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

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Slide 2

Company & Plant Profile

1800 mw for HPGCL Commissioned 600 mw for R-power commissioned 4400 mw for R-power under commissioning
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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.) 300

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Plant Performance Indices

Plant Load Factor (%)

101.79 101.53 100.99

102.33

101.00

2006-07

2007-08

2008-09

2009-10

2010-11

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Plant Performance Indices

Plant Availability (%)

96.79

96.7

96.31

97.18

96.48

2006-07

2007-08

2008-09

2009-10

2010-11

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Plant Performance Indices

Heat Rate (Kcal/kwh)

2279
2300 2278 2288 2282

2006-07

2007-08

2008-09

2009-10

2010-11

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Dahanu Thermal Power Station (2 x 250 Mw)

Auxiliary Power Consumption (%)

7.64

7.67

7.71

7.6 7.38

2006-07

2007-08

2008-09

2009-10

2010-11

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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
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Overall Plant Performance Indices

Turbine-Generator (TG) Heat Rate (Kcal/kwh) Boiler Efficiency (%) Auxiliary Power Consumption (%)

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Case Study On

Reduction In Auxiliary Power

Consumption

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Auxiliary Power Consuming Area

AHP CHP Compressors

DEA
ECO

SEA WATER CREEK

CONDENSER
BFP 9 mw CEP 0.625 mw CWP 5.04 mw

APH
4.70 mw

2.7 mw FD Fan Coal Mill

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ESP
ID Fan 3.5 mw
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PA Fan

1.45 mw

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%

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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
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Approach for Reduction in Auxiliary Power Consumption

Conventional Practices
Quality Tools
Operational Control Maintenance Control Energy Management Standard O&M Practices

Technology

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Auxiliary Power Reduction Through Operational Control

Cooling water pump
F-Grade Coal Wash Coal

ACW pump
Compressors

Coal Equipment Running Hours

Imported Coal High/Medium GCV

Blending
Mgt
@4000kcal/kg

Excess Air
Excess air
optimization Air ingress measurement at

control & air ingress monitoring

Maximizing
Generation

Current limit= < 9800

MS flow = <775 TPh

MS pressure = < 155 Kg/cm2 MS Temp = < 540C
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various location
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Optimization of Equipment running Hours

Condens er Unit # 1 Condens er Unit # 2

20750 m3/hr each

Cooling channel

Sea Water Creek

Tide Level Varies from -0.5 to 5.5 mtr

2.6 mtr duct

4th CW pumps running hours / day 104.99 105.30 104.86 104.68

1.8 km duct

Loading Factor

17.98

11.21

9.49 4.1

Running of 4th CW pump is optimized as per Tide Level,

2007 2008
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2008 2009

2009 2010

2010 2011

Sea water temperature

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Operational Control
Condens er Unit # 1 Condens er Unit # 2

20750 m3/hr
Cooling channel

TC T+2 C @T
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

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Optimization of Coal Quality

Auxiliary power reduction through Operational Controls

Optimization of Coal Blending

950 900 850

Boiler Auxiliaries Current

GCV kcal/kg
4300

Ratio (@ 4000 kcal/kg)

42004200 920 860 3800 3600

4100

4000
820 780

4000 3900 3800 3700 3600 3500 3400 3300

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

800 750 700

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

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Maintenance Control
Performance Performance based Liner reversal, grinding

based Boiler feed

pump cartridge replacement

Boiler Feed Pump Duct

Coal Mill
Boiler
Maint

media segregation. Liner replacement done

from Manganese to Hichrome

Duct leakages of Air and Flue gas arrested in every

Leakages

Arresting Steam leakages online HVOF Coating LFET

opportunity

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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 0.19 %

Performance Based BFP cartridge Replacement (serviced cartridge)

BFP Cartridge Replacement

Before (Kw) After (Kw)

