Knowledge Exchange Program

28th OCT

Dahanu Thermal Power Station

 Contents

Company Profile

Energy Management System

Monitoring & review

Continual Improvement

Performance based approach

Energy Conservation Projects

Awards & Recognition

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Slide 2
Company Profile

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Slide 3
DTPS : Overview

Commissioning Year 1995

Capacity 500

No. of units & Size (MW) 2 X 250

Plant performance for last 10 years

Average PLF (%) 99.27

Average Availability (%) ~96

Gross SHR (kCal/kWh) 2292

Aux Consumption (%) 7.61

Fuel (Domestic + Imported) MTPA 2.6

Height of Chimney (Mtrs) 275

Water from reservoir (Cu Mtr./day) 5000

As on FY15
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DTPS Journey towards Excellence
Arogya
award
IMS
NABL
ISO
50001

DTPS Journey….. BS EN
16001
1998 ISO 9001 IMS RBNQA
ISO Energy
1999 ISO 14001 27001 Management
1999 QIP/SIP/EMP 6σ-II SA8000
2000 RAMCO ERP Package implémentation 6σ-I OHSAS System
Mercer,
2001 ISO Up gradation CII 2005 Benchmarking CII
2003 SAP & ESS implementation BSC 2005 Six Sigma drive I
2004 British Safety Council Audit SAP 2005 Mercer HR study
ESS 2006 OHSAS 18001

ISO
Upgrade 2007 SA 8000
2008 Integrated Management
RAMCO system
ISO
14001 2008 ISO 27001
ISO
9001 2009 SAP in place of RAMCO
2010 BS EN 16001

2011 ISO 50001:2011 (EMS)

2014 Integration of management system
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2013 2014 2015

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System Approach – Guiding Aspects

Feedback Documentation

Review by top
Implementation
Management

Deviation/
Control
Correction

Monitoring &
Analysis

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Energy Management System

 Heat rate  Data Collection, Identification Scope of

 APC Compilation & Record & Review of Improvement
 Fuel Keeping deviation
 Process  MIS
Parameters

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Energy Management System

ISO 50001:2011

 Energy Policy  Daily Deviation  Rectification &

 EMC report Improvement plan
 AOP  Daily Plant  Energy Audits as
 E-Lan system meeting per CEA guidelines
 Data collection  Evaluate and  Innovative O&M
and MIS analyze approach
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Online Energy Monitoring System

PCR-1 PCR-2
Compressor
Process parameter Process parameter Room
FGD
Process parameter
Process parameter
4-20 mA 4-20 mA

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

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

RS485

RS485

ELAN ELAN
VIEW SERVER
LAN

Continual Improvement
ELAN
VIEW RS485
RS485 Total 250 meters installed
Single Login

6.6 KV Swgr 6.6 KV Swgr

U-1 U-2

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Monitoring Facilities At DTPS
100% digitalization
Energy Consumption Process
from E LAN Parameters
Reports from DCS

Control

Auto Email for MIS

Daily Energy
Deviation report
for review
Digital Logbooks SAP

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 Daily Energy Deviation Report

Operating BaseValue:
Operational Control:
Value:
Maintenance
It includes Control:
Itthe
Is Decided Based On Average
It Includes
This Effect
control OfValue
Coal Quality
includes Variation,
of 1 Condition,
Un-optimized Year Data
Condenser
Detail Analysis Vacuum
Of Problems
Operation Deviation,
Other In
Solution Seasonal Effects.
ValveTerms
/ DamperOfPassing,
New Alternative
Average Power Operators Have To Run Equipment In This
Technology
Preventive Maintenance Due,
Consumption  Repair
Standardized
or Operating Range.
Replacement.
Set Points At Various Parameters
Rate As On Date

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 Monthly Building Energy Deviation Report

All Buildings Of Plant Are Covered Under Monitoring

10 % reduction in Energy consumption achieved during last year

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 Performance Review System

?
Review

Monthly Operation
Daily Departmental Daily Plant Meeting
Meeting Review Team Meeting

Monthly Review Of
Departmental Plant Performance, Energy
Overall Plant
Meeting With All deviation review with all
Performance
Team Members Sectional Heads
&Energy deviation

