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On line Energy conservation System

13 May,2010

K.R. Nerkar GM ( Electrical)

Content

  • Introduction

  • Aux power at DTPS

  • Aux power reduction Strategy

  • EMS at DTPS

  • Application

  • Benefits

Company Profile Reliance Energy Limited

  • 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 MW of power.

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.

DTPS Mission

Excellence in Generation of Electricity to :

  • 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.

Auxiliary power consumption at DTPS

  • Total Plant Generation

  • Auxiliary Power consumption

520MW

39.5MW@7.6%

  • HT Motor consumption

37.50MW

  • LT Motor consumption

1.50MW

  • Misc. consumption

0.50MW

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
Measure
Detect Control
Detect
Control

On Line EMS at

DTPS

Objective Of EMS

The main objectives of EMS are :

  • 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

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.

Network Connectivity

eLAN ® DATA DATA CONVERTOR CONVERTOR
eLAN ®
DATA
DATA
CONVERTOR
CONVERTOR
Network Connectivity eLAN ® DATA DATA CONVERTOR CONVERTOR EM-6400 MULTIFUNCTION METERS

EM-6400 MULTIFUNCTION METERS

Network Connectivity

PCR-2 Back Up Desk

ELAN Network Connectivity:

ELAN

SERVER

Network Connectivity PCR-2 Back Up Desk ELAN Network Connectivity: ELAN SERVER 24 channel Process Scanner PSC-2

24 channel Process Scanner

PSC-2

Panel CWA-12

8 PORT PCI

RS485 CABLE-6 RS485 RS485 2SB CABLE-4 CABLE-5
RS485
CABLE-6
RS485
RS485
2SB
CABLE-4
CABLE-5

OSC

RS485 to RS232 converter

2PA

Network Connectivity PCR-2 Back Up Desk ELAN Network Connectivity: ELAN SERVER 24 channel Process Scanner PSC-2

OPB

OSD 2SC 2SA
OSD
2SC
2SA

Network Connectivity

PCR-1 PCR-2 Compressor Process parameter Process parameter Room FGD Process parameter Process parameter 4-20 mA 4-20
PCR-1
PCR-2
Compressor
Process parameter
Process parameter
Room
FGD
Process parameter
Process parameter
4-20 mA
4-20 mA
4-20 mA
16 channel
24+16 channel
SCANNER
24+16 channel
SCANNER
4-20 mA
16 channel
SCANNER
SCANNER
RS485
RS485
RS485
RS485
ELAN
ELAN
VIEW
SERVER
LAN
ELAN
RS485
VIEW
RS485
Single Login
6.6 KV Swgr
6.6 KV Swgr
U-1
U-2

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.

Home page

Home page

Mimic.

Mimic .

Matrix

Matrix

Trends

This Screen shows Trend (of real time data of every individual feeder (Flow, pressure, Active power).

This Screen shows Trend (of real time data of every individual feeder (Flow, pressure, Active power).

Dashboard

Dashboard

History

History

History

History

History

History

History

History Trend history for one month

Trend history for one month

Alarm

Alarm

Reports

Reports

SLD

SLD

View Reports

View Reports Feeder name

Feeder name

View Reports Feeder name
View Reports Feeder name

Utility

Utility

Application

A. Data Monitoring

  • 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.

Application

B. Strategy for operation of equipment

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.

Case :1

BFP # 1A Unit - 1 BFP 1A/1B Daywise energy consumption BFP # 1B 8000.00 7500.00
BFP # 1A
Unit - 1 BFP 1A/1B Daywise energy consumption
BFP # 1B
8000.00
7500.00
7000.00
6500.00
6000.00
5500.00
5000.00
4500.00
4000.00
3500.00
252 KW /hr &
Around 55000 unit saved
3000.00
2500.00
2000.00
1500.00
1000.00
500.00
0.00
Date
KW

Case :2

700.00 Mill # 1AB Mill # 1CD Unit-1 Mill 1AB/1CD/1EF Daily consumption Mill # 1EF KW
700.00
Mill # 1AB
Mill # 1CD
Unit-1 Mill 1AB/1CD/1EF Daily consumption
Mill # 1EF
KW
100.00
200.00
300.00
400.00
500.00
600.00
0.00
800.00
900.00
1000.00
1100.00
1200.00
1300.00
1400.00
1500.00
Around 150 KW /hr saving done during this month.
( 94173 units )
700.00 Mill # 1AB Mill # 1CD Unit-1 Mill 1AB/1CD/1EF Daily consumption Mill # 1EF KW

Date

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

Predictive maintenance

BFP Changeover

20 19 18 18 16 14 13 12 12 10 2008-09 8 2009-10 6 4 2
20
19
18
18
16
14
13
12
12
10
2008-09
8
2009-10
6
4
2
0
Unit 1
Unit 2
Nos

Unit

Predictive Maintenance

Mill changeover

15 Unit 1 Unit 2 Nos 2009-10 2008-09 0 5 10 35 15 18 20 23
15
Unit 1
Unit 2
Nos
2009-10
2008-09
0
5
10
35
15
18
20
23
25
30
30

Unit no

Predictive Maintenance

Generation Loss due to Mill Changeover

0.7 0.648 0.6 0.5 0.428 0.4 0.3 0.2 0.1 0.047 0 2007-08 2008-09 2009-10 M Units
0.7
0.648
0.6
0.5
0.428
0.4
0.3
0.2
0.1
0.047
0
2007-08
2008-09
2009-10
M Units

Gen loss

Year

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

Software

  • Make

  • Data cable

  • Converter kit

: Conzerve Limited

: EIA Industrial RS-485 cable, 22 AWG (7x30) stranded tinned copper. Twisted pairs. Overall standard tinned copper drain wire.

: 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

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

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.