ENERGY CONSERVATION BLA Power Pvt. Ltd

PREPARD BY:

MANOJ KUMAR MAHARANASr. EngineerElectrical [O&M]BLA Power Pvt. Ltd

ENERGY CONSERVATION

Verification, Monitoring & Analysis of Use Of Energy including submission of Technical Report containing recommendation for improving Energy efficiency with cost benefit analysis & action plan to reduce Energy Consumption

Overall Plant Performance Indices

Turbine-Generator (TG) Heat Rate (Kcal/kwh)

Boiler Efficiency (%)

Auxiliary Power Consumption (%)

Approach for Reduction in Auxiliary Power Consumption

Maintenance Control

Operational Control

Energy Management

StandardO&M

Practices

Technology

Operational ControlEquipment Running HoursMaximizing Machine loading

factorStandardization of O&M

Practices through Energy Monitoring

Scheduled changeover of

Equipments as per energy deviation

Most energy efficient equipment run for maximum time

Predictive maintenance

Maintenance Control

Boiler Maintenance Arresting Steam leakages onlineDuct LeakagesDuct leakages of Air and Flue gas

arrested in every opportunity

Energy Management / Monitoring

Adoption of Energy Efficient Technology like

> V. F. D installation > On-line Monitoring System. MVAR Management Compressor Loading & Unloading. Service Auxiliaries such as illumination etc. Off Peak Hour CHP running. Switchyard Contact thermal observation to

avoid losses.

Block Diagram Of VFD

Rated Vs Actual Parameter

HT Motor Rated Current (Amp) Rated KW Rated RPM Actual

current (Amp) Actual KW % IGV / Valve

Running Hours

CWP-1 40 Amp 350 742 35.74 320.0 100 24CWP-2 40 Amp 350 742 37.32 337.0 100 24

BFP-1 156.5 Amp 1475 2986      ID FAN-1 57 Amp 520 993 47.52 442.9 34 24PA FAN-1 61 Amp 580 1492 50.69 492.6 14.5 24SA FAN-1 24 Amp 210 1488 18.6 167.4 45 24CWP-3 40 Amp 350 742      

BFP-2 156.5 Amp 1475 2986 130.2 1266.0 61 24ID FAN-2 57 Amp 520 993 47.11 442.0 24 24PA FAN-2 61 Amp 580 1492 52.55 516.6 17.7 24SA FAN-2 24 Amp 210 1488 18.36 164.8 41 24

Affinity Laws for Centrifugal Equipments

Assuming an Example:- A 520 Kw Fan motor operating 24 hrs/day,260 Days per Yr with

IGV 41% Open & assuming Rs. 2.50 per KWH. Now, Cost of running full speed: 520x24x260x2.50=81,12,000 per yr.

After ,VFD installation as for Operation requirement motor operates full speed(100%) for 12 hrs 80% speed for 12 hrs , with

IGV 100% open Now, Cost of running with VFD controlling the motor:As per affinity Law: Power α (N)3 520x(1)3x12x260x2.50=40,56,000 per yr 520x(0.8) 3x 12x260x2.50=20,76,672 per yr

Annual Saving : 81,12,000-(40,56,000+20,76,672)=19,79,328 per yr

Features of Energy Monitoring System Online monitoring.

Elimination of human error

Measurable outputs

Compares and identifies the efficient processes & equipment

Different type of reports like daily, monthly, quarterly or yearly can be generated .

Report generation and archiving is possible.

Date Time(Hours)

Total Generation

MWH

Plant Auxilary Consumption Aux. Consumption Constrction

PowerMWH

Actual Import

MWHActual Export

MWHMax. Demand

MW

Plant Utilization Factor %

(PUF)

Rev.BLA

Rev.SLDCNET CONSUMP.

[GEN+IMPORT]-EXPO

% [SAT+UAT] MWH

01-Aug-12 00 hr-24 hr 187.9102 45.8375 24.39 45.2517 0.5513 23.5986 165.6713 45.26 17.40 R-1 R-1

02-Aug-12 00 hr-24 hr 0.0000 23.7488 N.A. 23.6113 0.5941 23.7488 0.0000 0 0.00 R-0 R-0

03-Aug-12 00 hr-24 hr 0.0000 21.6696 N.A. 21.4206 0.5188 21.6696 0.0000 0 0.00 R-0 R-0

04-Aug-12 00 hr-24 hr 0.0000 21.4956 N.A. 21.3391 0.5363 21.4956 0.0000 0 0.00 R-0 R-0

05-Aug-12 00 hr-24 hr 0.0000 14.2380 N.A. 14.0888 0.5730 14.2380 0.0000 0 0.00 R-0 R-0

06-Aug-12 00 hr-24 hr 0.0000 15.1342 N.A. 14.9954 0.5521 15.1342 0.0000 0.0000 0.00 R-0 R-0

07-Aug-12 00 hr-24 hr 0.0000 32.9980 N.A. 32.3800 0.5507 32.9980 0.0000 0.0000 0.00 R-0 R-0

