Best O&M Practices – Energy Efficiency

Dahanu Thermal Power Station

Bureau of Energy Efficiency
Knowledge Exchange Platform – 2015

Anirudha Asawa
GM Operations
Energy Auditor
 Contents
 Company Profile

 DTPS at a glance

 Approach

 Energy Monitoring & System

 Maintenance Practices

• Modular maintenance concept

• “PROMPT” Priority on Managing Performance Trends maintenance

• Efficiency based maintenance practice

Confidential Slide 2
 Contents
 Operation practices

• Optimisation of running hours [ Soot blower & CW running hours ]

• Managing Changeovers [ Efficiency Based ]

• Managing Air ingress

• Coal Blending management

• Thermo vision camera applications – managing unaccounted losses

Confidential Slide 3
Company Profile
 Infrastructure
 Generation
 EPC
 Transmission
 Distribution
 Trading

Confidential Slide 4
About DTPS

Confidential Slide 5
DTPS Geographical location

Well connected by Western

Railway & National Highway No. 8

At a distance of 128 Kms from

Mumbai

Surrounded by two natural

Creeks - Savata and Dandi

Surya Dam nearby – 32 kms

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About DTPS
The setting up of the Plant was
approved in 1989 for 2 x 250 MW
capacity.

First Synchronization
Unit – I - January 1995
Unit – II - March 1995

Station Commercial operation

- July 1995/Jan 1996

Till date Running Hours

Unit – I - 1.57 lacs
Unit – II - 1.54 lacs

Confidential Slide 7
DTPS Journey towards Excellence
NABL
ISO
50001
BS EN
DTPS Journey….. 16001
1998 ISO 9001 IMS RBNQA
ISO
1999 ISO 14001 27001
1999 QIP/SIP/EMP 6σ-II SA8000
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
2008 Integrated Management
RAMCO system
ISO
14001 2008 ISO 27001
ISO 2009 SAP in place of
9001 RAMCO
2010 BS EN 16001
2011 ISO 50001:2011 (Energy Management
System)

1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2013

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System Approach
First ISO
9001:2008
Certification
by BVQI ISO ISO
50001:2011 14001:2004

SA OHSAS
8000:2008 18001:2007

ISO/IEC
27001:2005

Continual improvement is ensured through improvement plans for IMS,

ISMS, SA and EnMS
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Process
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

Log-books Environment Systems

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Selection of process for Improvement

Stretch targets

Benchmarking

Resource optimisation

Energy conservation

Efficiency improvement

Legal requirement

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Approach for Improvement Brainstorming
D-logbooks
Event analysis
MIS reports
Technical
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 ISO systems and controls are placed
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Energy Conservation -Techniques

Energy
Conservation

New technology
R&M Fuel Switch Optimisation
introduction

 Online Energy  HFO to LDO  Modular  Innovative

monitoring Scaffolding approach
System  APH Brush  Equipment
Seals running hours
 Thermo-vision  VFD applications
applications  Soot blowers
 Standardization
 “PROMT”
maintenance
 Coal Blending

Confidential Slide 13
 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 219 New Energy
VIEW RS485
Meters Installed (HT&LT)
Single Login

6.6 KV Swgr 6.6 KV Swgr

U-1 U-2

Confidential Slide 14
 Daily Energy Deviation Report

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

Confidential Slide 15
 Monthly Building Energy Deviation Report

All Buildings Of Plant Are Covered Under Monitoring

Confidential Slide 16
Innovative Maintenance Approach
“PROMT”
Modular Maintenance Priority on Managing
concept Performance Trends
maintenance
Innovative
Maintenance Approach

Efficiency Based Maintenance Concept

Energy Monitoring System

Confidential Slide 17
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

Confidential Slide 18
 BFP Cartridge Replacement

BFP Cartridge

Boiler Feed Pump Saving Achieved

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

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 Air pre heater basket cleaning
 During overhaul APH baskets of cold end are removed and water jet cleaning at 40
ksc pressure is carried & chocking is removed..

Confidential Slide 20
 Modular Scaffolding

Confidential Slide 21
 Overhaul Best Practices
 Generator decoupling within 17 Hrs of unit De-synchronization saving 5 days
in Generator activities.

