Operation & Maintenance Management at DTPS

Flow of Presentation

1. Company & Plant Profile2. Introduction3. Strategic Approach For Plant management –Through Effective

Maintenance3.1 Objectives for Maintenance3.2 Maintenance Organisation Structure 3.3 ERP for Maintenance Process3.4 Maintenance Monitoring3.5 Strategies for effective maintenance

4. Strategies For Continual Improvement5. New technologies adopted.6. Performance7. Conclusion8. Awards and Reorganization

1. Company & Plant Profile

REL- An Overview• Corporate history dating back to 1929• Among India’s top 25 private sector companies, on

all major financial parameters• Market capitalization of over Rs 13,100 Cr• Rank 3rd in Net worth among private sector

companies in India• Pool of 5765 strong dynamic and talented employees

India’s No.1 integrated private sector power company

Dahanu Thermal Power Station

• Well connected by Western Railway & National Highway No.–8.

• On the bank of Arabian Sea

• Surrounded by two natural creeks.

• Nearby Surya River dam (32 kms).

Dahanu

DTPS Geographical Location

Mumbai - Thane Map

Dahanu Road

DTPS

Plant Area in 1989

Plant Area in 1989

DTPS AS ON TODAY

Background

LAND :LAND :--

Total land 821.58 hectares

Land for Plant 351.58 hectares

Land for Ash disposal 370.00 hectares

Land for colony 100.00 hectares

Background

RESOURCE REQUIREMENTRESOURCE REQUIREMENT

• Total Coal - 2.1 Million tonns

• Wash coal - 1.7 Million tonns

• Imported coal - 0.4 Million tonns

• Sea Water (M3/Hr.) - 84,000

• Sweet Water (M3/Hr.) – 300

DTPS Features

• First power utility to be certified for ISO-9001 & 14001• First 250 MW Units in the Country.

• Concrete volute pumps for C.W.System.• Tallest Chimney in the country.• Four A.A.Q.M. Stations and one Mobile Van.• SCADA system for Transmission & Distribution.

DTPS Features• Advance Air Pollution Monitoring System.

• ERP System for Managing business process

• CCTV network

• Optical Fiber back bone Data Highway for office automation.

• Advance FFT analyzers for Condition Monitoring system.

• OPGW Optical Fiber Cable connectivity to Mumbai.

Business processes

• Operation• Maintenance • Purchase & Inventory• HRM• Finance & Account

SA

E M S OHS

Q M S

System approach

• Quality Management System ISO : 9001:2000• Environment Management System ISO : 14001:2004• Occupational Health and Safety Management System

OHSAS:18001:1999• Social Accountability Management System SA 8000

Best practices

• On-line process monitoring & control through Plant Monitoring System.

• ERP system for integrated management of Operation, Maintenance, Logistics, Purchase, Finance, HR etc.

• Coordinated Condition Monitoring

• Focused Energy Management

• Knowledge Management Portal

• Advanced Maintenance Management

• Systematic measurement , monitoring procedures with Corrective / Preventive actions

Best practices

Performance Monitoring

• Daily Planning Meeting

• Daily Generation Report

• Daily Maintenance Report

• Weekly Review of PM, WO pending for material & Safety work order compliance.

• Monthly Divisional Review

Best practices

• Equipment Criticality Analysis • Risk Assessment• Failure Mode & Effect analysis• Improvement projects through 6 sigma Initiatives

Bench-marking“ Make Indian Power Plants World Class “Under this objective CII has carried out benchmarking exercise“Best practices in Indian Thermal Power generating units”

• 18 Agencies participated in this exercise• 4 Teams visited 16 best performing power plants in the

country• 2 Teams visited Germany, Australia & Japan for global

benchmarking • 23 best practices identified out of which 4 are from REL

DTPS.

2. Introduction

2.0 Introduction

• At present country targeting 10% GDP growth.• Performance of power industry vital in terms of

– Economical– Reliable– Efficient

• The deficit in availability of quality power.• Resulting customer dissatisfaction • Many favorable changes by planners.• Private sector participation invited.• Resulting in Competition & buyers market• For sustenance supply of reliable & economical power is –must • Strategic approach DTPS For operation & maintenance Management

3.0 Strategic Approach For Plant Management Through Effective Maintenance

• To Improve quality of generation

• To maintain Highest reliability

• To attain Highest standard of safety

• To generate electricity at low cost

• To maximise utilization of existing assets

3.1Objectives for Maintenance

3.2Maintenance Organisation Structure

• Culture of customer – supplier relationship

• Maintenance planning as the administrator

– Prepare, maintain & manage the maintenance management system

– Measure & monitor maintenance performance indicators

– Maintenance as a customer for MTP

– Operation as the final customer

3.3 ERP for Maintenance Management system

• Defect Registration

• Permit to work system

• Defect monitoring/tracking to its logical conclusion

• Identification of repetitive defects

• History of work done.