08-Aug-12 00 hr-24 hr 842.4411 129.4173 15.36 120.8759 0.9089 11.2774 724.3012 45.2900 78.00    

09-Aug-12 00 hr-24 hr 1053.6027 128.0791 12.16 126.6573 0.6385 0.0000 925.5236 45.3000 97.56 R-0 R-0

10-Aug-12 00 hr-24 hr 1048.5206 131.1004 12.50 126.6944 0.5255 0.0000 917.4202 45.3000 97.09 R-1 R-0

11-Aug-12 00 hr-24 hr 681.4661 118.9805 17.46 114.9359 0.5133 0.0000 562.4856 44.3062 63.10 R-0 R-0*

12-Aug-12 00 hr-24 hr 653.8169 116.5612 17.83 114.2477 0.6135 0.0000 537.2557 44.4200 60.54 R-0 R-0*

13-Aug-12 00 hr-24 hr 781.7993 117.7024 15.06 115.4830 0.3110 0.0000 664.0969 38.2202 72.39 R-2 R-2

14-Aug-12 00 hr-24 hr 615.2586 115.3600 18.75 113.0708 0.3113 16.1626 516.0612 40.5771 56.97 R-5 R-3

15-Aug-12 00 hr-24 hr 1007.4397 124.1597 12.32 121.4729 0.2356 0.0000 883.2800 45.3260 93.28 R-0 R-0

16-Aug-12 00 hr-24 hr 1029.1149 126.9881 12.34 121.9607 0.2285 0.0000 902.1268 45.2500 95.29 R-1 R-1

17-Aug-12 00 hr-24 hr 1053.6539 132.9391 12.62 124.5252 0.1753 0.0000 920.7148 45.3109 97.56 R-0 R-0

18-Aug-12 00 hr-24 hr 1045.7193 129.3059 12.37 125.5823 0.2040 0.0000 916.4134 45.3083 96.83 R-1 R-0

19-Aug-12 00 hr-24 hr 1010.5977 129.7518 12.84 124.9794 0.3614 0.0000 880.8459 45.3537 93.57 R-1 R-0

20-Aug-12 00 hr-24 hr 789.4197 124.4742 15.77 118.8999 0.3071 7.8875 672.8330 45.2680 73.09 R-5 R-5

21-Aug-12 00 hr-24 hr 900.6403 123.6932 13.73 122.4100 0.1602 0.0000 776.9471 45.2630 83.39 R-3 R-3

22-Aug-12 00 hr-24 hr 977.1813 131.1305 13.42 126.2523 0.3858 0.0000 846.0508 45.3839 90.48 R-2 R-223-Aug-12 00 hr-24 hr 962.7620 126.6416 13.15 125.4549 0.3496 0.0000 836.1204 45.3159 89.14    

24-Aug-12 00 hr-24 hr 1033.4637 135.8749 13.15 126.5416 0.3434 0.0000 897.5888 45.8472 95.69 R-0 R-025-Aug-12 00 hr-24 hr 797.6023 119.5955 14.99 115.3832 0.2501 16.4098 694.4166 45.2800 73.85 R-2 R-0

26-Aug-12 00 hr-24 hr 1078.7355 135.5828 12.57 129.2128 0.3438 0.0000 943.1527 45.2700 99.88 R-0 R-0

27-Aug-12 00 hr-24 hr 1078.9963 130.5336 12.10 128.8854 0.3392 0.0000 948.4627 45.2907 99.91 R-0 R-0

28-Aug-12 00 hr-24 hr 1080.3202 132.5365 12.27 128.9368 0.3303 0.0000 947.7837 45.3461 100.03 R-0 R-0

29-Aug-12 00 hr-24 hr 1084.6341 135.2539 12.47 128.2091 0.5166 0.0000 949.3805 45.3537 100.43 R-0 R-0

30-Aug-12 00 hr-24 hr 1066.1845 134.8903 12.65 127.9227 0.4280 0.0000 931.2942 45.2835 98.72 R-0 R-0

31-Aug-12 00 hr-24 hr 1084.0267 135.7393 12.52 128.5743 0.4198 0.0000 948.2874 45.3310 100.37 R-0 R-0

2-MVA X-former loading at 45 MW

TR-1 I/C TR-3 I/C TR-5 I/CDate KW KVA KVAR VOLT AMP KW KVA KVAR VOLT AMP KW KVA KVAR VOLT AMP

12 Nov 197 217.1 92.96 424 293 313.6 374 201.8 438 419 336.1 456 341 435 709.2

13 Nov 198.2 219.2 93.42 424 297 296.5 354.7 196.3 438.2 466.9 283.8 436.1 326.8 438.1 574

TR-2 I/C TR-4 I/C TR-6 I/CDate KW KVA KVAR VOLT AMP KW KVA KVAR VOLT AMP KW KVA KVAR VOLT AMP

12 Nov 142.4 166.2 85.37 425 225 220.6 274.7 163.2 440 359 410.4 494.5 267.3 420.3 630.3

13 Nov 141.6 165.3 84.97 424 224.4 217.6 271.8 162.2 440 357 364.1 486.1 264.4 420 560

2 MVA TR-1 = appox. 10.85 to 12 % Loading2 MVA TR-2 = appox. 08.31 to 10 % Loading2 MVA TR-3 = appox. 17.77 to 20 % Loading At Full Load 45 MW Generation2 MVA TR-4 = appox. 13.55 to 15 % Loading2 MVA TR-5 = appox. 21.85 to 25 % Loading2 MVA TR-6 = appox. 24.31 to 27 % Loading

Compressor AIR Compressed air is very energy intensive. Only 5% of

electrical energy is converted to useful energy. Use of compressed air for cleaning is rarely justified.

