Efficiency Improvement at Dahanu

Thermal Power Station- a success story.

29 August 2012
Flow of Presentation
●
Company Profile
●
DTPS at Glance
●
Plant Performance
●
Approach for Efficiency Management

●
Performance Monitoring
●
Performance Review
●
Data Management and control

●
Sustainability improvement Initiatives
●
Use of Renewable Energy Resources
●
Employees Involvement & Team Work
●
Effectiveness in Reliability & Energy Efficiency Improvement
Company Profile

 Infrastructure
 Generation
 EPC
 Transmission
 Distribution
 Trading

R- Infra Emerged as Winner and Voted one of the India's 10

Most Admired Companies

Confidential Slide 3
DTPS at a Glance
Commercial Operation

Confidential Slide 4
DTPS Milestones

EnMS
1998 Quality Management System ISO 9001 BS EN 16001:2009
1999 Environment Mangement System ISO 14001 ISO 50001:2011
RBNQA
2000 RAMCO ERP Package implementation
2001 ISO upgradation SAP ECC
ISO 27000
2002 Optic Ground wire (OPGW) & Backbone data highway
SA 8000
2003 SAP & Employee self service implementation
6 Sigma-II
2004 British Safety Council Audit KM, OHSAS
6 Sigma-I
Mercer, CII 2006 Occupational Health and Safety Assessment
2005 Benchmarking in CII
Studies OHSAS 18001
BSC
2005 Six Sigma Drive I SAP & 2006 Knowledge Management
2005 HR Mercer study ESS
OPGW 2006 Six Sigma Drive II
ISO
Upgrade 2007 Social Accountability SA 8000

RAMCO 2008 Integrated Management System (ISO 9001, ISO

14001, OHSAS 18001)
ISO 14001
2008 Information Security Mangement system ISO 27001
ISO 9001
2009 SAP ECC - In place of RAMCO

2010 Ramkrishna Bajaj National Quality Award

2011 Energy Management System s : BS EN

16001:2009 & upgraded to ISO 50001:2011
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011

Confidential Slide 5
 System Approach
ISO 14001:2004

Continual improvement is ensured through improvement plans for IMS,

ISMS, SA and EnMS
Confidential Slide 6
Working Philosophy

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

People Team Work Standardisation

Confidential Slide 7
 Monitoring for Sustenance
Divisional
AOP

Departmental
Objectives &
Targets

Deviation
Yes FIR on respective Department Corrective / Preventi
ve Actions

Closure of Improvement in Improvement Plans

FIR System based on CA / PA

Departmental Sc
ore Cards based
on Yearly O&T

Linked with PMS

Confidential Slide 8
 Objectives Of Monitoring System

Confidential Slide 9
 Monitoring Facilities At DTPS

DTPS Web Portal

Monitoring
Facilities

●
Departmental websites
●
All departments

System cell websites

Human
●

X-force
Machine
IMS , ISMS, SA, EnMs, 6 Sigma(Customize
● Digital
Interface (HMI) Logbooks
●
Various Standards on site Formats)
●
BIS standards
●
ISO standards
On line library Intranet website
●
Onlineinformation
EMS
Department wise
●
Legal (Acts, Notifications and Legal
updates)

Confidential Slide 10
 Performance Monitoring

Performance
Monitoring

Auxiliary Power Plant Pre & Pro

Heat Rate Energy Audit
Consumption Reliability Outage Survey

Testing Of
Individual All
Energy
Auxiliary Equipment
Boiler & Auditing Of Tripping &
Power Before &
Turbine All Area As Event
Side Losses Consumptio After
Per CEA Analysis.
n By Online Overhaul &
Guideline
EMS Estimation
Of Gain

Confidential Slide 11
 Performance Review

Performance
?
Departmental
Monthly Review
Daily
Monthly OfReview
Meeting
Overall
With All
Departmental
Plant
Operation
Meeting Plant
Team
Performance
Review
MeetingMembers
Team Meeting