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Control system

Notification raised in
SAP

Discussed in Daily
plant meeting

Categorized Aux
power / Heat rate
Opportunities for continual improvement
No

New
Running
Requirement /
Defect
Modification

Yes

Planning done to Equipment

Short Shutdown Major Overhaul
attend Shutdown

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 Continual Improvement

Continual Improvement

Performance Test Energy Audits O&M Strategy

a) Monthly Efficiency Test a) Periodic External a) Performance Based

b) Air Ingress test Audits maintenance
c) Insulation survey b) Internal Audits as per b) Process
d) Pre & Post outage survey CEA guidelines Optimization

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 O&M process at DTPS

Safe
Reliable Sustainable
Efficient Economical Clean

O
M C
P R
O O
T E
N N
I V
I T
M I
T R
I E
O O
S W
R L
E

Communication Team Work Standardisation

100% Digitalization Environment Systems

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 O/M Approach

I “PROMT” T
N Modular Priority on Managing E
N Maintenance concept Performance Trends C
O maintenance H
V N
A O
Approach
T L
I O
O G
N Process Optimisation Y

Energy Monitoring System

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Modular Maintenance Concept
 A maintenance procedure that allows the replacement of major
assemblies in a minimum amount of time and expenditure is
called “module” (e.g. HP turbine module, CW debris filter, Primary &
Secondary fans rotor, Boiler feed pump cartridge, vacuum pump, CW
pump)

BFP Cartridge HP Turbine Module

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PROMT Maintenance Concept

 “PROMT”- Priority On Managing Performance Trends maintenance

(e.g. wise Flue gas duct leakages, HP heaters performance)

Flue Gas duct leakages HP Heaters parting plate leakages

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Process Optimisation

 Process optimization is the discipline of adjusting a process so as

 to optimize specified set of parameters

 without violating system constraint.

 Process optimization is a continuous process it’s a “Journey not

Destination”

 “The savings are recurring”

 Investment - NIL

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Approach for optimization
Brainstorming
D-logbooks
Event analysis
MIS reports
Technical
From EM MIS
Validation

Validation &
Data conversion GAP Probable
Pilot testing Monitor
Collection in reportable Analysis solutions
format

OEM data
Benchmarking
Other plant visit
Other site inputs

Once the optimisation process reached the desired results solutions

are finalized through IMS Systems and controls are placed
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Process Optimization

Process Optimization

Periodic Review of
Rationalization Optimization
SOPs

In case of Stand by
1. Cooling water
equipments Higher 1. SOP for back down
System
efficiency period prepared to
2. Soot blower
equipments are kept minimize the losses.
operations etc
in service
0.19% Reduction in
Aux power potential

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Energy Conservation Projects
 Energy Conservation projects
Sr.
Description Savings
No.

1 Installation OF VFD 5.2 Mus/annum

2 Refurbishment of HP turbine module 20 kcal/kwh

3 Installation of Vapor Absorption Machine 1.8 Mus/annum

4 Energy Efficient Lighting 0.624 Mus/annum

5 Optimization of Compressed air system 0.5 Mus /annum

6 Monitoring Computer Idle time 0.1 Mus/annum

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 Energy Conservation projects
Sr.
Description Savings
No.

7 BFP Cartridge Replacement 2.6 Mus / annum

Replacement of Manganese Liner By Hi-Crome Liner

8 6.72 Mus / annum
In Coal Mill

9 Replacement with Renewable Energy 0.3 Mus /annum

10 Rationalization of equipment running hours 0.1% of APC

11 Optimization of Cooling water pumps 0.1% of APC

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Technology - Installation of VFD

Before and after CEP Kw

Energy Saving
Total 12 Nos. Of VFD Are Installed for Different Application 622 KW/Hr

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 BFP Cartridge Replacement

Boiler Feed Pump Saving Achieved

Performance Based BFP BFP-1A = 461 kw

cartridge Replacement BFP-2A = 656 Kw
(serviced cartridge) BFP-1B = 347 Kw BFP
Cartridge

Boiler Feed
Pump

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Replacement of Liner In Coal Mill
Replacement of Manganese Liner By Hi-Crome Liner

Mill Liner

Mill Grinding Media

Coal Mill

Before and after Mill Kw

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Renewable Energy Projects

Solar Water Heater

Saving achieved 3.6 kwh

per ventilator

Totalstreet
Solar 14 nos.
lighting Total
2 HP1100
SolarLPD
Water Pump

1056 Watts (Total 48 nos)

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Awards & Recognitions

National Meritorious Award by Rajiv Gandhi Award for Clean

Ministry Of Power Technology

Vasundhara Award by Maharashtra Pollution Ramkrishna Bajaj National

Control Board Quality Award
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 Save Energy

DTPS “Journey Towards sustainable excellence”

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