Ensure low temperature of inlet air. Increase in inlet air temperature by 3°C increases power consumption by 1%.

It should be examined whether air at lower pressure can be used in the process. Reduction in discharge pressure by 10% saves energy consumption upto 5%.

A leakage from a ½” diameter hole from a compressed air line working at a pressure of 6.5kg/cm2 can drain almost Rs. 2500 per day.

Reactive Power Management Quality of power supply judged from two factors i.e. voltage

and frequency.a. All generators having defined capability to generate reactive

/active power. If export of reactive power increases correspondingly reduces active power.

b. Transmission line generates the reactive power according to voltage level. Higher the voltage level will be the generation of reactive power.132 KV Lines - 0.05 MVAR/KM

MVAR balancing minimizes I2R Losses and increases capacity utilizations of transformers/lines.

BLA Power, Line Voltage Fluctuates frequently from 125.4 KV to 132KV to 140 KV So MVAR should maintain 25 MVAR to 20 MVAR to -8 MVAR

accordingly.

Energy Conservation From Service Auxiliaries

Lighting conservation done mainly in two Parts: a. Operational Area b. Office / Service Area & street Lighting

• Use of CFL lamp in place of GLS lamp can save energy upto 70%.

• Clean the lamps and fixtures regularly. Illumination levels fall by 20-30% due to collection of dust.

• Use of sodium vapour lamps for area lighting in place of mercury vapour lamps saves electricity upto 40%.

TG floor 15 mtrBEFORE AFTER

6.6 KV Switch Gear RoomBEFORE AFTER

Cable Cellar RoomBEFORE AFTER

Switchyard AreaBEFORE AFTER

DG Room & PMCC - 3BEFORE AFTER

WTP PlantBEFORE AFTER

WTP MCC & Cooling TowerBEFORE AFTER

Street LightBEFORE AFTER

Energy SavingLight Load Area Quantity watt Consu KW / Hr Running hr Daily Consum. In KWH Daily KWH Monthly KWH Yearly KWH

TG floor 15 mtr Before 12 250 3 12 36.027.0 810 9720

After 3 250 0.75 12 9.0

AC package Before 12 36 0.432 24 10.48.6 258 3096

After 2 36 0.072 24 1.7

6.6 KV Before 114 36 4.104 24 98.543.2 1296 15552

After 64 36 2.304 24 55.3

0 mtr TG floor Before 6 250 1.5 12 18.09.0 270 3240

After 3 250 0.75 12 9.0

PMCC-3 Before 64 36 2.304 12 27.614.7 441 5292

After 30 36 1.08 12 13.0

Compressor house

Before 14 250 3.5 12 42.033.0 990 11880

After 3 250 0.75 12 9.0

wtp mcc & Hall Before 40 250 10 12 120.075.0 2250 27000

After 15 250 3.75 12 45.0

cable celler room

Before 114 36 4.104 12 49.240.6 1218 14616

After 20 36 0.72 12 8.6

DG room Before 12 250 3 12 36.027.0 810 9720

After 3 250 0.75 12 9.0

DM plant MCC Before 36 36 1.296 12 15.66.9 207 2484

After 20 36 0.72 12 8.6

cooling Tower Before 8 250 2 12 24.024.0 720 8640

After 0 250 0 12 0.0

Swith Yard Before 24 400 9.6 12 115.2 115.2 3456 41472After 0 400 0 12 0.0

Net Saving per Day/Month/Yr In KWH 424.2 12726 152712

CHP Running in OFF Peak Hrs.

DATE A-Shift B-Shift C-Shift Total Running Hrs

15-Nov-12 2:40 2:10 3:10 8

16-Nov-12 0:30 4:15 2:20 7:30

17-Nov-12 2:20 3:30 2:15 8:05

18-Nov-12 2:37 3:15 3:00 8:52

19-Nov-12 0:50 3:00 2:50 6:40

20-Nov-12 2:40 2:50 2:05 7:35

21-Nov-12 1:25 4:50 2:35 8:50

Peak Hours – 18:00 Hrs to 22:00 Hrs

Forward Path

LT consumption metering &

monitoring Capacitor Bank Implementation. ESP Efficiency & monitoring. Target ≥ 10.5 %

Aux. Consumption

THANKS Prepared By:

MANOJ KUMAR MAHARANASr. EngineerElectrical [O&M]BLA Power Pvt. Ltd