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    On line Energy conservation System

    13 May,2010

    K.R. NerkarGM ( 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 MW of 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 ofoperational 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 powerto 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 [email protected]%

    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

    DATACONVERTOR

    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

    CABLE-5

    RS485

    RS485 RS485

    8 PORT PCI

    RS485 to RS232converter

    CABLE-6

    CABLE-4

    ELAN Network Connectivity:

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    Network ConnectivityPCR-1 PCR-2

    4-20 mA 4-20 mA

    ELAN

    SERVER

    6.6 KV Swgr

    U-1

    6.6 KV Swgr

    U-2

    RS485RS485

    ELAN

    VIEW

    ELAN

    VIEW

    LAN

    Single Login

    Process parameter Process parameter

    RS485RS485

    FGD

    Process parameter

    SCANNER

    4-20 mA

    Compressor

    RoomProcess parameter

    SCANNER

    4-20 mA

    RS485

    SCANNER SCANNER

    RS485

    24+16 channel 24+16 channel

    16 channel16 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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    Home page

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    Mimic.

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    Matrix

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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

    http://localhost/var/www/apps/conversion/tmp/scratch_4/Daily%20Energy%20Deviation%20Report-11-MAY-2010.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_4/Daily%20Energy%20Deviation%20Report-11-MAY-2010.pdf
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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

    KW

    Date

    Unit - 1 BFP 1A/1B Daywise energy consumptionBFP # 1A

    BFP # 1B

    252 KW /hr &

    Around 55000 unit saved

    Case :1

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    Case :2

    0.00

    100.00200.00

    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

    KW

    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

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    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

    Nos

    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

    Nos

    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

    MUnits

    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.