7568 7404

7264
7057 6803 6912

BFP-1B

BFP-1A

BFP-2A

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Maintenance Control

APC reduction Through Replacement of Manganese liners by Hi-chrome

liners & ball charging optimization

Mn Liner

Hi-Cr Liner

1472 1185

1478 1196

1398

1430 1162

1395
1113

1135

MILL -1AB

MILL -1CD

MILL -1EF

MILL -2CD

MILL -2EF

APC Reduced = 0.26% approx

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

Befor Overhaul 1517 1290 914 After Overhaul

670
283 260

ID Fan

PA Fan

FD Fan

APC Reduced = 0.18% approx

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Maintenance Control
Reduction In Forced Outages through

1 BTL = 1.125 (Mus) APC Loss (0.023%)

HVOF coating Done at Leak Prone Area

Reliability improvement of boiler tubes by carrying out corrosion mapping (LFET)

Tube Thickness survey in every opportunity by Inhouse Cross functional team

From Overhaul to Overhaul average Boiler tube leakage per Unit is 2 Radiography of old erection joints 20% completed
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Adoption of Energy Conservation Technology

14 Nos of hybrid wind ventilator (TG floor) 30 Nos natural wind ventilator Total 8 Nos of VFD are installed ID Fan VFD installation

Wind ventilators

Variable Frequency Drive

is under study

Solar lights Solar lighting (1050 W) Solar water heaters & water heaters, LED lights

IFC air
controller at service air compressor Intelligent Flow

Control for demand

side air control IFC for instrument air is under study

(1100 Liters/day)

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Innovative Project CEP VFD

CD-60

OCST
PT

PT

CD-58 DM-2

TO DEAERATOR

PT TT

PT

TT

CD-37
PT

CD-34 CD-33

CD-30

LPH - 1
CD-31
TT TT

DM-4

CONDENSER

LPH - 3

CD-36 CD-35

LPH - 2
CD-32

DRAIN COOLER

MIN. RECIRCULATION

Saving Achieved = 2 x 148 kwh

PT

TO O/H SURGE TANK

TT PT

TT

CEP-B VA-6

CEP-A VA-5

PT

CD-29

TT

PT

CD-14 CD-17

CD-53 CD-19

TO HP FLASH TANK SPRAY

CD-21 CD-4 CD-23 CD-25 CD-27

FT

CD-3
FT TT PT

100%

0%

GSC CPU TO LPBP

Condensate System Overview

Slide 26

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IFC Air controller for Service Air System

Saving Achieved = 807 kwh per day

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Slide 27

Adoption Of Energy Conservation Technology

Sr. No. Application Population Running Drives Energy cons. without VFD kwh 473 583 583 75 68 10 40 16 1847 Energy cons with VFD kwh 222 435 435 44 42 8 24 10 1219 Energy saving Cost of Drive

Nos 1 2 3 4 5 6 7 8 Coal Mill Seal Air Fan CEP-1B CEP-2A ACW Pump Ash SILO LDO Pump CDWP Sevice Water Pump 12 2 2 2 2 2 2 1

Nos 4 1 1 1 1 1 1 1

kwh 251 148 148 31 26 2 16 6

Rs in Lakhs 30.55 106.09 90.50 4.50 6.50 2.00 5.00 2.00 247
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0.11% reduction in APC

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622

Approach for Reduction in Auxiliary Power Consumption

Conventional Approach
Auxiliary Power Consumption (%) Quality Tools

Operational Control

Maintenance Control
Energy Management
2006-07 2007-08

7.64

7.67

7.71

Standard 7.6 O&M 7.38 Practices

2009-10 2010-11

Online Energy Monitoring system

2008-09

Technology
Improvement plans / CA / PA MIS

Continual Process
Confidential Slide 29

Online Energy Monitoring System

PCR-1 FGD
Process parameter
Process parameter

PCR-2
Process parameter

Compressor Room
Process parameter

4-20 mA
24+16 channel SCANNER RS485

4-20 mA
24+16 channel SCANNER RS485 RS485 16 channel SCANNER 4-20 mA

4-20 mA 16 channel SCANNER

RS485

ELAN VIEW LAN

ELAN SERVER

Continual Improvement
ELAN VIEW Single Login RS485 RS485

Total 161 New meters installed (HT)

6.6 KV Swgr U-1

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6.6 KV Swgr U-2

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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.

