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  2.75 Million tons

Indian coal  2.0 Million tons
Imported coal  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

Confidential Slide
 Plant Performance Indices
Plant Load Factor (%)

101.79 102.33
101.00

101.53 100.99

2006-07 2007-08 2008-09 2009-10 2010-11

Confidential Slide
 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

Confidential Slide
 Plant Performance Indices

Heat Rate (Kcal/kwh)

2279
2300 2288
2278 2282

2006-07 2007-08 2008-09 2009-10 2010-11

Confidential Slide
 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

Confidential Slide
 System Approach
ISO 9001:2008

BS EN ISO
16001:2009 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

DEA

SEA WATER CREEK

ECO
CONDENSER

BFP CWP

9 mw 5.04 mw
CEP
0.625 mw
APH
4.70 mw

ESP
2.7 mw
FD Fan
ID Fan 3.5 mw
Coal Mill PA Fan 1.45 mw
Confidential Slide
 Auxiliary Power Consumption at DTPS

Auxiliary Power Breakup at DTPS

LT Motor
Consumption
1.99 Mw HT Motor
5.0% 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%
ESP
Net Generation APC 7.60% 0.1%
92.40% Main Plant
6.43% Raw
water PH
0.09%

2009-2010

Confidential Slide 14
 Approach for Reduction in Auxiliary Power
Consumption
Conventional Practices

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

Technology

Confidential Slide 15
Auxiliary Power Reduction Through Operational
Control
• Cooling water • F-Grade Coal
pump • Wash Coal
Coal • Imported Coal
• ACW pump
• Compressors
Equipment Blending High/Medium GCV
Running Mgt
Hours @4000kcal/kg

Excess Air
control & Maximizing
• Excess air • Current limit= < 9800
air ingress Generation
optimization • MS flow = <775 TPh
monitoring
• Air ingress • MS pressure = < 155
measurement at Kg/cm2
various location • MS Temp = < 540⁰C

Confidential Slide
Optimization of Equipment running Hours

Condens Condens 20750 m3/hr each

er Unit # er Unit # Cooling channel Sea
1 2
Water
Creek
1.8 km duct
ɸ 2.6 mtr duct Tide
Level
4th CW pumps running hours / day Varies
from
104.99 105.30 -0.5 to
Loading Factor
104.86 104.68 5.5 mtr
17.98
11.21 9.49
4.1 Running of 4th CW pump is
optimized as per Tide Level,
2007 - 2008 - 2009 - 2010 -
2008 2009 2010 2011 Sea water temperature
Confidential Slide
Operational Control

20750 m3/hr
Condens Condens
er Unit # er Unit # Cooling channel
1 2
Sea
TC Water
Creek
T+2
@T C Ø2.6 mtr - 1.8 km duct 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

 Optimization of Coal Blending Boiler Auxiliaries Current GCV kcal/kg

950 4300
42004200
Ratio (@ 4000 kcal/kg) 900
920
4100
4000 4000
850 3900

Boiler Auxiliaries 800

860
3800
3800
3700
820 3600
Coal Mills, ID Fans, PA Fans, FD Fans 750
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 • Performance based

based Boiler feed Liner

pump cartridge reversal, grinding

replacement Boiler media segregation.

Coal
Feed • Liner replacement done
Mill from Manganese to Hi-
Pump
chrome

Duct Boiler
• Duct leakages of Leakages Maint • Arresting Steam
Air and Flue gas 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
Performance Based BFP cartridge
BFP-2A = 656 Kwh 0.19 %
Replacement (serviced cartridge)
BFP-1B = 347 Kwh

BFP Cartridge Replacement

Before (Kw) After (Kw)

7568
7404
7264
7057
6912
6803

BFP-1B BFP-1A BFP-2A

Confidential Slide 21
Maintenance Control
 APC reduction Through Replacement of Manganese liners by Hi-chrome
liners & ball charging optimization

Mn Liner Hi-Cr Liner

1472 1478 1398 1430 1395

1185 1196 1135 1162 1113

MILL -1AB MILL -1CD 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

283 260

ID Fan PA Fan 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 Variable is under study
Wind
wind ventilator Frequency
ventilators
Drive

Solar lights IFC air

• Solar lighting (1050 & water controller at • Intelligent Flow
W) heaters, service air Control for demand
• Solar water heaters LED lights compressor side air control
(1100 Liters/day)
• IFC for instrument air
is under study

Confidential Slide
 Innovative Project – CEP VFD
CD-60
OCST
PT PT
CD-58
PT TT PT TT DM-2
TO DEAERATOR CD-30
CD-37 CD-34
LPH - 1
PT CD-31 DM-4
CD-33 TT CONDENSER
CD-36 TT
LPH - 3 LPH - 2
CD-35 CD-32

