On line Energy conservation System

13 May,2010
K.R. Nerkar
GM ( Electrical)
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Content
Introduction
Aux power at DTPS
Aux power reduction Strategy
EMS at DTPS
Application
Benefits
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Largest integrated private utility company in power sector
Involved in generation, transmission, distribution, trading of electricity and
EPC business related to power projects
Supplies electricity to 2 out of 3 Mumbai consumers and 1 out of 2 Delhi
consumers
Caters to 25 million people in Mumbai, Delhi and Orissa.
Distributes > 28 Billion units of electricity .
Generate > 900 MWof power.
Company Profile Reliance Energy Limited
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DTPS Vision
To be amongst the world class power plants, delivering reliable
generation of electricity at competitive costs, with international
standards of environmental emission.
To set new benchmarks in standards of performance through the
pursuit of operational and financial excellence.
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DTPS Mission
Attain global best practices and become a world-class power plant.
Provide affordable, reliable and clean power to millions of customers.
Achieve excellence in service, quality, reliability, safety and customer care.
Work with vigor, dedication and innovation with total customer satisfaction
as the ultimate goal.
Consistently achieve high growth with the highest levels of productivity.
Be a technology driven, efficient and financially sound organization.
Promote a work culture that fosters individual growth, team spirit and
creativity to overcome challenges and attain goals.
Encourage ideas, talent and value systems.
Uphold the guiding principles of trust, integrity and transparency in all
aspects of interactions and dealings.
Excellence in Generation of Electricity to :
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Total Plant Generation 520MW
Auxiliary Power consumption 39.5MW@7.6%
HT Motor consumption 37.50MW
LT Motor consumption 1.50MW
Misc. consumption 0.50MW
Auxiliary power consumption at DTPS
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Aux. Power consumption reduction strategy
DTPS having 16 no's Energy auditors.
DTPS O&M has internal energy audit schedule through system.
Joint Energy auditing carried out for all utilities by CII & DTPS
Recommendations out of audit report are reviewed monthly.
Measure
Detect Control
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On Line EMS at
DTPS
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Objective Of EMS
Online monitoring of auxiliary wise energy consumption.
To optimize the power consumption.
Benchmarking energy consumption
To identify the inefficient equipment operation
To provide useful input for Predictive maintenance decisions
The main objectives of EMS are :
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Components of EMS system
Energy meter class 1 model -6400 (135)
Analog card for the process parameters
Data converter
Communication cable
Dedicated PC and printer
Conzerve Energy management software eLAN customized to DTPS.
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Network Connectivity
eLAN

