1

DTPS experience on ISO 50001:2011 (EnMS)

Dahanu Thermal Power Station 2 x 250 MWDinesh Mantri

Company Profile

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Reliance Infrastructure

Reliance Infrastructure

2400 MW of Power project

commissioned

17000 MW for R-power under

installation/ commissioning

DTPS Geographical Location

Well connected by Western Railway & National Highway No. 8

At a distance of 128 Kms from Mumbai

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Dahanu

Mumbai

Surrounded by two natural creeks -Savata and Dandi

Surya Dam nearby – 32 kms

Plant over view

First 250 MW sets in the

Country

Indigenous technology

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Coal Based plant far away from

Coal Mines

Recognised as best performing

plant at National / international

level

GPrimary Air Fan (PA)

Coal Mills

Steam Generator

Turbine

CondenserTo Creek

Sea Water

Cooling Water

HP Heaters

Generator

Electricity Generation Process

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ESP FGD

STACK

Secondary Air Fan (SA)

Water Pumps

Condensate Extraction

PumpLP HeatersBoiler Feed

Pump

ID Fan (ID)

Generates 500 MW Power, Consumes 7000 T/day Coal & @ 44 MW Power during this process

ISO 9001:2008

ISO 14001:2004

ISO 50001:2011

System

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OHSAS 18001:2007

ISO/IEC 27001:2005

SA 8000:2008

System Approach

2

Documentation

I l t tiC ti

Feedback

Management System

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Implementation

Control

Monitoring

Analysis

Correction

System Approach

Policy

Planning

Documentation, Implementation Management Review

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and Operation

Feedback

Monitoring measurement &

analysisInternal Audit

Management Review

Nonconformities, correction, corrective and

preventive action

ISO 50001:2011

DTPS is the first to be certified for ISO 50001:2011 Energy Management Certification in the World.

System approach for energy use and conservation

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EnMS improves the process by measurement, monitoring and control in

• energy performance

• efficiency

• use, and consumption.It also helps to reduce

• greenhouse gas emissions,

• energy cost and

• environmental impacts.

CONDENSER

DEAECO

SE

A W

AT

Area wise focus for Energy Conservation

AHPCHP

Compressors

HT Aux – 90%LT Aux – 10%

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APH

ER

CR

EE

K

BFP

CEP

CWP

ID FanCoal Mill

FD Fan

PA Fan

ESP

9 mw

3.5 mw1.45 mw

4.70 mw

2.7 mw

5.04 mw

0.625 mw

Energy Planning Process

Planning Inputs Energy Review Planning Outputs

Past and Present Energy Uses

A. Analyze Energy Use and

Consumption

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•Energy Baseline•EnPl(s)•Objectives•Targets•Actions Plans

Relevant Variables affecting significant energy usePerformance p

B. Identify areas of significant

energy use and consumption

p

C. Identify opportunities for improving energy

performance

Master list of energy use & consumption Format 12.1.0

Sr. no

EquipmentProcess / System/ Activity

Type of Energy use EnPI

Potential for renewable / alternative

energy

Legal Requirement

Yes /No

Significant Yes / No

Energy Planning

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Activity energy sources

Yes /No

1 BFP Feed Water

systemElectricity 9000 kW No No Yes

Like Wise done for > 850 Equipments

3

Sr. No Descriptions Details

01. Energy Use & ConsumptionEnergy consumption of Boiler Feed Pump (BFP) during operation.

02 Type of Energy use Electricity

03. Process / Equipment / Systems / Activity Feed water system.

04. Area / Location Turbine Building 0 mtr floor.

05 Energy performance indicators (EnPI) Power consumption kW

06 Source of Data Online

07 Frequency of monitoring Daily

Energy Planning – for individual Significant Equipments.

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07 Responsibility Sectional Head

Energy Use & Consumption Factors affecting EnPI

Energy consumption of Boiler Feed Pump (BFP) during operation.

