Auxillary Power Consumption

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


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


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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2278

2279

2300 22882282

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

Heat Rate (Kcal/kwh)



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 (%)



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



Overall Plant Performance Indices

10

Turbine-Generator (TG) Heat Rate (Kcal/kwh)

Boiler Efficiency (%)




Case Study On

Reduction In Auxiliary Power

Consumption



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%



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



Approach for Reduction in Auxiliary PowerConsumption

Maintenance Control

Operational Control

Energy Management

15

Standard

O&M

Practices

Technology

Conventional Practices

Quality Tools



Auxiliary Power Reduction Through OperationalControl

Current limit= < 9800

MS flow =



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



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



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



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



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



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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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


?

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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Online Energy Monitoring System


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Online Energy Monitoring System


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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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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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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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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



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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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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.

Auxillary Power Consumption

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