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8/2/2019 Auxillary Power Consumption
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Plant Performance Improvement byReduction In Auxiliary Power Consumption
Date: 27-05-2011
Presented By
Reliance Infrastructure Limited
Anirudha AsawaBhu esh Raut
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Confidential Slide
Flow of Presentation
2
Company & Plant Profile
Plant Performance Indices
System Approach
Case Study
Results
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Confidential Slide
Company & Plant Profile
3
1800 mw for HPGCL Commissioned
600 mw for R-power commissioned
4400 mw for R-power under
commissioning
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Confidential Slide
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 coolingsystem (M3/Hr.) 84,000
Nearby Surya River dam (32 kms).
Sweet Water (M3/Hr.) 300
Dahanu Thermal Power Station (2 x 250 Mw)
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Confidential Slide
Plant Performance Indices
101.79
101.53 100.99
102.33101.00
2006-07 2007-08 2008-09 2009-10 2010-11
Plant Load Factor (%)
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Confidential Slide
Plant Performance Indices
96.79 96.7 96.31 97.18 96.48
2006-07 2007-08 2008-09 2009-10 2010-11
Plant Availability (%)
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Plant Performance Indices
2278
2279
2300 22882282
2006-07 2007-08 2008-09 2009-10 2010-11
Heat Rate (Kcal/kwh)
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Dahanu Thermal Power Station (2 x 250 Mw)
7.64 7.67 7.71 7.67.38
2006-07 2007-08 2008-09 2009-10 2010-11
Auxiliary Power Consumption (%)
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Continual improvement is ensured through improvement plans likeQuality Improvement Plan, Safety Improvement Plan
Environment Management Plan, Energy Management Plan
System Approach
SA 8000OHSAS
18001:2007
ISO14001:2004
ISO 9001:2008
ISO27001:2005
DTPS
BS EN16001:2009
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Overall Plant Performance Indices
10
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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APH
CONDENSER
DEAECO
SEAW
ATERCREEK
BFP
CEP
CWP
ID FanCoal Mill
FD Fan
PA Fan
ESP
Auxiliary Power Consuming Area
9 mw
3.5 mw1.45 mw
4.70 mw
2.7 mw
AHPCHP
Compressors
5.04 mw
0.625 mw
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Auxiliary Power Consumption at DTPS
HT MotorConsumption
37.90 Mw95.00%
LT MotorConsumption1.99 Mw
5.0%
Auxiliary Power Breakup at DTPS
Auxiliary Power Consumption 2009-2010 7.6%
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Auxiliary Power Consumption at DTPS
Net Generation92.40% Main Plant
6.43%
CHP 0.11%AHP 0.11%
CWPH 0.78%
ESP0.1%
Raw
water PH0.09%
APC 7.60%
DTPS APC BreakupDTPS Net Generation Vs APC
2009-2010
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Approach for Reduction in Auxiliary PowerConsumption
Maintenance Control
Operational Control
Energy Management
15
Standard
O&M
Practices
Technology
Conventional Practices
Quality Tools
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Auxiliary Power Reduction Through OperationalControl
Current limit= < 9800
MS flow =
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Optimization of Equipment running Hours
Condenser Unit #
1
Condenser Unit #
2Cooling channel Sea
WaterCreek
TideLevelVariesfrom
-0.5 to5.5 mtr
Running of 4th CW pump is
optimized as per Tide Level,
Sea water temperature
20750 m3/hr each
17.9811.21
9.49
4.1
2007 -2008
2008 -2009
2009 -2010
2010 -2011
4th CW pumps running hours / day
104.68
105.30
104.86
104.99
Loading Factor
1.8 km duct 2.6 mtr duct
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Operational Control
Condenser Unit #
1
Condenser Unit #
2Cooling channel
Sea
WaterCreek
TideLevel
1.8 mtr
20750 m3/hr
2.6 mtr - 1.8 km duct
T C
T+2 C@T C
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
Ratio (@ 4000 kcal/kg)
Boiler Auxiliaries
Coal Mills, ID Fans, PA Fans, FD Fans
Optimization of Grinding media in coal mills as per the coal Quality
920
860
820
7803600
3800
4000
4200
3300
3400
3500
3600
3700
3800
3900
4000
4100
4200
4300
700
750
800
850
900
950
Boiler Auxiliaries Current GCV kcal/kg
Ball charging are optimized from 100 Mt to 80 Mt, without compromising coal
fineness & required output
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Maintenance Control
Arresting Steam
leakages online
HVOF Coating
LFET
Duct leakages ofAir and Flue gas
arrested in every
opportunity
Performance based
Liner
reversal, grinding
media segregation.