Confidential Slide 13
Sustainability Improvement Initiatives

 Coal Management

 Overhaul Strategy

 Maintenance Philosophy

 Planned Maintenance
 Coal Management
Coal Auxiliary Power Heat Rate
% Kcal/kwh

F-Grade 9.5 2325

Wash coal 8.75 2305

Blended coal
8.25 2290
Wash + Imported

Confidential Slide 15
Coal Management - Benefits

 Reduction in

●
Coal moisture

●
Coal consumption

●
ASH generation

●
Wear and tear

●
Auxiliary power

●
Boiler tube leakages

Confidential Slide 16
Overhauling Strategy -Rolling Plan

Equipment OEM Recommendation DTPS Plan

HP Turbine 6 years 6 years

IP Turbine 5 years 4 years

LP Turbine 5 years 2 years

Generator 4 years 2 years

Exciter 4 years 2 years

Boiler 2 years

Power Transformers 7 years 6 years

HT Motors - 4 years

Confidential Slide 17
Overhauling Strategy -Rolling Plan Benefits

Initial observations Benefits

 Many surprises  No surprises – No major defect
● LPT - Blade looseness, minor deposits,
 Reduced Spare consumption
rubbing of rotor, sealing fin damages
● Generator - Hot spots, core looseness,  Reduced overhaul time
stator core bar cracks, wedge looseness,  Efficient running of plant
H2 leakage from current carrying bolts &
 Less resources
terminal bushings.
● Exciter & PMG damages, oil leakages

Confidential Slide 18
Reduction in Overhaul time

●
Modular conceptualization
●
HP module
●
Short shutdown opportunities
●
Overhauling of redundant auxiliaries
●
Standardized procedure for turbine cooling
●
De-coupling of Generator,

Confidential Slide 19
Reduction in Overhaul time

●
New technology - Induction heaters,
Quick erect type aluminum boiler
scaffolding, LFET etc.
●
Extra bigger size manhole for boiler
●
Project management software
●
Round the clock working – 2 shifts

Confidential Slide 20
Reduction in Overhaul time

Overhaul Days

18

45
1999-2000 2009-2010

Additional efficient generation of - 162 Million units /year

Confidential Slide 21
Maintenance Philosophy
Opportunity Based Maintenance
Short shutdown Defects

Confidential Slide 23
Arresting Duct Leakages in Opportunity
Air Ducts

Before and after Fan Kw Flue Gas Duct

Confidential Slide 24
Condenser Vacuum Improvement
Condenser Vacuum Improvement Helium Leak Detection Test

Vacuum is maintained over design value of -0.9 ksc

Confidential Slide 25
Efficiency Based Maintenance
Energy deviation concept

Defects which affects the efficiency, auxiliary power are given top priority
e.g. HP heaters, Condenser, Duct rectification, APH Seals rectification, Mill
Performance 26
Confidential Slide 26
of
 Major Initiatives
 HP module replacement
 BFP cartridge replacement
 Coal mill liners replacement
 APH basket replacement
 Installation of CEP VFD
 Reduction in startup time
 Reduction in oil consumption
 Reduction in DM make-up
 Smart soot blower operations
 Daily Energy Deviation Monitoring
HP module replacement

 HP module Replacement

Turbine Heat Rate (Kcal/kwh)

2010 2006

1980
1955

Unit-1 Unit-2

Before After

Confidential Slide 29
BFP cartridge replacement

Boiler Feed Pump Saving Achieved

BFP Cartridge
Performance Based BFP BFP-1A = 461 kw
cartridge Replacement BFP-2A = 656 Kw
(serviced cartridge) BFP-1B = 347 Kw

Boiler Feed Pump

Confidential Slide 30
Replacement of liners by Hi-Crome Liner
Mill Liner

Mill Grinding Media

Coal Mill

Before and after Mill Kw

Confidential Slide 31
APH basket replacement

Flue Gas Temp At APH Outlet (°C)

152 148
140
130

Unit-1 Unit-2
Before After

Confidential Slide 32
 VFD Installation at CEP

Installation of CEP VFD Before and after CEP Kw

Energy
Total 12 Nos. Of VFD Are Installed In Different Saving
Application 622 Kw
Confidential Slide 33
Reduction In Warm Start Up Time