Pump performance

Motor performanceBooster pump performance

Hydraulic coupling performance

Feed water flowRecirculation flow

Drum level 3E/DP modeBFP R/C valve healthiness

Action plan criteria: Operating Zone Value Data period

Base value 7100 kW

Dec’10 to Nov’11Operating Value 7100 kW - 7350 kW

Operational Controls 7350 kW - 7450 kW

Maintenance Controls > 7450 kW

Sr.No. Operating Value controls1 Operating with standard operating guidelines as per operation manual (DTPIM/12M01)

2 Preventive Maintenance of Equipment & its sub-systems as per maintenance manual (DTPIM/14M/01/PM/TM/01)

3 Periodic energy audits and implementation of recommendation, wherever feasible.

4 il d i i i (10 1 1 )

Energy Planning – for individual Significant Equipments'

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4 Daily energy deviation report review (10.1.1 B)

Sr. No. Operational controls

1 Checking of recirculation valve for passing, if found raise notification. Auto control loops to be kept in auto with optimum control

2 Equipment changeover schedule based on energy deviation report. . Optimization of equipment change over timing.

3 Monitoring of BFP parameters & BFP & its systems for any abnormality such as leakages, if found get it attended

Sr. No. Maintenance controls

1 Online maintenance / Ensuring tight closure of Recirculation valve. Servicing/ replacement of Recirculation valve as per requirement.

3 Overhauling of Equipment & its sub-systems (DTPIM/14M/01/SD/TM/01) . Servicing/ replacement of BFP cartridge as per requirement

5 Check energy meter for accurate measurement. with the help of standard energy meter. (DTPIM/14M/O2/CAL/IMT/01) 6 Carry out Current Signature Analysis of motor. 7 If any defect observed in signature analysis, carry out overhauling of motor. (DTPIM/14M/02/PM/MR/01)

Online Energy Monitoring System

4-20 mA 4-20 mA

PCR-1Process parameter

PCR-2Process parameter

RS485

RS485

FGDProcess parameter

SCANNER

4-20 mA

Compressor Room

Process parameter

SCANNER

4-20 mA

RS485

SCANNER SCANNER

RS485

24+16 channel 24+16 channel16 channel

16 channel

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ELANSERVER

6.6 KV SwgrU-1

6.6 KV SwgrU-2

RS485RS485

LAN

ELAN VIEW

Single Login

RS485

ELAN VIEW

Total 161 New meters installed (HT)

Continual Improvement

?

Holding And Sustaining The Improvement

Maintenance Control

Operational Control

Standard

O&M

Online Energy

Quality Tools

Conventional Approach

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Maintenance Control

Energy Management

16

O&M

Practices

gyMonitoring

system

Continual Process

MISImprovement plans / CA / PA

Technology

Review Of Daily Energy Deviation of HT Auxiliaries

Base Value:

Base value of individual auxiliary

is decided based on average

Operating Value:

Operating value is band decided by studying

Energy consumption pattern of individual HT

Operational Control:

There may be chances of power

ti t b hift f tiMaintenance Control:

Monitoring

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is decided based on average

value 1 year dataauxiliary throughout the year, which includes

the effect of coal quality variation, condenser

vacuum & other seasonal effects. Operators

have to run equipment in this standardized

operating range.

consumption to be shift from operating

range, because of un-optimized

condition, such as operation deviation,

valve passing, preventive

maintenance due, set points at

various parameters etc.

Maintenance Control:

This control action to be carried out, if power

consumption of individual auxiliary is goes

beyond operational control. This control

includes detail analysis of problems, which give

the solution in terms of new alternative

technology or repair, replacement.

Average power

consumption

rate as on date

Color Coding for

easy identification

of operating range% of APC of Individual

Auxiliary w. r. to

Generation & total APC

Building Energy Deviations

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4

O iD t

MR Review

Audit Cycle

Audit Plan

Schedule

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Opening Meeting

Audit

Closing Meeting

Document Updation

Audit Cycle

Closure of Observations/N

Cs

5

Auxiliary power reduction through installation of Seal Air Fan VFD

Mill Seal Air Fan Energy Consumption Saving

Without VFD application 122 KW

With VFD application 58 KW 64 KW

Few Examples - LT Auxiliaries

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Equipment No of Running Drives

Saving

Mill Seal Air Fan

4 ~ 221.76 KW

Tangible Benefits through Energy Conservation Projects

Sr. No. Name of ProjectCumulative Savings

(Rs. Lacs)

1 MV VFD for 6.6 KV CEP Motor – 1st in India 231

2 LV VFD for 415 V 120 KW Seal air fan motor 257

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3 LV VFD for 415 V 90 KW ACW pump motor 5.58

4 LV VFD at Ash Silo compressors 24.64

5 Colony drinking water & Plant service water pumps 11.87

6 Energy saving lighting projects 13.01

Total Cumulative Savings: 543.1 / Yr.

