Reliability & Energy Efficiency Improvement By O&M Practices In Thermal Power Station

Reliability & Energy Efficiency Improvement By O&M Practices In Thermal Power Station

Reliance Infrastructure Ltd. Dahanu Thermal Power Station

Suhas Patil AVP-O&E,MTP

Anish kumar Shukla

Date:14-02-2012

DGM Operation

About Dahanu TPS The setting up of the Plant was approved in 1989. Start of Land Development - January 1990 First Synchronization Unit – I - January 1995 Unit – II - March 1995 Station Commercial operation - July 1995/Jan 1996 Running Hours (till Jan 2012) Unit – I - 1.35 lakh Unit – II - 1.32 lakh Confidential

Slide 2

DTPS Milestones EnMS BS EN 16001:2009 ISO 50001:2011

1998 Quality Management System ISO 9001 1999 Environment Mangement System ISO 14001 RBNQA

2000 RAMCO ERP Package implementation SAP ECC

2001 ISO upgradation

ISO 27000

2002 Optic Ground wire (OPGW) & Backbone data highway SA 8000

2003 SAP & Employee self service implementation 2004 British Safety Council Audit

6 Sigma-I Mercer, CII

2005 Benchmarking in CII

6 Sigma-II KM, OHSAS 2006 Occupational Health and Safety Assessment Studies OHSAS 18001

BSC

2005 Six Sigma Drive I

SAP & ESS

2005 HR Mercer study

2006 Knowledge Management 2006 Six Sigma Drive II

OPGW

ISO Upgrade

2007 Social Accountability SA 8000

2008 Integrated Management System (ISO 9001, ISO 14001, OHSAS 18001)

RAMCO 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 Confidential

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011 Slide

Indian Power Scenario Power Supply Deficit in India (%) 20

16.6 16 12.9

12.7 11.9

12

11.1

10.1

9.9

9.8

10.3

8.5 8

4

0

2007-08

2008-09

2009-10

Avg

2010-11

2011-12

Peak Source :Business-standard.com

Confidential

Slide 4

Objective

To Generate

Confidential

• • • •

Reliable Economical Efficient power Green power

without Affecting

• Plant Availability • Reliability

Maintaining

• Safety • Environmental conditions

Slide

O&M Philosophy Safe Reliable

Sustainable

Efficient M O N I T O R People

Confidential

Economical O P T I M I S E

C O N T R O L Team Work

Clean R E V I E W

Standardisation

Slide

System Approach ISO 9001:2008 ISO 14001:2004

ISO 50001:2011

OHSAS 18001:2007

SA 8000:2008 ISO/IEC 27001:2005

Continual improvement is ensured through improvement plans for IMS, ISMS, SA and EnMS Confidential

Slide

Use of Quality Tools -6 sigma FMEA etc

Objective & Targets at departmental level

Rolling Plan

Adopting modular Concept for maint.

Enhanced Monitoring

Reliability Improvement Condition Monitoring Tripping / Critical Event Analysis Residual life assessment Study Confidential

Opportunity Based maintenance

Slide

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 9

Confidential

Slide

Modular maintenance concept Lower downtime of critical equipments / Reduction in overhaul time

Enhanced plant efficiency Modular Maintenance Concept Quality Maintenance

Inventory Control

Confidential

Slide 10

Modular maintenance concept Reduction in Overhaul time



Modular conceptualization o



Short shutdown opportunities



Overhauling of redundant auxiliaries



De-coupling of Generator o

Confidential

HP module - reduced 6 days

Saving of 5 days

Slide 11

HPT Module replacement Turbine Heat Rate (Kcal/kwh)

2010

2006

1980

1955

Unit-1

Before

Confidential

Unit-2

After

Slide 12

Condition Monitoring Techniques Multiparameter Vibration Monitoring Dissolved Gas Analysis

In- situ Balancing

In house Thermography

Chemical Analysis of lube oil

Motor Current Signature Analysis

Confidential

Noise Monitoring

Slide

Condition Monitoring Techniques

Wear Debris Analysis Magnetic Particle Inspection (MPI)