DATA
CONVERTOR
DATA
CONVERTOR
EM-6400 MULTIFUNCTION METERS
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Network Connectivity
ELAN
SERVER
PCR-2 Back Up Desk
24 channel
Process Scanner
PSC-2
Panel CWA-12
OSC
OSD 2SC
2SB
2SA
2PA
OPB
C
A
B
L
E
-
5
RS485
RS485
RS485
8 PORT PCI
RS485 to RS232
converter
CABLE-6
C
A
B
L
E
-
4
ELAN Network Connectivity:
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Network Connectivity
PCR-1 PCR-2
4-20 mA 4-20 mA
ELAN
SERVER
6.6 KV Swgr
U-1
6.6 KV Swgr
U-2
RS485
RS485
ELAN
VIEW
ELAN
VIEW
LAN
Single Login
Process parameter Process parameter
RS485
RS485
FGD
Process parameter
SCANNER
4-20 mA
Compressor
Room
Process parameter
SCANNER
4-20 mA
RS485
SCANNER SCANNER
RS485
24+16 channel 24+16 channel
16 channel
16 channel
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Display Available
Home page
Mimic : Can view individual equipment parameters.
Matrix : Group of equipment Swgr wise, application wise can be viewed.
Trends : This Screen shows of real time data of every individual feeder
Dashboard : At a glance provide the data regarding lighting, HVAC etc.
History :To monitor trend of the all feeder with selected parameters and time.
Alarm : Initiate the alarm when the value cross the max. or min. value.
Reports: Hourly, daily, monthly consumption report are available.
SLD : Single line diagram with parameters can be viewed.
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15 15
Home page
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Mimic.
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Matrix
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19
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Trends
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This Screen shows Trend (of real time data of every individual feeder (Flow, pressure, Active power).
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Dashboard
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History
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History
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History
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Trend history
for one month
History
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Alarm
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Reports
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SLD
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View Reports
Feeder name
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Utility
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Application
Electrical parameters like
Current,
Voltage,
Power
Freq.
Power factor
KWH
Process parameters like flow ,pressure etc
Specific energy consumption and comparison
Historical data equipment wise.
A. Data Monitoring
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1 .Scheduled operation
Daily Auxiliary load profile helps to reschedule the changeover operation
Ex. Mill changeover, BFP changeover by comparing power consumption.
Priority base scheduling peak/off-peak hours
Ex. operating the coal bunkering, Hydrogen/ DM plant during off-peak hours.
2. Enhancing the efficient operation by
Identifying the inefficient equipment.
Operating the most efficient equipment comparing the power consumption.
B. Strategy for operation of equipment
Application
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0.00
500.00
1000.00
1500.00
2000.00
2500.00
3000.00
3500.00
4000.00
4500.00
5000.00
5500.00
6000.00
6500.00
7000.00
7500.00
8000.00
K
W
Date
Unit - 1 BFP 1A/1B Daywise energy consumption
BFP # 1A
BFP # 1B
252 KW /hr &
Around 55000 unit saved
Case :1
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Case :2
0.00
100.00
200.00
300.00
400.00
500.00
600.00
700.00
800.00
900.00
1000.00
1100.00
1200.00
1300.00
1400.00
1500.00
K
W
Date
Unit-1 Mill 1AB/1CD/1EF Daily consumption
Mill # 1AB
Mill # 1CD
Mill # 1EF
Around 150 KW /hr saving done during this month.
( 94173 units )
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Benefits
Elimination of human error in measurement
Benchmarking energy consumption
Different type of reports like daily, monthly, quarterly or yearly can be
generated automatically.
Enhanced the efficient equipment operation
Useful Data available for Predictive maintenance decision.
Availability of online data of all electrical and process at single point which
is very useful for Energy audit.
Measurement and verification
Thank you
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Predictive maintenance
18
19
13
12
0
2
4
6
8
10
12
14
16
18
20
Unit 1 Unit 2
N
o
s
Unit
BFP Changeover
2008-09
2009-10
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Predictive Maintenance
30
23
15
18
0
5
10
15
20
25
30
35
Unit 1 Unit 2
N
o
s
Unit no
Mill changeover
2008-09
2009-10
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Predictive Maintenance
0.428
0.648
0.047
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
2007-08 2008-09 2009-10
M

U
n
i
t
s
Year
Generation Loss due to Mill Changeover
Gen loss
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Multi Function Meter
Make : M/s. Conzerv Limited
Model : EM 6400
Measurement parameters : All electrical parameters
Accuracy class : 1.0 class
Auxiliary power supply : 44-300V AC/DC
Display : 3 lines,4 digits LED
Dimensions : 92 X 92 mm
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Software
Make : Conzerve Limited
Data cable : EIA Industrial RS-485 cable, 22 AWG (7x30) stranded tinned
copper. Twisted pairs. Overall standard tinned copper drain wire.
Converter kit : 2W/4W operation Half Duplex ,Data range 064Kbps,
Communication speed for distance upto 4000 ft 64Kbps,
Termination resistor can be enabled/disabled, Surge
suppression & Fuse protection provided, Optical isolation
as protection from ground loops
Data repeater : 05 Nos.
PC for EMS : 02 Nos
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No. of meters installed
Meters installed on HT feeders : 99
Meters installed on LT feeders : 36
Meters installed on lighting feeders in plant area : 19
Meters installed in colony : 7
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Benefits
Availability of online monitoring of all electrical and process parameters of
critical auxiliary at single point which is very useful in Energy audit.
Elimination of human error in measurement due to real time energy management.
Measurable outputs in terms of area wise, equipment wise energy consumption
and aux power measurement is possible.
Compares and identifies the efficient processes & equipment which will be
helpful in taking important operational and maintenance decisions.
Report generation and archiving is possible.
Different type of reports like daily, monthly, quarterly or yearly can be generated
automatically.