6.igen_auxpower_fbd

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    ATAR SINGH

    Dy. DIRECTOR

    NPTI FARIDABAD

    ENERGY AUDIT OF AUXILIARY POWER CONSUMPTION

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    Energy Conservation in Power

    Utility

    Power plant produces electrical energy

    and also consumes a substantial amountof energy in the form of auxiliary

    consumption required for various plant

    equipments and services

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    Energy Conservation in Power Utility

    Achieved mainly by:

    Operating the equipments at maximum

    efficiency and

    Reduction of auxiliary Power

    consumption

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    The auxiliary power consumption (APC) varies from 6-14% ,

    depending on Size of plant ,use of TDBFP &age of plant

    The 500 MW units register the least APC, largely due to the

    incorporation of TDBFP.

    In some of the old 110 MW plants, APC consumption of 14%

    is also observed.

    Energy audit in a vast thermal power station (TPS) is better

    tackled when the thermal power plant operations are

    segregated into different sub-areas like:

    main plant auxiliaries, draft system (consisting of ID/FD/PAfans), feed water system [consisting of Boiler Fed Pumps

    (BFPs) / Condensate Extraction Pumps (CEPs), Circulating

    Water (CW) system-including Cooling Tower (CTs)], and off

    sites (consisting of coal handling plants, ash handling plants,

    air compressors, AC plants, station lightings etc.).

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    Auxiliary Power Consumption in ThermalPower Plant is major source of energyconsumption.

    During the financial year 2007-08 totalgeneration by coal plant was 488157.46 MUswith PLF 78.75.

    Auxiliary Power Consumption was 8.17%.

    If this APC gets reduced only by 0.17%then it is equivalent to fresh capacity additionof 120 MW without any investment.

    APC Scenario In India

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    Trombay Station of Tata Power Co. Ltd achieved lowest

    auxiliary power consumption (4.30%) in the country.

    Among Central Sector Stations, Talcher

    STPS of NTPC achieved the lowest auxiliary

    power consumption (5.34%).

    Among State Sector Stations, Chandrapur

    STPS of MAHAGENCO achieved the lowest

    auxiliary power consumption (7.40%).

    Among different capacity groups, the lowest

    auxiliary power consumption was 6.13% in 500

    MW group.

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    Requirement of works power with load

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    Factors Affecting Auxiliary Power

    Consumption

    - Unit Generation and load Pattern

    - Operation of Plant Auxiliaries

    - Service auxiliary such as Illumination , air

    conditioning

    - Unit Startup / shutdown

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    STEPS INVOLVED IN CONDUCTING

    ENERGY AUDIT

    Data collection

    Measurements & Observations

    Exploration for energy conservation

    measures

    Report preparation

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    STEPS INVOLVED IN CONDUCTING

    ENERGY AUDIT

    DATA COLLECTION

    Motor details required-

    ID code, Application, Make, Brief details of drivenequipment, Type of the Motor, Motor kW, Motor frame,

    Duty, Rated RPM, Rated p.f., Rated motor efficiency ,Motor

    make, Motor voltage, Rated current of motor, Year,

    Operating hours, Energy meter installed or Not , No. oftimes the motor is rewound

    Collect the above information for all motors to be covered inthe energy audit.

    Collect the motor efficiency curves

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    STEPS INVOLVED IN CONDUCTING

    ENERGY AUDIT

    Instruments Required-

    Power Analyzer: Used for measuring electrical parameters

    such as kW, kVA, pf, V, A and Hz Infrared pyrometer (In case any heating of cable or

    motor is suspected)

    Stroboscope: To measure the speed of the driven

    equipment and motor

    The above instruments can be used in addition to thecalibrated online / plant instruments

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    STEPS INVOLVED IN CONDUCTING

    ENERGY AUDIT

    Parameters to be measured-

    Energy consumption pattern of motors (daily / monthly/yearly consumption if available)

    Motor electrical parameters (kW, kVA, Pf, A, V, Hz,etc.) for individual motors

    Equipment operational details

    While conducting the measurement or performanceevaluation of any system simultaneously, the followingneed to be noted

    Unit load of the plant

    Date & time of measurement

    Instruments used for measurement

    Frequency of the measurement

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    STEPS INVOLVED IN CONDUCTING

    ENERGY AUDIT

    MEASUREMENTSAND OBSERVATIONS

    System detailsDetailed interactions with the plant personnel

    Energy consumption Pattern

    If the plant is monitoring the energy consumption, itis suggested to record the data and monitor the daily and

    monthly consumption pattern

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    STEPS INVOLVED IN CONDUCTING

    ENERGY AUDIT

    Equipment Annual

    Consumption

    MWH

    Average Load

    KW

    % of Total

    Generation

    % of total APC

    Air Compressors

    Coal Handling

    Plant

    Raw Water

    pumps

    DM water pumps

    A/C systems

    ESP

    Total

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    STEPS INVOLVED IN CONDUCTING