Eddy current testing

Outsourced Recurrent Surge Oscillograph (RSO) Test

Natural Frequency Test

NDT Ultrasonic

Confidential

ELCID Test

Slide

Reliability Improvement by Maintenance Planning Scheduled Preventive Maintenance of equipments

Inspection & maintenance of Critical equipments during short shutdown

Reliability Improvement

Monitoring and review of daily defect report

Compilation and review of planned to total orders ratio

Monitoring and review of work order age Confidential

Slide 15

Opportunity Based Maintenance

Short shutdown

Boiler tube inspection

Opportunity based maintenance APH seal inspection & repair

Confidential

Flue gas duct inspection & rectification

Slide 16

Arresting Of Duct Leakages in Every Opportunity Before Ovehaul

After Overhaul

Air Ducts

1517

1290

914

kw

670

283

ID Fan

PA Fan

260

FD Fan

Flue Gas Duct

Before & After Overhaul-Fan Kw Confidential

Slide 17

Equipment healthiness checks Weekly/Fortnightly changeover of standby equipments

Daily trial of DG sets Healthiness of Auxiliaries Weekly trial of other DC auxiliaries

Daily trial of Critical DC Auxiliaries

Confidential

Slide

Best O& M Practices Maximize capacity utilization

System based approach

Knowledge sharing at different forums

Creating energy conservation awareness

Efficiency Improvement

Enhanced monitoring & control

Use of Break through quality tools Use of new technologies

Confidential

Regular system & energy audits

Slide

Performance improvement areas

Safety & Reliability

Efficiency & Cost

Performance improvement areas

Environment Protection

Confidential

Availability & Output

Slide 20

Operation philosophy

Improve Heat Rate

Reduce Auxiliary Power Consumption

Confidential

Slide 21

Heat Rate Improvement

Confidential

Slide 22

Heat Rate Monitoring

Kcal/Kwh

Daily Heat Rate Calculation & Identification Of Heat Rate Losses Heat Rate

Monitoring

Daily Boiler Efficiency Calculation By Heat Loss Method Monthly Boiler & Turbine Performance Test as per BHEL PG test Method

Boiler Efficiency Air -Preheater performance Economizer Performance Turbine Heat Rate HP-LP-IP Cylinder Efficiency

Kcal/Kwh Confidential

Heaters & condenser Performance Heat Rate & Cycle Efficiency

Slide 23

Factors affecting heat rate Better Heat Rate

Un-burnt Carbon Exit Flue Gas Temperature

MS Pressure

Condenser back pressure

Feed Water Temperature

DM Make-up

MS / RH Temperature

Excess air

Better Heat Rate

Confidential

Slide 24

MS/RH temperature improvement Burner Tilt Auto Operation

SADC Operation as per requirement

MS/RH Temperature Improvement

Coal Mill Combination

Soot Blower Scheduler

Every 1° C more flue gas outlet temp. causes a heat rate loss of 1.13 KCal/kwh. Confidential

Slide

Confidential

Slide 26

Effect of Soot Blower Model RH Temp & Heat Rate Loss

RH Temperature Heat Rate Loss

538.00 537.00 536.00 535.00

534.75

6 535.63

535.54

535.81

4

534.72

534.47

534.00

533.00

2

532.00

531.00

1.53

1.72

0.99

1.55

0.93

0.81

2009-10

2010-11

530.00

2005-06

2006-07

Ms Temperature

Heat Rate Loss

536 531.88 3.48

532.69

533.23

2.93

2.56

526 2005-06 Confidential

2008-09

MS Temp & Heat Rate Loss

541

531

2007-08

2006-07

2007-08

535.72

535.89

2

0.87

0.75

2008-09

2009-10

2010-11

534.05

0

10 8 6 4 2 0 Slide 27

Flue Gas temperature reduction Optimized Mill loading

Optimized soot blower operation APH outlet flue Gas temperature < 134°C

Water washing of APH Monitoring APH seal leakage

APH soot blowing

APH Outlet temperature (°C) 147 143.5

144.5

143

141.5 139

140

139

137.5 135.5

135 131 2004-05 Confidential

2005-06

2006-07

2007-08

2008-09

2009-10

2010-11

Slide 28

Condenser vacuum improvement

Condenser Vacuum Improvement

Monitoring performance, Check list, Helium Leak Detection Test

Operation of Condenser Online tube cleaning system

Optimization of Operation of CW pumps

Every 0.01 kg/cm2 change in vacuum causes heat rate loss of 11-12 KCal/kwh.