• Reports on defects for shutdown

• Inventory Management

• Purchase process Management

• MIS generation

3.4 Maintenance Monitoring

• Daily planning meeting

– Generation & maintenance report

– Defect report

• Weekly review

– Preventive maintenance compliance

– Pending defects for material

• Monthly review

– QIP / EMP / SIP review

– CA / PA action review

– Shutdown work orders

– Objective targets

3.5Strategies for effective maintenance

• Short term strategies

• Long term strategies

• System approach

– Quality management system

– Environment management system

– Occupational Health & safety management system

– Social accountability system

3.5Strategies for effective maintenance-Methodologies

• Methodologies for maintenance

– Preventive maintenance

– Corrective maintenance

– Predictive maintenance

– Pro-active maintenance

– Maintenance prevention

3.5Strategies for effective maintenance -Preventive Maintenance

• Preventive maintenance done for equipments

– Subject to wear out

– Known failure patterns

– Defined frequency

– Schedule generation through ERP

– Standard operating guidelines (SOG)

3.5Strategies for effective maintenance -Corrective Maintenance

• Mainly for

– Minor defects

– Inconsequential equipments

– Redundant equipments

– Carried out through work requests

– Efforts for minimisation of Corrective maintenance

3.5Strategies for effective maintenance -Predictive Maintenance

• Use of latest technology for condition monitoring

– Vibration analysis

– Lubrication analysis

– Motor current signature analysis

– DGA

– Wear debris analysis

– Noise

– Magnetic particle inspection

– Thermography

3.5Strategies for effective maintenance -Proactive Maintenance

• Analytical tools & techniques

– Six Sigma approach

• Failure mode effect analysis

• Risk assessment

• Equipment criticality analysis

• Equipment reliability indices

3.5 Strategies for effective maintenance -Maintenance Prevention

• Most crucial

• Advanced techno-economic considerations

• Used for equipments with high down time & costly maintenance

• Replacement as the strategic tool

3.5 Strategies for effective maintenance – Planned Maintenance

“Failing to plan is planning to fail”• Assessment of Corrective & preventive maintenance activities

• Scope of work

– Pre outage survey

– Efficiency tests

– Up gradation of technology

• Beat the surprises

– Learn from past problems

– Knowledge sharing

• Selection & motivation of contracting agencies

– Incentive for timely completion

– Penalty for violation of safety

• Tools, tackles & moving equipments

– Upkeepment of tools prior to overhaul

– Back up arrangements

• Safety & environment

– Safe & hygienic work environment

• Use of information technology

– ERP

– Project management software

3.5 Strategies for effective maintenance – Planned Maintenance

Maintenance Management System

Maintenance Philosophy

Continual Improvement

Performance Indicators

Maintenance Process Structure

Analytical Tools Monitoring

Maintenance Planning & Administration

Maintenance Process Structure

Control &Instrumentation

Electrical Maintenance

CHP / AHP

Maintenance Planning

Operation

Civil Maintenance

CUSTOMER

Mechanical Maintenance CUSTOMER

CUSTOMER

CUSTOMER

Maintenance Setup

4. Strategies For Continual Improvement

4.0Strategies For Continual Improvement

• Benchmarking.

– Participation in survey with CII, NTPC

• Measurement of Cost of Poor Quality (COPQ).

– Identification of areas for improvement

• Break through Improvement by adopting Six Sigma.

– Reduction in cycle time for shutdown & start up process

– Reduction in incoming spare rejection

– Reduction in overhauling cycle time

• Participation in awards & competition.

5. New Technology Adopted

5.0 New Technology Adopted• Introduction surface coated tubes in boiler• Co-rocoating of CW & ACW pumps & impellers.• Super cleaning of lubricating oil of turbo generator• Quick erect type UP RIGHT scaffolding:• Provision of LDO firing at all the elevation:• Installation of Fabric expansion bellows:• Advance Remote metering system:• Installation of sq-300 field controller:• Disturbance/fault recorder for 220 KV system:• PID instrument for checking of porcelain insulators:• In house development of HT/LT motor test bench:• Pull cord indicator for CHP conveyer system:• CW pump house PLC:• Beck actuator:• IFM igniter to HE conversion:• Islanding of DTPS with Up gradation of SCADA system:• Up gradation of HMI system.