Saving of Coal, oil, water are intangible benefits

E l I l t T W k i E

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Employees Involvement, Team Work in Energy Conservation

Energy Management Cell “Awareness drive“

Training for all employees By Internal faculty By External Faculty

Employees Involvement & Team Work

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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

Employees Involvement -3L Programme with Bureau of

Energy Efficiency, Govt. of India since Last 04 years

P d t d

Employees Involvement & Team Work

ParticipantsParticipants

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Program conducted every year

since 2008

Every year 100+ participants are

present from, NTPC, Tata Power,

JSW Energy, Godrej etc.Site VisitPlant Visit

Quarterly News Letter On Energy Conservation for Employee Awareness

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6

DTPS Becomes

The First

Organization In The World

Certified For

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ISO 50001:2011(Energy Management System)

On

15-June-2011.

100.3 101.35 98.7 101.79 101.53 100.99 102.32 101 101.33

72.96 74.82 73.71 77.03 78.75 77.22 77.53 78 78.85

Plant Performance: Plant Load Factor (PLF)

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2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12

DTPS PLF (%) National Average (%)

32

The ratio of average load of the year to the installed capacity

96.84 96.88 94.71 96.79 96.7 96.31 97.18 96.48 97.48

81.93 82.93 81.78 83.72 84.76 85.05 85.1 86 87.12

Plant Performance : Availability

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2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12

DTPS Availability (%) National Average (%)

33

Ratio of Actual Running hours of the plant to Total hours in a year

2265 22612286 2278 2279

23002288 2282 2282

2500

Plant Performance : Heat Rate

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2261

2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12

DTPS Heat Rate (kcal/kWh) CEA Norm (kcal/kWh)

34

Total Energy required in kcal to generate 1 kWh of Energy

7.34 7.53 7.59 7.64 7.67 7.71 7.6 7.38 7.43

9.91

8.57 8.448.29 8.3

9.018.85 8.64 8.6

Plant Performance : Aux Power

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2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12

DTPS Aux Power (%) National Average (%)

35

Power consumed by various process auxiliaries like fans, Pumps, Blowers, Compressors etc to generate electricity.

1998 Quality Management System ISO 9001

1999 Environment Mangement System ISO 14001

2000 RAMCO ERP Package implementationRBNQA

2001 ISO upgradation SAP ECC

2002 Optic Ground wire (OPGW) & Backbone data highwayISO 27001

2003 HR SAP & Employee self service implementationSA 8000

2004 British Safety Council Audit6 Sigma-IIKM, OHSAS

2005 Benchmarking in CII

6 Sigma-I Mercer, CII 2006 Occupational Health and Safety Assessment

EnMSBS EN 16001:2009ISO 50001:2011

DTPS Milestones

IMS

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2005 Benchmarking in CII ,Series OHSAS 18001

2005 Six Sigma Drive IBSC

2006 Knowledge Management2005 HR Mercer study

HR SAP& ESS

2006 Six Sigma Drive IIOPGW

2007 Social Accountability SA 8000ISO

Upgrade

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

RAMCO

2008 Information Security Mangement system ISO 27001ISO 14001

2009 SAP ECC - In place of RAMCO

ISO 9001

2010 Ramkrishna Bajaj National Quality Award

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

2011 Energy Management Systems : BS EN

16001:2009 & upgraded to ISO 50001:2011

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7

Awards & Recognition

Received > 90 National and International awards in the category of -

Performance

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Environment

Safety

Corporate social responsibility

Experience and Constraints DTPS was the 1st Power Utility to go in for ISO certification.

Varity of Manpower

Executives - 200

Non Executives - 300

C L b 500

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Contract Labour – 500

It was a big challenge to train this vast variety of personnel on systems

Mapping of different processes/practices into a single integrated system

Initially huge quantity of paper work was involved which was then convertedinto soft in a phased manner.

All above constraints were overcome due to Team Work and dedication

Thank You

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Thank You

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8

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Environment ManagementConfidential Slide 44

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