Confidential

Slide

Minimization of unburnt carbon

Coal Mill Changeover based on Un-burnt Carbon Report

Ball charging & segregation based on coal fineness

Reduction in Un-burnt Carbon Loss

Mill changeover

Coal Mill O&M Decision Template

Confidential

Slide

DM make-up optimization Fuel switching from HFO to LDO

Optimization of Soot Blowers operation Reduction in DM water Loss

SOP/Checklist for Identification of Leakages

Optimization of VAM operation

Every 1 % increase in DM make up causes heat rate loss of 10 KCal/kwh. Confidential

Slide 31

Auxiliary Power Reduction

Confidential

Slide 32

Auxiliary Power Consumption Monitoring Daily APC calculation based on Generation & Net export

Kwh

Daily Energy Deviation Monitoring of Individual Auxiliary Monthly Energy Balance Report APC Monitoring

Monthly Building Energy Consumption Monitoring Report Monthly Auxiliary Power Consumption Report

Kwh Confidential

Pumps & Fans Performance Testing

Based on Generation & Net Export Based On Consumptions Of Station & Unit Transformers Based On Consumptions Of 6.6 Kv Station & Unit Boards Based On Consumptions 415 V Stn. LT Boards Aux. Power Cons HT & LT Auxiliaries Power consumption

Slide 33

Online Energy Monitoring System PCR-1

PCR-2

Process parameter

FGD Process parameter

4-20 mA

24+16 channel

SCANNER

SCANNER

Process parameter

4-20 mA 24+16 channel

4-20 mA 16 channel

Compressor Room

Process parameter

SCANNER

RS485

4-20 mA

16 channel SCANNER

RS485

RS485 RS485

ELAN VIEW

LAN

ELAN VIEW

ELAN SERVER

Continual Improvement RS485

RS485

Total 161 New meters installed (HT)

Single Login

6.6 KV Swgr U-1 Confidential

6.6 KV Swgr U-2 Slide

Auxiliary Power Reduction • Excess air optimisation • Coal Mill / BFP • VFD: CEP, Seal air fan, ACW, Vent Fan • Cooling Water pump • Compressor

• BFP cartridge / Recirculation valve • Attending duct leakages • Use of VFD Confidential

• • • • Optimized Equipment Operations

Maximising machine loading factor

Maintenance control

Use of beneficiated coal

Current limit= < 9800 MS flow = <775 TPh MS pressure = < 155ksc MS Temp = < 540⁰C

• F-Grade Coal • Wash Coal • Imported Coal High/Medium GCV

Slide

VFD Installation at CEP

Before and after CEP Kw VFD Installation at CEP 700

565

560

500 439

435

300 CEP-1A

CEP-2A

Without VFD

Total 12 Nos. Of VFD Are Installed In Different Application

Confidential

With VFD

Energy Saving 622 Kw Slide

ACW Power Consumption Chart 74.7 76

43.6 50

Oct-10

50

Nov-10

43

61

60

60.5

59

46

46

46

46

44 40

40.9

40.9

40.9

Dec-10

Jan-11

Feb-11

40 Mar-11

ACW Power Consumption (Kw) Confidential

Apr-11

May-11

Jun-11

Jul-11

Frequency Slide 37

Excess air optimization

Excess air

• Secondary air optimization by CO monitoring

• SADC operation

• Online / Offline monitoring

Duct leakages

• Rectification during opportunity • Thermovision Monitoring

Confidential

Slide 38

Optimization of Equipment running Hours

20750 m3/hr Condenser Unit # 1

Condenser Unit # 2

Cooling channel

1.8 mtr

1.8 km duct

1.5 mtr

The area above the duct is filled with water in summer

Sea Water Creek

CW pumps Power Consumption % Aux Power 0.821

0.817 0.730

2008 Confidential

2009

2010

0.700

2011

Running of 4th CW pump is optimized as per Tide Level, Sea water temperature, Condenser Vacuum, Generator Current, MS Flow Slide 39