TO O/H SURGE TANK

Saving Achieved

MIN. RECIRCULATION
= 2 x 148 kwh DRAIN TT TT
COOLER PT PT
CEP-B CEP-A
PT CD-29 TT PT
VA-6 VA-5

CD-21
TO HP
FLASH TANK CD-4 CD-3
CD-14 CD-53 SPRAY CD-23
CD-17 FT
CD-19 CD-25
100% 0% TT
PT
CD-27
FT
GSC
CPU TO LPBP
Condensate System Overview
Confidential Slide 26
 IFC Air controller for Service Air System
Saving Achieved =
807 kwh per day

Confidential Slide 27
 Adoption Of Energy Conservation Technology
Energy Energy
Running cons. cons Energy Cost of
Sr. No. Application Population
Drives without with saving Drive
VFD VFD

Nos Nos kwh kwh kwh Rs in Lakhs

1 Coal Mill Seal Air Fan 12 4 473 222 251 30.55

2 CEP-1B 2 1 583 435 148 106.09

3 CEP-2A 2 1 583 435 148 90.50
4 ACW Pump 2 1 75 44 31 4.50
5 Ash SILO 2 1 68 42 26 6.50
6 LDO Pump 2 1 10 8 2 2.00
7 CDWP 2 1 40 24 16 5.00

8 Sevice Water Pump 1 1 16 10 6 2.00

0.11% reduction in APC 1847 1219 622 247

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
?
Online
Energy
Monitoring
Practices
system
Energy Management
2006-07 2007-08 2008-09 2009-10 2010-11

Technology

Improvement plans / CA / PA MIS

Continual Process
Confidential Slide 29
 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
RS485 Total 161 New meters
VIEW RS485
Single Login
installed (HT)

6.6 KV Swgr 6.6 KV Swgr

U-1 U-2

Confidential 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 Base value Operating Operational Maintenance

Value Control Control
Kwh kwh kwh Kwh
Boiler Feed
7100 < 7350 7350 - 7450 > 7450
Pump

Confidential Slide
Daily Reports - MIS

Confidential Slide 36
System Approach

• Equipment wise • Energy deviated for three

standardization of consecutive days above
Operating & Control control limit, FIR to be raised
limits Daily FIR by O&E dept through SAP on
• Review of report in Energy Against
respective department.
Daily Plant Meeting Deviation Energy
Report Deviation

Maintenanc Operational • Study & rectification of

• Online / Offline e Control Control the problem & process
Maintenance work will
optimization
be carried out against
• Any defect observed
FIR
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 Predictive maintenance
Most energy efficient
energy deviation
equipment run for
maximum time

Confidential Slide
Equipment Changeover Condition Based
BFP Changeover
37
25 Unit-1
APC Loss per BFP
21
18 19 changeover = 2.7 Mw
Unit-2
13 12
11 10 (Approx.)
Station

Linear
2008-09 2009-10 2010-11 (Station)

Mill Changeover
55 Unit-1
APC Loss per Mill
33 33
Unit-2 changeover = 1.5 Mw &
22 24
Station
Generation Loss =11 Mw
18
15 14 (Approx.)
10
Linear
(Station)

2008-09 2009-10 2010-11

Confidential Slide 39
Enhancement of Energy Efficient Equipment
Operation
Running Average Power Energy
Sr. No. Auxiliary + Stand consumption Efficient
By (kw) Rating
Unit-1

Increased Running Hour of EE

1 BFP-1A 7010 1

can Reduced by
1+1
2 BFP-1B 7200 2

0.19 %
APC
3 CEP-1A 555 2

Equipment
1+1
4 CEP-1B 440 1
5 ECW-1A 299 1
6 ECW-1B 2+1 310 3
7 ECW-1C 308 2
8 COAL MILL-1AB 1149 1
9 COAL MILL-1CD 2+1 1213 2
10 COAL MILL-1EF 1252 3

Confidential 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 Solar Street lighting
Mwh per year 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 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

7.39 7.52 7.45 7.41 7.43 7.51 7.69 6.20 6.04
7.11
7.25 6.24 6.07
7.31 6.17 6.16
7.24 7.29

Apr/10 Jun/10 Aug/10 Oct/10 Dec/10 Feb/11 Apr/10 Jun/10 Aug/10 Oct/10 Dec/10 Feb/11

APC (%) Average Main Plant APC (%) Average

Confidential Slide 43
 Mission
Auxiliary Power consumption %
7.64 7.67 7.71 7.6 7.38
7

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….. RBNQA
BS EN
16001
Performa
1998 ISO 9001 nce
IMS
1999 ISO 14001 ISO 27001

1999 QIP/SIP/EMP SA8000

6σ-II
2000 RAMCO ERP Package implémentation 6σ-I OHSAS
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

RAMCO 2008 Integrated Management system

ISO 14001 2008 ISO 27001

ISO 9001 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 = 3 Units Generated

Confidential Slide
 Think Bigger Think
Better.

Thank you
Date: 27-05-2011

Journey Towards Excellence

Continues……