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Online Energy Monitoring System

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32

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Online Energy Monitoring System

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Online Reports

Feeder name

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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
Base value Kwh Operating Value kwh < 7350 Operational Control kwh 7350 - 7450 Maintenance Control Kwh > 7450

Equipment

Boiler Feed Pump

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7100

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Daily Reports - MIS

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System Approach
Equipment wise standardization of Operating & Control limits Review of report in Daily Plant Meeting Energy deviated for three consecutive days above control limit, FIR to be raised

Daily Energy Deviation Report

FIR
Against Energy

by O&E dept through SAP on respective department.

Deviation

Maintenanc
Online / Offline Maintenance work will be carried out against FIR

Operational Control

Study & rectification of the problem & process optimization Any defect observed notification is raised through SAP

e Control

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EMS based O&M Practices

Standardization of O&M Practices through Energy Monitoring

Scheduled changeover of Equipments as per Most energy efficient equipment run for Predictive maintenance

energy deviation

maximum time

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Equipment Changeover Condition Based

BFP Changeover
37 25
Unit-1 Unit-2 Station Linear (Station)

18 19
13 12 11 10

21

APC Loss per BFP changeover = 2.7 Mw (Approx.)

2008-09

2009-10

2010-11

Mill Changeover
55
Unit-1

33 22

33 24

Unit-2
Station Linear (Station)

15

18

14

10

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

2008-09

2009-10

2010-11

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Enhancement of Energy Efficient Equipment Operation

Sr. No. Auxiliary

Running Average Power + Stand consumption By (kw)

Energy Efficient Rating

Unit-1

Increased Running Hour of EE Equipment

1+1 2 3 4 5 6 7 8 9 10
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BFP-1B CEP-1A 1+1 CEP-1B ECW-1A ECW-1B ECW-1C COAL MILL-1AB COAL MILL-1CD COAL MILL-1EF 2+1 2+1

7200 555 440 299 310 308 1149 1213 1252

2 2 1 1 3 2 1 2 3

can Reduced by 0.19 %

Slide

BFP-1A

7010

APC

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

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Slide 41

Use of Renewable resources

Wind Ventilator at TG Roof
3.7 kw replaced with 116 watt = saving 3.6 kwh per ventilator

Solar Water Heater 1100 LPD

Saving : 16 Mwh per year Total Saving : 441 Mwh per year
Total Installation : 14 Nos

Solar Street lighting 48 Nos = 1056 watts

Saving : 3.1 Mwh per year

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Results
Auxiliary Power Consumption (%)

7.64

7.67

7.71

7.6

7.38

2006-07

2007-08

2008-09

2009-10

2010-11

DTPS APC (%) 2010-11

DTPS Main Plant APC (%) 2010-11

6.31 6.30 6.31 6.29 6.31 6.42 6.07

7.39 7.52 7.45 7.41 7.43 7.51 7.31

7.69 7.11 7.25 7.24 7.29 6.24

6.20

6.04 6.17 6.16

Apr/10

Jun/10

Aug/10 APC (%)

Oct/10

Dec/10 Average

Feb/11

Apr/10

Jun/10

Aug/10

Oct/10

Dec/10 Average

Feb/11

Main Plant APC (%)

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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

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LT consumption metering & monitoring

Slide 44

DTPS Journey..
1998 ISO 9001 1999 ISO 14001 1999 QIP/SIP/EMP 2000 RAMCO ERP Package implmentation 2001 ISO Up gradation 6-I Mercer, CII 6-II OHSAS SA8000

IMS ISO 27001

RBNQA Performa nce

BS EN 16001

2005 Benchmarking CII

2003 SAP & ESS implementation

2004 British Safety Council Audit ESS ISO Upgrade RAMCO ISO 14001 ISO 9001 SAP

BSC

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
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Energy Conservation Is Cheaper Than Generation

1 Unit Saved

3 Units Generated

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Think Bigger Think Better.

Thank you
Date: 27-05-2011

Journey Towards Excellence Continues