Liner replacement done
from Manganese to Hi-
chrome
Performance
based Boiler feed
pump cartridge
replacement Boiler
FeedPump
Coal
Mill
Boiler
Maint
Duct
Leakages
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Maintenance Control
21
Maintenance Control Saving Achieved
Performance Based BFP cartridgeReplacement (serviced cartridge)
BFP-1A = 461 kwhBFP-2A = 656 KwhBFP-1B = 347 Kwh
0.19 %
74047264
7568
7057
68036912
BFP-1B BFP-1A BFP-2A
BFP Cartridge Replacement
Before (Kw) After (Kw)
Auxiliary power reduction Through BFP cartridge Replacement
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APC reduction Through Replacement of Manganese liners by Hi-chromeliners & ball charging optimization
Maintenance Control
APC Reduced = 0.26% approx
1472 1478 1398 1430 1395
1185 1196 1135 1162 1113
MILL -1AB MILL -1CD MILL -1EF MILL -2CD MILL -2EF
Mn Liner Hi-Cr Liner
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Confidential Slide
Maintenance Control
APC reduction Through Arresting Air& Flue gas Duct Leakages duringEvery Opportunity
23
APC Reduced = 0.18% approx
1517
914
283
1290
670
260
ID Fan PA Fan FD Fan
Befor Overhaul After Overhaul
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Confidential Slide
Maintenance Control
Reduction In Forced Outagesthrough
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 In-
house Cross functional team
1 BTL = 1.125 (Mus) APC Loss
(0.023%)
24
From Overhaul to Overhaul average Boiler tube leakage per Unit is 2
Radiography of old erection joints 20% completed
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Confidential Slide
Adoption of Energy Conservation Technology
Intelligent Flow
Control for demand
side air control
IFC for instrument air
is under study
Solar lighting (1050
W)
Solar water heaters
(1100 Liters/day)
Total 8 Nos of VFD are
installed
ID Fan VFD installation
is under study
14 Nos of hybrid
wind ventilator (TG
floor)
30 Nos natural
wind ventilatorWind
ventilators
Variable
FrequencyDrive
IFC air
controller at
service air
compressor
Solar lights
& water
heaters,
LED lights
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Confidential Slide 26
Condensate System Overview
CD-37
CD-36
CD-35 CD-32
CD-33
CD-34 CD-30
CD-31
CD-29
CD-19D-17CD-14 CD-53
CD-21CD-4 CD-3
CD-23CD-25
CD-27
VA-6 VA-5
CEP-B CEP-A
GSC
DRAINCOOLER
CONDENSER
DM-2
DM-4
CD-60
CD-58
TO HPFLASH TANKSPRAY
TO/
E
MIN
R
ON
TO DEAERATOR
CPU
LPH - 2PH - 3
LPH - 1
OCST
TO LPBP
FTTT
TT TT
TTT PTPTT
PT
FT
PT
PT PTPT PT
TTTT
TTT
0%100%
Innovative Project CEP VFD
Saving Achieved= 2 x 148 kwh
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Confidential Slide 27
IFC Air controller for Service Air System
Saving Achieved =807 kwh per day
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Confidential Slide
Adoption Of Energy Conservation Technology
28
Sr. No. Application PopulationRunning
Drives
Energy
cons.
without
VFD
Energy
cons
with
VFD
Energy
saving
Cost of
Drive
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
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Confidential Slide
Approach for Reduction in Auxiliary PowerConsumption
Maintenance Control
Operational Control
Energy Management
29
Standard
O&M
Practices
Online
EnergyMonitoring
system
Continual Process
MISImprovement plans / CA / PA
Technology
Quality Tools
7.64 7.67 7.71 7.6 7.38
2006-07 2007-08 2008-09 2009-10 2010-11
Auxiliary Power Consumption (%)
?
Conventional Approach
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Confidential Slide
Online Energy Monitoring SystemPCR-1 PCR-2
4-20 mA 4-20 mA
ELANSERVER
6.6 KV SwgrU-1
6.6 KV SwgrU-2
RS485RS485
ELANVIEW
ELANVIEW
LAN
Single Login
Process parameter Process parameter
RS485
RS485
FGD
Process parameter
SCANNER
4-20 mA
Compressor
RoomProcess parameter
SCANNER
4-20 mA
RS485
SCANNER SCANNER
RS485
24+16 channel 24+16 channel16 channel
16 channel
Total 161 New metersinstalled (HT)
Continual Improvement
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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 canbe generated automatically
Report generation and archiving is possible.
