dahanu thermal power station company profile · 2016-08-19 · dahanu thermal power station 17th...

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Dahanu Thermal Power Station

17th National Award for“Excellence in Energy Management –2016”22 nd & 24 th August 2016: HICC, Hyderabad

Confidential Slide confidential Slide 2

Company Profile

Solar

Wind

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DTPS : Overview

Plant Commissioning 1995

No. of Units 2

Unit Size 250 MW

Total Hrs Run > 1.7 L

Aux Consumption 7.81

Heat Rate 2302

Plant Load Factor 87.087

Availability 92.7

FY 15-16


Documentation

Implementation

Control

Monitoring & Analysis

Deviation/Correction

Review by top Management

Feedback

System Approach – Guiding Aspects

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ISO 9001:2008ISO 14001:2004

BS OHSAS 18001:2007ISO 50001:2011

ISO/IEC 27001:2005 SA 8000:2008

Accreditation - ISO/IEC 17025:2005

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Benchmarking

2500

2302 2370

Heat rate kcal/kwh

8.5

7.812

9.75

Auxiliary Power Consumption %

National SEC

Benchmark

DTPS FY 15-16

MERC SEC Target for FY Year

2015 - 2016

MERC MYT TargetGross Heat rate

2370 kcal/kwh

Aux Power

8.5 % + 55.78 musfor FGD


Monitoring Facilities At DTPS

Monitoring Facilities

HMI

To Monitor

Process

Parameters &

Control

X-Force AIMS

To Generate

Report In

Customize

Format &

Access To All

Dept.

Online EMS

To Monitor

Energy

Consumption

Of Individual

Auxiliary

D-Log Book

To Log Events

& Local

Process

Parameter

Intranet Website

To Share

Information Of

Individual

Dept.

Energy Management System

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Objectives Of Monitoring System

Monitoring Objectives

100% Monitoring Of Plant Operations

To Identify Energy Deviation

Heat Rate

APC

Fuel Consumption

Process ParametersTo Identify Energy Losses In System & Improve Efficiency

Reporting of DeviationThrough

FIR/Notification/Work Order

To Provide Right Information, In Right Time At Right LEVEL

Data ManagementData Collection,

Compilation & Record Keeping

Energy Management System


Energy Conservation Projects 2015-16

Energy Saving Project

Servicing of HP module and overhauling of LP Turbine module in U1

Renovation and modernization of flue Gas Path Duct in U1

Improvement in HP heater performance by attending parting plate leakage

BFP 2B cartridge replacement

Attending instrument air leakage by using ultrasonic air leak detector on quarterly basis

Reduction in LDO consumption during cold start up.

Servicing of VAM

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Energy Conservation Projects 2014-15Energy Saving Project

Replacement of HP module and overhauling of LP Turbine module. (modular concept)

Renovation and modernization of APH brush seal (new technology)

BFP 2A Cartridge replacement (innovative approach)

Renovation and modernization of flue Gas Path Duct (“PROMT” approach)

Improvement of HPH performance (“PROMT” approach)

Reduction in Main Hall Fan energy consumption by low rating fan in Store room

Optimization of running of air blower at Colony Sewage treatment Plant

Optimization of blower running hours of wagon tippler main motor

Providing VFD for VAM cooling water pump (45KW)

Energy conservation by changing washed coal unloading operation process.


Energy Conservation Projects 2013-14Energy Saving Project

Coal Mill Seal Air fan sliding pressure operation in VFD mode by maintaining D.P

Operation in Sliding Pressure Loop during Partial loading of Turbine

Reduction in ACW Pump power consumption by sliding operations of Variable Frequency Drive during backing-downCondensate Extraction pump sliding pressure operation in VFD mode by maintaining Header pressureReduction in PA fans power consumption by optimization of PA header pressure during back-down operationsJacket type insulation to feed water line valve

Rectification of flue Gas Duct and Dampers (ID fan-1A & 1B)

Rectification of Primary Air Duct and Dampers (PA fan-1A & 1B)

Rectification of flue Gas Duct and Dampers (FD fan-1A & 1B)

Reduction in condensate flow after DR-40 Valve replacement

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Renovation & Modernization of HP/ LP TurbineReplacement of HP module with spare have the following benefits

ü Improve Turbine heat rate as refurbishment module is serviced at

OEM. where seal leakages, blade clearance are attended

ü Due to spare turbine module ,overhaul time was reduced by 6 days.

ü Quality of maintenance work .


Improvement in HP heater performance by attending parting plate leakage

HP heater 5 and 6 -Feed water Temperatureis improved by @ 5°C

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R&M of flue Gas Path Duct in U1q Following are the major boiler defects got attended in overhaul which

achieved in Boiler auxiliaries current reduction.

• Flue gas duct air ingress.

• SA duct air leakage.