 Modular concept – maintain HP module, which has reduced overhaul time

by 6 days

 Use of SAP PM and PS module for effective overhaul management

 Round the clock working.

 Zero idle time in & between succeeding /preceding activities

 Cross-functional teams for Safety and Quality.

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22
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

Confidential Slide 23
Identification of Air Ingress in Boiler & Flue
gas Duct – Unit Running Condition
Visual Inspection- Daily
routine rounds

Sound/Temperature
observations
Identification during
Offline 02 %
Unit Running
measurement & analysis
Condition
Offline flow measurement
(Pitot Tube) – Third Party

Air ingress checklist –

Scheduled
Confidential Slide 24
 Defects Management process
Notification raised in
SAP

Discussed in Daily
plant meeting

Categorized Aux
power / Heat rate

No
Running
Defect

Yes
Equipment Short
Major Overhaul
Planning done to Shutdown Shutdown
attend

Confidential Slide 25
 Arresting Of Duct Leakages in Every Opportunity

Air Ducts

Flue Gas Duct

Confidential Slide 26
Efficiency based O&M
 Along with preventive and predictive maintenance, scheduled
equipment changeovers focus is shifted to Efficiency based O&M

 Equipments where standby are available, less power consuming or

more efficient kept in service most of the time.

 Reasons for lower efficiency are find out and maintenance is planned
accordingly.

 Coal mill O&M is based on the output and quality of the pulverised coal.

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Innovative Operation Approach

Intelligent Soot blower Efficiency Based

operations operations

Innovative Operation
Approach

Coal Blending Mechanism

SOG, SOP & Checklists, Digital Logbooks

Optimization Benchmarking

Confidential Slide 28
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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 Soot blowers conventional schedule
 DTPS is provided by 56 Water wall soot blowers and 18 Long retractable soot
blowers in convective zone of super heaters, re-heaters & economizer tubes

 Effects of conventional approach

 Timed based approach typically results in over cleaning.
 Excessive use of steam is an economic penalty for this type of operation.
 Results in the around 80% variation in the main-steam & re-heat temperatures.
 High furnace exit flue gas temperature.
 Lower efficiency.
 Erosion of tubes.

Confidential Slide 30
 Intelligent approach
 “Intelligent soot blower operation” is an innovative strategy to achieve optimum
steam generator operation & performance by controlling the cleanliness and fouling
of heat transfer surfaces.
 Development
The Soot blowers are operated in a pair left and right side of each bank. The data is collected
and logged.
Typical data includes:
 Fluid temperatures at inlets and outlets of each convection pass including the
temperature before and after attemperators.
 Operating pressures (drum, super heater, re-heater)
 Boiler exit gas temperatures before and after Soot blowing
 Flue gas excess Oxygen (O2) – at the boiler exit
 Fluid flow (main steam, reheat steam, feed water)
 Fuel and total air flow
 Boiler tubes metal temperature before and after Soot blowing
 Flue gas temperature at different zones before and after Soot blowing
 Coal Elevations in service.

Confidential Slide 31
 Intelligent approach
 After Analysis of the data collected for 3 months for each LRSB a schedule is
prepared for operation of long retractable soot blowers in group as per the locations.
Day LRSB numbers
1 65, 57, 58, 69
3 66, 59, 60, 70
5 63, 68, 71
7 64, 67, 72
9 61, 62, 73, 74

 Group operation of water wall soot blower like 1, 4, 8, 12 (in gap of 3) or 1, 6, 11 (in
gap of 4) gives better results than simply whole set (1-14,15-28,29-42) sequential
operation previously carried out.
 The scheduled of WWSB operations kept the same but the sequence of operation is
changed.

Confidential Slide 32
 Flow Chart for Scheduler Software

Confidential Slide 33
Development of Soot blower Scheduler

Confidential Slide 34
Development of Soot blower Scheduler
Conventional Approach Intelligent approach
 Time based fix interval approach.  Need and condition based approach.
 Over cleaning or under cleaning of tubes.  Optimum cleaning of tubes.
 Excessive use of steam.  Optimum use of steam.
 Variations in Main steam and Reheat steam  Main steam and Reheat temperature are
temperatures than the design. maintained in a narrow band nearer to design
 Probability of erosion of tubes high due to value.
over cleaning.  Probability of erosion of tubes is very less.
 Attemperation spray required in on higher  Attemperation spray required in very low or
side. nil.
 High boiler exit flue gas temperature.  Low boiler exit flue gas temperature.
 Lower efficiency.  Higher efficiency.
 No logical explanation.  Manual decision is replaced by logical
 High TPM. software.
 Low TPM.