    ENERGY AUDIT

    Equipment Annual

    Consumption

    MWH

    Average Load

    KW

    % of Total

    Generation

    % of total APC

    Boiler Feed Pump

    Condensateextraction Pump

    CW Pumps

    ID Fans

    FD Fans

    PA Fans

    Mils

    CT Fans

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    M M M M M M

    BFP's 4 52 2 78 4 29 2 98 4 52 3 39 13 34 1 02

    P's 0 43 0 26 0 43 0 30 0 41 0 31 1 69 0 45 1 78 0 42 4 73 0 36

    FD's 0 35 0 22 0 31 0 22 0 30 0 23 1 21 0 29 1 26 0 29 3 43 0 26

    D's 2 26 1 38 2 08 1 44 2 34 1 51 8 18 2 24 7 25 1 51 22 12 1 69

    PA's 2 31 1 41 2 38 1 65 2 36 1 52 4 85 1 34 4 82 1 00 16 72 1 28

    oa M s 1 21 0 74 1 53 1 06 1 69 1 08 2 92 0 81 2 92 0 61 10 25 0 79

    P 0.57 0.35 0.57 0.39 0.57 0.36 1.11 0.31 1.11 0.23 3.92 0.30%

    AHP 0.47 0.29 0.47 0.33 0.47 0.30 0.52 0.14 0.52 0.11 2.45 0.19%Air

    Compressors

    0.42 0.26 0.42 0.29 0.42 0.27 0.38 0.11 0.38 0.08 2.04 0.16%

    O hers

    (CWPs

    RWPs DM

    Plan e c )

    3.89 2.37 4.21 2.92 4.11 2.64 10.28 2.84 10.22 2.13 32.70 2.50%

    a 16 42 10 06 16 67 11 58 17 18 11 61 31 14 8 53 30 26 6 38 111 70 8 56

    M

    Total Generation 1305.57 81.60 (of installed capacity)

    Au iliary Power Consumption 111.7 8.56 (ofactual generation)

    1 2 3 4 5 O e

    S E S INVOLVED IN OND ING ENERGY

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    Motor loading survey

    Details

    Rated Kw

    Rated Efficiency

    Rated Speed

    Measurement of parameters

    Power factor

    kVA KW drawn

    Frequency

    Harmonics

    Motor speed

    Driven Voltage

    Current

    Power equipment speed

    Driven equipment parameters

    Operational observations Transmission

    % loading on the motor

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    STEPS INVOLVED IN CONDUCTING

    ENERGY AUDIT

    Motor loading can be estimated by:

    % Loading =

    Input kW to motor x 100

    ---------------------------------------------------------------------

    Name plate kW /Name plate full load motor efficiency

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    STEPS INVOLVED IN CONDUCTING

    ENERGY AUDIT

    While conducting motor load survey,

    observations on machine side:

    parameters such as speed, load, pressure,temperature, etc., (as relevant) are also taken

    availability of load-end capacitors for PF

    correction & energy meters for monitoring isalso looked into for each case.

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    STEPS INVOLVED IN CONDUCTING

    ENERGY AUDIT

    Motor Rewinding History

    comparison of no load current and stator resistance

    per phase of a rewound motor with the original no-load

    current and stator resistance at the same voltage can be one

    of the indicators to assess the efficacy of rewinding.

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    STEPS INVOLVED IN CONDUCTING

    ENERGY AUDIT

    Power Factor Correction

    Induction motors are characterized by power factorsless than unity, leading to lesser efficiency (higher overall operating cost) associated with a plant'selectrical system.

    Capacitors connected in parallel (shunted) with themotor are typically used to improve the power factor

    The impacts of PF correction include reduced kVAdrawn , KVAR & current, reduction of transformer load,

    Reduction of cable losses, reduction of switch gear rating,

    Enhanced life of equipment

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    STEPS INVOLVED IN CONDUCTING

    ENERGY AUDIT

    EXPLORATION OF ENERGY CONSERVATION

    MEASURES

    Replacement / sizing of motors Opting forenergy efficient motors, Use of high efficiency

    motors,

    Use of energy efficient transmission

    Replacement of pulleys

    Direct coupling

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    STEPS INVOLVED IN CONDUCTING

    ENERGY AUDIT

    Analysis of observations

    o Loading pattern - % loading

    o Comments of power supply quality

    The BIS standards specify that a motor should becapable of delivering its rated output with a voltage

    variation of 6 % and frequency variation of 3 %. Motor

    o Identified motors with less than 50 % loading, 50 75 %

    loading, 75- 100 % loading, over 100 % loading

    o Identified motors with machine side losses / inefficiencieslike idle operations, throttling/damper operations

    o Motor load survey is aimed not only as a measure to

    identify motor efficiency areas but equally importantly, as a

    means to check combined efficiency of the motor, driven

    machine and controller

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    AUXILIARY POWER CONSUMPTION

    Operating only 4 mills instead of 5 mills in 210 MW units

    Shutting of CTs cells in conjunction with favorable weatherconditions and replacing existing aluminum cast and GRP blades

    with FRP

    avoiding idle running of conveyors & crushers

    incorporating soft starter - energy savers etc.

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    STRATEGY

    Variable frequency drive for PA Fans & ID Fans & CEPs

    Air in-leaks in draft system (O2 measurement) blanketing

    Replacement of inefficient BFPs as a part of R& M of the oldplants.

    Clipping of one stage from the multi stage BFPs to balance thepressure drop requirements between HP heaters, economizer andboiler drum etc.

    Use of higher pressure in the deareator to commensurately reduce

    BFP power consumption (reduced head developed) Running of two CEPs instead of 3 CEPs (3 CEPs are run to avoid

    tripping due to lower frequency in some of the power plants)

    Application of variable speed drives

    Installation of hydraulic turbine instead of feed regulating sectionto avoid pressure drops and to generate additional power

    AUXILIARY POWER CONSUMPTION

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