Defined Roles and SOP

Responsibility
Standardisation of
procedure
Standardization of Parallel –
Sequential Activities
Review
Condensate Dumping
High Cycle Reduction in
Change in operation
Time Philosophy
Parallel operation of Both CPU Cycle Time
Use of RIM Phones to all

Replacement of HFO with LDO

Replacement of Oil ignitors with

Innovative Approach
HEA
Use of Instrument air for OIL
Average atomization Target
10 hrs 7 hrs
Confidential Slide 34
Reduction In Start up time
Actual Linear (Actual) Linear (Actual) Target
14

12.44
12
11.2 11.5 11.52
10.3 10.29
10.11
10 10.05
9.4
8.58 8.37
8
7.26 7.38 Target 7 hrs
6.7
6.23 6.32 6.22 6.27
6 Mar-06 5.07
5.49 5.43
4.78
4 4.27 5.08
3.57 4.6
10.08 Hrs 5.53 Hrs
2
Before Project After Project
0

35
Confidential Slide of
Reduction In Start up time - Benefits
Reduction in Start-up time 4.55 hrs

Direct Benefits
Per Warm Start-up
Reduction in Oil consumption 16 kl

Increase in Generation 1.14 Mus

Indirect Benefits:
Reduction in
●
Auxiliary power consumption
●
DM water consumption
●
Customer dis-satisfaction

Confidential Slide 36
Reduction In Oil consumption

Defined Roles and

Responsibility
Standardisatio
n of procedure Standardization of
Parallel – Sequential
Activities
High Specific Reduction in
Oil Change in OIL guns trial
Specific OIL
schedule
Target < 42 KL –
Change in Monitoring OIL pressure Warm Start-up
operation during Startup
Philosophy
Use of SCAPH
Dearator initial heating

Confidential Slide 37
Reduction In Oil consumption

Oil used for Startup Target

60
56.78 55.41
50 49.91 Target < 42 KL
42.58 42.58
43.04
40
37.48 34.34 37.72

30 31.06 34.03 31.5927.93

20

10

0
39496 39512 39572 39678 39802 39810 40034 40491 40597 40706 40739 40762 40785

Confidential Slide 38
DM makeup reduction
Optimization of Soot
Blowers operation

SOP for Identification of

Leakages
Reduction in DM water
Loss
Optimization of VAM
operation

Fuel switching from HFO

to LDO

Every 1 % increase in DM make up causes heat rate loss of 10

KCal/kwh.
Confidential Slide 39
Smart soot blower operations - Results
538 RH Temp
RH Temperature & Heat Rate Loss 6
537
536
Linear (RH Temperature)
535.54 535.63 535.81 535.88 5
535 534.75 534.47 534.72 4
534 3
533
532
2
1.72
531
1.53 1.55 1
0.99 0.93 0.81 0.76
530 0
2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12

538 MS Temp & Heat Rate Loss 536.4 10

Ms Temperature 535.72 535.89
536 Linear (Ms Temperature) 8
534.05
534 532.69 533.23
531.88 6
532
530 4
3.48
528 2.93 2.56 2
2
526 0.87 0.75 0.45 0
2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12

Confidential Slide 40
Installation of Magna Drive Coupling
Magna Drive Coupling - Couplings transmits torque from

Benefits of Magna Drive Coupling

Savings Investments
(Rs. Lacs) (Rs. Lacs)
0.01 3.5

41
Confidential Slide of
 Daily Energy Deviation Report

Operating Value:
Base
theValue:
Operational
It includes Control:
Maintenance
 Effect Control:
Of It IsQuality
Coal
It Includes Decided Based
Variation, On
This 
control
 includes
Condenser Average
Vacuum
Un-optimized Value of 1 Year Data
Condition,
 Detail Analysis
 Other Of Problems
Seasonal
 Operation Effects.
Deviation,
 Solution In Terms
 Operators OfRunNew Alternative
 Valve /Have To
Damper Equipment
Passing, In This
Average Power Technology
Standardized
 PreventiveOperating Range.
Maintenance Due,
Consumption  Repairor Replacement.
Set Points At Various Parameters
Rate As On Date