6.Performance

Availability (%)Plant Performance

Next Best Availability-250MW Unit : 97.04%National Availability (Average Thermal units) : 81.78%

96.84 96.88 94.71 96.79

03-04 04-05 05-06 06-07

Plant PerformanceHeat Rate (Kcal/Kwh)

Internal Target :2290 kCal/kWhNext Best Heat Rate(Avg.)- 250MW Unit : 2466 kcal/kWh

2268 2261 2286 2278

03-04 04-05 05-06 06-07

Plant Load Factor (%)

Next Best PLF-250MW Unit : 99.77%National PLF (Average Thermal units) : 73.6%

100.34 101.3598.70

101.79

03-04 04-05 05-06 06-07

Plant Performance

Next Best Aux Power-250MW Unit : 8.19%National Aux .Power (Average Thermal units) : 8.57%

Aux. Power Consumption (%)

7.647.597.537.34

03-04 04-05 05-06 06-07

Plant Performance

Sp. Oil Consumption (ml/kWH)

National Sp. Oil Consumption ( Avg for 250MW) : 1.37ml/KWH

0.11

0.130.18

0.11

03-04 04-05 05-06 06-07

Plant Performance

0.38

0.37

0.39

0.67

0.24

2002-03 2003-04 2004-05 2005-06 2006-07

DM MAKE UP (%)

7. CONCLUSION

7.0Conclusion

• Close monitoring of maintenance process

• System based approach

• Use of ERP for Maintenance process.

• Advanced quality tools like FMEA,equipment criticality analysis

• Benchmarking & identification best practices.

High degree of consistent reliable operation of plant canbe easily achieved by adopting strategic approach for maintenance of assets

8.0 Awards & Recognition

Environmental Awards

1999 “Environment Performance Award” for standing first amongst the power plants of below 700 MW category awarded by Council of Power Utilities as a part of Thermal Centenary Celebration-1999.

2000 “Millenium Business Award” for Environmental Achievement” by United Nations and International Chamber of Commerce At BUDAPEST

2000 Federation of Indian Chambers of Commerce & Industry (FICCI) Award 1999-2000 in the field of environment conservation and pollution control.

Environmental Awards2000 “Indo-German Award for Environmental

Excellence” by Greentech Foundation at New Delhi on 17th January 2001.

2001 “Indo-German Award for Environmental Excellence” by Greentech Foundation at New Delhi in December 2001.

2004 Final Nominee for TERI Corporate Environmental Award.

2004 “Award for Environmental Excellence” by Greentech Foundation at Goa in October 2005.

2005 “Award for Environmental Excellence” by Greentech Foundation at Goa in October 2005.

2005 Nominated for TERI Corporate Environmental Award.

1999 “National Safety Council-Maharashtra Chapter” for longest accident free period during 1999

2001 “Safety Award-2001” by “National Safety Council of India”for good performance in OSH for 1998 to 2000

Safety Awards

2004 “National Safety Award-2003” Govt. of India.

2004 National Safety Council-Maharashtra Chapter

2004 “Four Stars” Ranking by British Safety Council, UK for Occupational Health and Safety Management System

2005 “National Safety Council-Maharashtra Chapter”for longest accident free period during 2004

2005 “National Safety Council-Maharashtra Chapter”for lowest accident frequency period during 2004

2006 “National Safety Council-Maharashtra Chapter”for lowest accident frequency period during 2005

Safety Awards

2004 QIMPRO Benchmark Award by the QIMPRO Foundation in the “Service Category”

2004 Vishwakarma Rashtriya PuraskarThree awards to eight employees from DTPS by Ministry of Labour and Employment, Govt. of India

Performance Awards

2004 Top Plant of World by platts Power Magazine.

Performance Awards

2005 CII National Award for Energy Management.

2005 CII National Award For Water Management.

2005 1st Prize for Excellence in Energy Conservation & Management in

TPS sector for year 2005 by MEDA.

2006 CII National Award for Energy Management.

2006 First prize National Award for Meritorious Performance by Central

Electricity Authority (CEA), for Excellent PERFORMANCE in the year

2004-2005

2006 International Quality Crown Award in the Gold Category by BID

(BUSINESS Initiative Directions, Spain.)

2006 “CII National Water Management Award - Excellence Water Efficient Unit, Excellence Water Efficient Unit (Beyond the Fence), Most useful presentation.