Confidential Slide 35
Development of Soot blower Scheduler

MS Heat rate loss kcal/kwh RH Heat rate loss kcal/kwh

2.74 1.45

0.92

0.7

Average Loss 2005- Average Loss 2009- Average Loss 2005- Average Loss 2009-
2009 2014 2009 2014

Confidential Slide 36
Optimization of Cooling water Pumps operations

20750 m3/hr
Condenser Condenser
Unit # 1 Unit # 2 Cooling channel
1.8
mtr
1.8 km duct
1.5
mtr
Running of 4th CW pump is Sea
optimized as per Water
Creek
 Tide Level
 Sea water temperature,
 Condenser Vacuum,
 Generator Current, 0.1% reduction in APC is achieved
 MS Flow
Confidential Slide 37
Phase wise evolution of optimisation
Phase-I Phase-II Phase-III

Standardized
with logical Low load
explanations operations
3.5 – 3.0 mtr

1.8 – 1.5 mtr

Pump start stop

Pump as per operator 1.0 – 0.8 mtr
continuous experience no
running logical
explanation

Confidential Slide 38
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 39
 Applications of Variable frequency drives
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
Drinking Water
7 2 1 40 24 16 5.00
Pump
8 Sevice Water Pump 1 1 16 10 6 2.00

0.11% reduction in APC 1847 1219 622 247

Confidential Slide 40
Blending Mechanism

Two different grades of coal are mixed uniformly in predetermined

proportion for achieving desired calorific value. Blending of coal is
done on conveyor and as per requirement.

Two / three different grades of Coal are lifted from separate locations.
Lifting rates / flow is predetermined and is monitored through Belt
Scale by the operator as well as from Control room.

These different grades of coal are fed on a single conveyor (three

locations) There are minimum two transfer points where these three
grades of coal get mixed uniformly (due to free fall of about 8-10 meter)
before being fed to bunker. During bunkering, there is another free fall
of coal. The process itself ensures proper blending of two/three coal.

Confidential Slide 41
Adoption of Imported Coal in DTPS
1. Loading factor improved & PLF achieved more than
100 % LCV coal is generally used as a partial substitute
consistently
1. Coal quantity reduced
P 2. 2. Failure of equipments
Unit Load increased in CHP
of Indian wash & due
coal AHPtoreduced
acute shortage of
E 3. 3. Plant Reliability and availability improved by
Emission level reduced
reduction in washed
tube coal, . equipment break down
leakages
R 4. Aux power reduced
F 5. 4. Environmental
Flame stability improved The parameters
same level ofimproved
performance is maintained.
O 6. 5. Aux.
Formation of clinker power
& soot reduced.
is minimum
R 7. Overall performance improved Wash coal +
M Commercial various grades of
A operations imported coal
N F-grade Wash coal +
C Coal
E Imported coal
Indian raw coal +
Imported coal

1995-96 1st Phase1999 2nd Phase 2001 3rd Phase2006

Confidential Slide 42
Use of Thermography
 Portable thermo-vision camera is used for
 Insulation surveys
 Coal pipe chocking
 Monitoring bearing temperatures
 Monitoring Valve passing (reducing DM make-up)
 Finding cold spot (air ingress)
 Finding hotspot
 Bunkers
 Coal yards
 Motor terminals
 Motor winding
 DDC panel
Confidential Slide 43
1] Boiler Insulation Survey

Insulations to all
manholes done

Confidential Slide 44
Boiler Insulation Survey

Before After
Insulation Insulation

Confidential Slide 45
Piping Survey

Main Steam (MS), Cold Reheat (CRH) & Hot Reheat steam
piping (HRH) insulation survey
Confidential Slide 46
Reducing Steam and water leakages

Confidential Slide 47
Thank you