Confidential Slide 42
 Monthly Building Energy Deviation Report

All Buildings Of Plant Are Covered Under Monitoring

Confidential Slide 43
 Energy Conservation Projects

Solar Water Heater

Saving achieved 3.6 kwh

per ventilator
Total 14 nos. Total 1100 LPD
2 HP Solar Water Pump
Solar street lighting

1056 Watts (Total 48 nos)

Confidential Slide 44
Employees Involvement
&
Team Work
 Employees Involvement
Conductance ‘3L’ Life learning Program O&M Conference for group companies
With BEE

46
Confidential Slide of
Employees Involvement & Team Work

Energy Management Cell “Awareness drive“

 Training for all employees
●
By Internal faculty
●
By External Faculty
 Celebration of Energy Conservation week
●
Energy conservation walk involving all
employees
●
Create awareness among local school
children about energy conservation through
Film show & competition
●
Display of energy conservation posters
●
Exhibition on energy conservation

47
Confidential Slide of
 Improvement plans implemented

– Quality Improvement plans: 767 Nos.

– Environment Improvement plans: 75 Nos.

– Safety Improvement plans: 178 Nos.

– Energy Improvement plan : 58 Nos.

– Total – 1020+ Improvement Plans

Confidential Slide 48
Six Sigma Initiatives
 Over 15 O&M related six sigma projects are implemented

Example
 Reduction in start-up time
 Reduction in Heat rate losses
 Auxiliary Power reduction
 Reduction in Overhaul time
 100% auto loops controls
 Condenser vacuum improvement
 Reliability improvement of cooling water pumps

49
Confidential Slide of
Simulator
 Technical Training center at DTPS has facility of 250 MW simulator

customized with HAIL

 Simulator facility is used for R & D

 GET training

 Refresher course

 Checking of LOGIC before any modification

 Optimization of operations related to efficiency improvement

50
Confidential Slide of
Effectiveness in Reliability & Efficiency Improvement

Confidential Slide 51
 Benefits

Heat rate less than 2300 Kcal/

Availability more than 96 %

PLF more than 100 %

Loading factor more than 104 %

Confidential Slide 52
 Conclusion

Confidential Slide 53
Confidential Slide 54
 Thank You

Confidential Slide
 NC raising in SAP system:

Confidential Slide 56
Corrective action against NC raised:

Confidential Slide 57
 58
Confidential Slide of
 59
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 60
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Confidential Slide 61
Confidential Slide 62
 Heat Rate Monitoring

Kcal/Kwh

Confidential Slide 63
Heat Rate Reporting
Deviation Analysis Report (Daily) Monthly Performance Test Report
Summary

Plant Performance Indices

Unit Wise Heat Rate And Losses

Generation Loss Classifications

Environment Parameters

Critical Process Parameters

Confidential Slide 64
 APC Monitoring

Kwh

Confidential Slide 65
 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 Energy
VIEW RS485
Single Login
Meters Installed (HT)

6.6 KV Swgr 6.6 KV Swgr

U-1 U-2

Confidential Slide 66
 Area wise focus for Energy Conservation
AHP
CHP
Compressors
HT Aux – 90%
LT Aux – 10%
DEA
ECO

SEA WATER
CONDENSER

CREEK
BFP CWP

9 mw 5.04 mw
CEP
0.625 mw

APH
4.70 mw

ES
2.7 mw P
FD Fan
ID Fan 3.5 mw
Coal Mill PA Fan 1.45 mw
67
Confidential Slide of
 Energy Auditing

Energy Auditing As Per CEA Guideline

System Is Divided Into 15 Sub-systems

(Boiler, Turbine, Pumps, Fans, Condenser Etc.)

Separate Energy Management Cell Is Formed To Co-

ordinate Energy Audit Activities

Confidential Slide 68
 Plant Reliability

Confidential Slide 69
 Pre-Outage & Post-Outage Survey

Chronic
ESP efficiency
Problems
TestIdentification
Performance Related Observations
Calculation Of Benefits From Overhaul
Chronic
ESP efficiency
Problems
TestIdentification

Confidential Slide 70
 Improvement plan 18.1 format in SAP:

Confidential Slide 71