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Confidential Slide 3232
Online Energy Monitoring System
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Confidential Slide 3333
Online Energy Monitoring System
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Confidential Slide 34
Online Reports
Feeder name
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Confidential Slide
Standardization with Energy MonitoringSystem 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 OperatingValue
OperationalControl
MaintenanceControl
Kwh kwh kwh Kwh
Boiler FeedPump
7100 < 7350 7350 - 7450 > 7450
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Confidential Slide 36
Daily Reports - MIS
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Confidential Slide
System Approach
Study & rectification ofthe problem & process
optimization
Any defect observed
notification is raised
through SAP
Online / Offline
Maintenance work will
be carried out against
FIR
Energy deviated for three
consecutive days above
control limit, FIR to be raised
by O&E dept through SAP on
respective department.
Equipment wise
standardization of
Operating & Control
limits
Review of report in
Daily Plant Meeting
Daily
EnergyDeviation
Report
FIR
Against
Energy
Deviation
Operational
Control
Maintenanc
e Control
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Confidential Slide
EMS based O&M Practices
Standardization of O&MPractices through Energy
Monitoring
Scheduled changeover
of Equipments as per
energy deviationMost energy efficient
equipment run for
maximum time
Predictive maintenance
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Confidential Slide 39
Equipment Changeover Condition Based
APC Loss per BFPchangeover = 2.7 Mw
(Approx.)
APC Loss per Millchangeover = 1.5 Mw &Generation Loss =11 Mw
(Approx.)
18
1311
19
1210
37
2521
2008-09 2009-10 2010-11
BFP Changeover
Unit-1
Unit-2
Station
Linear(Station)
33
15 1422
18
10
55
33
24
2008-09 2009-10 2010-11
Mill ChangeoverUnit-1
Unit-2
Station
Linear(Station)
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Confidential Slide
Enhancement of Energy Efficient EquipmentOperation
Sr. No. AuxiliaryRunning+ Stand
By
Average Powerconsumption
(kw)
EnergyEfficientRating
Unit-1
1 BFP-1A
1+1
7010 1
2 BFP-1B 7200 2
3 CEP-1A1+1
555 2
4 CEP-1B 440 1
5 ECW-1A
2+1
299 1
6 ECW-1B 310 3
7 ECW-1C 308 2
8 COAL MILL-1AB
2+1
1149 1
9 COAL MILL-1CD 1213 2
10 COAL MILL-1EF 1252 3
APC
canReduced
by
0.1
9%
IncreasedRunningH
ourofEE
Equipment
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Confidential Slide 41
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
Benefits
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Confidential Slide
Use of Renewable resources
42
Wind Ventilator at TG Roof3.7 kw replaced with 116 watt =saving 3.6 kwh per ventilator
Total Installation : 14 Nos
Total Saving : 441
Mwh per year
Saving : 16 Mwh per year
Solar Water Heater 1100 LPD
Saving : 3.1 Mwh per year
Solar Street lighting
48 Nos = 1056 watts
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Confidential Slide
Results
43
7.31
7.39 7.52 7.45 7.41 7.43 7.51 7.69
7.257.11
7.24 7.29
Apr/10 Jun/10 Aug/10 Oct/10 Dec/10 Feb/11
DTPS APC (%) 2010-11
APC (%) Average
6.24
6.20 6.31 6.30 6.31 6.29 6.31 6.42
6.07
6.04
6.17 6.16
Apr/10 Jun/10 Aug/10 Oct/10 Dec/10 Feb/11
DTPS Main Plant APC (%) 2010-11
Main Plant APC (%) Average
7.64 7.67 7.71 7.67.38
2006-07 2007-08 2008-09 2009-10 2010-11
Auxiliary Power Consumption (%)
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Confidential Slide
Mission
44
Forward Path 100 Mw Solar Power
ID Fan VFD
LT consumption metering & monitoring
7.64 7.67 7.71 7.6 7.387
2006-07 2007-08 2008-09 2009-10 2010-11
Auxiliary Power consumption %
Target
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Confidential Slide 45
DTPS Journey.. RBNQAPerforma
nce
BS EN
16001
1998 ISO 9001IMS
ISO 270011999 ISO 14001
1999 QIP/SIP/EMP6-II
OHSAS
SA8000
2000 RAMCO ERP Package implmentation 6-I
Mercer,
CII2001 ISO Up gradation 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
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Confidential Slide
Energy Conservation Is Cheaper Than
Generation
1 Unit Saved = 3 Units Generated
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Thank you
Date: 27-05-2011
Journey Towards ExcellenceContinues
Think Bigger Think
Better.