• ESP inlet outlet bellows replaced.

• GD damper seals repaired


R&M of flue Gas Path

Deflector plates erosionAPH A outlet FG duct manhole

APH B inlet bellow heavily erodedRHS duct hopper metallic bellow coverplate heavily damaged.

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Optimum oil consumption during cold start-up

§ To find out the GAP the process is divided in subgroups of cycleslike

§ Air & Flue gas cycle and§ Steam & water cycle.

§ The cold start-up procedure break-up in sequential and parallelactivities and a detail checklist was prepared.

§ During the cold start-up the reasons of delay or high oilconsumption was noted against each activity

§ analysed to find the factors or reasons for the delay. After each coldstart-up the reasons were analysed

§ Remedial corrective preventive actionswere finalised to further reduce the start-uptime and oil consumption. PDCA cycle wasused to optimise the process each time.


q The factors of delay in cold start up time and high oil consumption are categorize mainly as

• Delay/defects in starting of auxiliaries & Line-up

• Problem in oil guns firing system.

• Delay in coal firing

• Attaining desire steam parameters to fulfill X criteria (within Turbine stress

margins)

• Generator dry-out (low IR value)

• Delay in boiler pressure rise due to high silica

The above factors were analyzed in detail and remedial actionswere prepared and implemented to reduce the oil consumptionduring cold start-up.

Optimum oil consumption during cold start-up

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Oil Consumption Trend

256.99 250.23

188.54160.49

116.5875.00

2009-10 2010-11 2012-13 2014-15 2015-16 2016-17

Oil consumption in kl for cold start up

14:08 13:3811:40

9:32 9:00 8:25

0:00

2:24

4:48

7:12

9:36

12:00

14:24

16:48

2009-10 2010-11 2012-13 2014-15 2015-16 2016-17

Cold start up time in hh:mm


Attending instrument air leakage by using ultrasonic air leak detector on quarterly basis

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NO of Air Leakages in the system

40 267 5

Total Leakages - 78 Energy losses – 1.1 Lacs-kwh

Investment to attend Energy Loss - Nil


VAM OverhaulingBenefits

§ DDC room temperature improved from 20°C at 6.5 ksc steam input to

19°C at 4 ksc steam input (1°C improvement at reduced steam input).

§ Chilled water temperature difference across VAM improved from 2.8°C to

4°C (1.2° C improvement resulting in improvement in TR generated)

§ Steam requirement for required TR changed from 1.6 TPH at 6.5 ksc to

1.0 TPH at 4.0 Ksc

§ Differential pressure of cooling water across condenser reduced from

2.30 ksc to 1.2 Ksc which resulted in reduced load on cooling water

pump and improvement in Heat exchange performance.

§ Optimization of cooling tower fan operation resulted into requirement of

single fan even in summer season as compared to 3 Nos of fans

required before overhauling.

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Stack Emissions - SOx (T/Day)

Stack Emissions - NOx (ppm) Stack Emissions - TPM (mg/NM3)

Environment Management

Pioneer in use of blended coal as a fuel

56 56 55 54.3

29.4

3.94 4 3.9 4.1 3.9 4.1 4 3.9

80.4 80.4 80.4 80.4 80.4 80.4

8.04

88.5

88.5

86.1

73.3

69.9

75.4

75.6

75.9

71.8

69 69.4

70 68.8

150 150

49

29 34 39.8

34.9

37.3

40.7

42.3

43.9

44.6

46.1

46.1

46.4

150 150

FGD Installed


Ultra High Density Tree Plantation

Ultra High Density Tree Plantation which is a known Japanese method to promote forest regeneration using

mixed plant saplings of local species was done in DTPS plant premises. Saplings are planted very close to

promote fast growth due to competetion among species for light. 2-3 saplings planted per square meter. 30 -

40 different species of Mango, Tamarind, Almond, Neem, Gulmohar, Pipal etc. are planted. Total 10000

numbers of plants planted on the day & planned to plant more than 5000 plants during upcoming monsoon

season.

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Energy week Celebration§ Energy Conservation walk on 14th Dec 2016 from Colony (New guest

house) to Plant (administration building),

§ Pledge towards Energy Conservation by all DTPS employees.

§ Display of energy conservation video clips provided by BEE.

§ Mass Campaign for Energy Conservation to create public awareness

through School Children’s by arranging seminars at local schools.

§ Energy Conservation awareness to DTPS family members & Quiz

completion on Energy conservation

§ Energy Project by School and college students

Employee Involvement


Energy Conservation Week Celebration

“DTPS Earth Hour” Celebration

Employee Involvement

Energy Conservation awareness to DTPS family members

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Energy Conservation Project by school and college


DTPS “Journey Towards sustainable excellence”

dahanu thermal power station company profile · 2016-08-19 · dahanu thermal power station 17th...

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