other
Seasonal
Effects.
Operation
Deviation,
Solution
In Terms
New
Alternative
Operators
ToOfPassing,
Run
Equipment
In This
Valve
/Have
Damper
Average
Power
Consumption
Technology
Standardized
Operating
Range.Due,
Preventive
Maintenance
Repair or
Replacement.
Set
Points At Various Parameters
Rate As On Date
Confidential
Slide
15
Slide
16
PROMT
Priority on Managing
Performance Trends
maintenance
Innovative
Maintenance Approach
Slide
17
Confidential
Slide
18
Saving Achieved
BFP-1A = 461 kw
cartridge Replacement
BFP-2A = 656 Kw
(serviced cartridge)
BFP-1B = 347 Kw
Confidential
Slide
19
During overhaul APH baskets of cold end are removed and water jet cleaning at 40
ksc pressure is carried & chocking is removed..
Confidential
Slide
20
Modular Scaffolding
Confidential
Slide
21
in Generator activities.
Confidential
Slide
22
22
Confidential
Slide
23
routine rounds
Sound/Temperature
observations
Identification during
Unit Running
Condition
Offline 02 %
measurement & analysis
Offline flow measurement
(Pitot Tube) Third Party
Air ingress checklist
Scheduled
Confidential
Slide
24
No
Running
Defect
Yes
Planning done to
attend
Confidential
Equipment
Shutdown
Short
Shutdown
Major Overhaul
Slide
25
Slide
26
Reasons for lower efficiency are find out and maintenance is planned
accordingly.
Coal mill O&M is based on the output and quality of the pulverised coal.
Confidential
Slide
27
Efficiency Based
operations
Innovative Operation
Approach
Coal Blending Mechanism
SOG, SOP & Checklists, Digital Logbooks
Optimization
Confidential
Benchmarking
Slide
28
Process Optimisation
Investment - NIL
Confidential
Slide
29
DTPS is provided by 56 Water wall soot blowers and 18 Long retractable soot
blowers in convective zone of super heaters, re-heaters & economizer tubes
Results in the around 80% variation in the main-steam & re-heat temperatures.
Lower efficiency.
Erosion of tubes.
Confidential
Slide
30
Intelligent approach
Development
The Soot blowers are operated in a pair left and right side of each bank. The data is collected
and logged.
Typical data includes:
Fluid temperatures at inlets and outlets of each convection pass including the
temperature before and after attemperators.
Operating pressures (drum, super heater, re-heater)
Boiler exit gas temperatures before and after Soot blowing
Flue gas excess Oxygen (O2) at the boiler exit
Fluid flow (main steam, reheat steam, feed water)
Fuel and total air flow
Boiler tubes metal temperature before and after Soot blowing
Flue gas temperature at different zones before and after Soot blowing
Coal Elevations in service.
Confidential
Slide
31
Intelligent approach
After Analysis of the data collected for 3 months for each LRSB a schedule is
prepared for operation of long retractable soot blowers in group as per the locations.
Day
1
3
5
7
9
LRSB numbers
65, 57, 58, 69
66, 59, 60, 70
63, 68, 71
64, 67, 72
61, 62, 73, 74
Group operation of water wall soot blower like 1, 4, 8, 12 (in gap of 3) or 1, 6, 11 (in
gap of 4) gives better results than simply whole set (1-14,15-28,29-42) sequential
operation previously carried out.
The scheduled of WWSB operations kept the same but the sequence of operation is
changed.
Confidential
Slide
32
Confidential
Slide
33
Confidential
Slide
34
Intelligent approach
value.
over cleaning.
side.
nil.
Lower efficiency.
Higher efficiency.
No logical explanation.
High TPM.
software.
Confidential
Low TPM.
Slide
35
1.45
0.92
0.7
Confidential
Slide
36
Condenser
Unit # 2
Cooling channel
1.8
mtr
1.8 km duct
1.5
mtr
Sea
Water
Creek
Tide Level
Sea water temperature,
Condenser Vacuum,
Generator Current,
MS Flow
Confidential
37
Phase-II
Standardized
with logical
explanations
Phase-III
Low load
operations
Pump
continuous
running
Confidential
Slide
38
Auxiliary
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
APC
Unit-1
Slide
39
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
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
Drinking Water
Pump
40
24
16
5.00
16
10
2.00
1847
1219
622
247
Slide
40
Blending Mechanism
Two different grades of coal are mixed uniformly in predetermined
proportion for achieving desired calorific value. Blending of coal is
done on conveyor and as per requirement.
Two / three different grades of Coal are lifted from separate locations.
Lifting rates / flow is predetermined and is monitored through Belt
Scale by the operator as well as from Control room.
Slide
41
1.
2.
3.
4.
5.
6.
7. Overall performance improved
Commercial
operations
F-grade
Wash coal +
Coal
Imported coal
Indian raw coal +
Imported coal
1995-96
Confidential
1st Phase1999
Wash coal +
various grades of
imported coal
3rd Phase2006
Slide
42
Use of Thermography
Insulation surveys
Finding hotspot
Confidential
Bunkers
Coal yards
Motor terminals
Motor winding
DDC panel
Slide
43
Confidential
Slide
44
Before
Insulation
Confidential
After
Insulation
Slide
45
Piping Survey
Main Steam (MS), Cold Reheat (CRH) & Hot Reheat steam
piping (HRH) insulation survey
Confidential
Slide
46
Confidential
Slide
47
Thank you