CW Pump running hours optimization

Confidential

Slide 40

Coal Mill changeover duration Mill changeover time reduced by 16 min in first phase

Mill Changeover Time (Minutes) 83 72 65

68

64

60

42 35

2008-09

2009-10

Unit-1

2010-11

Unit-2

2011-12

Linear (Unit-1)

Power saved is approx 650 kw for each mill changeover Confidential

Mill changeover time reduced by 24 min by doing pre-drying of coal mill before taken into service. Slide 41

BFP changeover duration BFP Changeover Time (min) BFP changeover time reduced by 25 min in first phase 58

59 43

2008-09

42

31

2009-10 Unit-1

30

2010-11 Unit-2

Power saved is approx 1600 kw for each BFP changeover Confidential

Slide 42

Maintenance Philosophy Change Energy deviation concept

Equipment maintenance

Defect based to Energy efficient based Reduced heat rate & aux power consumption

Confidential

Improved plant performance

Slide 43

Replacement of Manganese Liners By Hi-Chrome Liners Life @16,000 hrs

High Power consumption

Manganese Liners & Balls Less Cost

Less Availability for operation

Life @60,000 hrs

Less Power consumption

Hi-chrome Liners & Balls Higher Cost Confidential

More Availability for operation Slide 44

Power saving after Liner Change

1478

1472

1430

1398 1185

1196

1395

1135

1162

MILL -1EF

MILL -2CD

1113

kw

MILL -1AB

MILL -1CD

Mn Liner

MILL -2EF

Hi-Cr Liner

APC Reduced = 0.26% Approx. Confidential

Slide 45

Daily Energy Deviation Report

Operating Value: Operational Control: It includes theValue: Base Maintenance Control: Is Decided Based On Average Effect OfIt Coal Quality Variation, It Includes This Condenser control includes Value of 1 Condition, Year Data Vacuum Un-optimized

Detail Analysis Of Problems Other Seasonal Effects. Operation Deviation, Solution In Terms New Alternative Operators ToOfPassing, Run Equipment In This Valve /Have Damper Average

Power

Consumption

Technology Standardized Operating Range.Due, Preventive Maintenance  Repair or Replacement. Set Points At Various Parameters

Rate As On Date

Confidential

Slide 46

BFP Cartridge Replacement Boiler Feed Pump

Saving Achieved

Performance Based BFP cartridge Replacement (serviced cartridge)

BFP-1A = 461 kw BFP-2A = 656 kw BFP-1B = 347 kw

BFP Cartridge

8000 7568 7404

7264 7057

7000

6803

6912

Boiler Feed Pump

6000 BFP-1B

BFP-1A

Before( kw)

Confidential

BFP-2A

After( kw)

Slide 47

Effectiveness in Reliability & Energy Efficiency Improvement Heat Rate sustained @ 2300 kcal/kwh since last 9 years

DM water makeup is reduced from 1.41% to 0.35 % (Including VAM) Specific oil consumption is reduced from 1.739 ml/kwh to 0.11 ml/kwh

Auxiliary power consumption reduced from 8.27% to 7.38 % and sustained Generation loss due to equipment nonavailability is less than 0.1% of total generation

Confidential

Slide 48

Sustainable DTPS Performance

Heat rate less than 2300 Kcal/Kwh

Availability more than 96 %

PLF more than 100 %

Loading factor more than 104 %

Confidential

Slide 49

Thank you

Divisional Objective: 1.1 Reduce the Unplanned Non - Availability of critical equipments 1.2 Gen, loss (MUs) on account of equipment Non-availability 1.3 Heat Rate 1.5 Unit Trip in Nos

Confidential

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Confidential

52 Slide of

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