nava bharat ventures limited power division...make :kirloskar pneumatic co.ltd. model :tbdqm...
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Nava Bharat Ventures LimitedPower Division
Encon in compressed air systems
Best Practices
in
Power Plant
Encon in compressed air systems
Encon in compressed air systems
Encon in compressed air systems
Energy 80%
Capital 9%Maintenance 3%
Water 8%
Encon in compressed air systems
Encon in compressed air systems
A properly managed compressed air system can saveenergy, reduce maintenance, decrease downtime,increase production throughput, and improveproduct quality.
Encon in compressed air systems
Compressed air usage in Power Plants
Compressed air usage in Power Plant
Instrument Air
For valves and dampers operation
Service air
For Cleaning floors.
Ash handling systems
To convey ash from various ESP and Boilercollection points
Compressed air usage in Power Plant
De dusting systems
Reverse air for pulse jet systems, Bags cleaning
Fire Fighting systems
Auto operation of fire fighting Deluge valves
Miscellaneous
Tools
Compressors details at NBVL
Plant air compressors
Make :Kirloskar Pneumatic co.ltd.Model :TBDQMCapacity :20.34 M3/min(FAD)Total compressors :4 numbers
Compressors details at NBVL
Ash Handling Compressors Make :Chicago Pneumatic.Model :1 HX2-31x31
Capacity :20.34 M3/min(FAD)Dis. pressure : 4 Kg/sq.cm
Total compressors :4 numbers
Make :Kirloskar pneumatic co.ltd.Model :TBDQL
Capacity :38 M3/min(FAD)Dis. pressure : 4 Kg/sq.cm
Total compressors :3 numbers
Encon in compressed air systems
Initial condition
Main air compressors
2 numbers in operation
ENERGY : 4000 kWh/Day
AHP Air compressors
2 numbers CP Make
2 numbers kirloskar make
ENERGY :10,000 kWh/Day
Encon in compressed air systems
Measures taken towards energy conservation
Measures towards energy conservation
Compressor efficiency monitoring & improvement.
Pressure tuning of compressors.
Piping layoutmodifications to reduce pressuredrops.
Leakage points identification & arresting.
Measures towards energy conservation
Cleaning of bags with transvector nozzles.
Conversion of pneumatic appliances to electricaloperated.
Separation of Low pressure and high pressureapplications.
Measures towards energy conservation
Pressure regulators installation for Low pressure/Volume required equipments.
Adopted a systematic preventive maintenanceschedule with previous experience for allcompressors and its systems.
Training the employees for efficient operation andmaintenance of compressor systems.
Measures towards energy conservation
Usage of DP switches for jet pulse filters for reducing the wastage of air.
Avoided usage of high pressure air for cleaning.
(using Pressure 3.5 Kg/cm2 instead of 6.7 Kg/cm2).
Encon in compressed air systems
Major projects
Pressure tuning of compressors:
Major projects
• Earlier main air compressors were operating at8 kg/cm2 as per design conditions.
• During the in house energy consumptionmonitoring activities, it was proposed to reducethe operating pressures. System losses wereconsidered on higher side during initial designstage.
• Gradually operating pressure of compressors brought down to 6.5 Kg/cm2 , with out disturbing the plant operations.
Major projects
Major projects
Advantages:
Power savings are 340 kWh/day
Annual savings @Rs.2 2.48 Lakhs
• Investment Nil
Pay back period ---
Installation of Godrej control Air IFC Model GE-30
Major projects
Godrej make, “Intelligent flow controller”
was installed in compressed air system.
Major projects
Major projects
Advantages:
Isolates compressors from demand side peaks &troughs.
Reduces load period of compressors.
Saves compressed air energy through reduction
in artificial demand.
Major projects
Advantages:
Reduces leakage losses in the plant.
Ensures constant & stable air pressure at the end use point.
Operating the plant air system at optimum pressure.
Major projects
Advantages:
Power savings are 600 kWh/day
Annual savings observed @Rs.2 4.38 Lakhs
Investment 3.77 Lakhs
Pay back 11 months
Major projects
Separation of Low pressure and High pressure air:
• During the initial design stages both the courseash and fine ash was designed to convey witha pressure of 4 kg/cm2.
• Air required for ash conveying separated based on the density of ash.
•Course ash was conveyed with High pressure air of 4 kg/cm2
•Fine ash was conveyed with low pressure air of 2 kg/cm2
•For this purpose, compressors, air receiver tanks, and air conveying lines were separated.
Major projects
Separation of Low pressure and High pressure air
Both systems operating at different pressures
Major projects
Advantages:
Power savings are 2500 kWh/day
Annual savings observed @Rs.2 18 Lakhs
Investment 1 Lakhs
Pay back 1 Month
Major projects
Increase in energy consumption will be 2% forincrease of every 250 MMWC suction filter DP.
DP monitoring for compressors suction filters:
Major projects
To ensure the healthiness of the suction filters following steps were taken.
•Increased the frequency of suction filter cleaning.•On line monitoring provided for suction filter DP.•Replacing suction filters as per schedule.
Continuous monitoring arranged for suction filter DP
Major projects
Advantages:
Power savings are 80 kWh/day
Annual savings observed @Rs.2/kWh 0.6 Lakhs
Investment Nil
Pay back ---
Major projects
Cleaning floors with low pressure air :
•Avoided Cleaning of Equipment ,floors etc. with high pressure air 6 Kg/cm2 .
• Tapings are taken from ash handling Air lines which is 3.6 kg/cm2 for cleaning activities
•By using transvector nozzles.
Major projects
Advantages:
Power savings are 400 Units/day
Annual savings observed @Rs.2 2.90 Lakhs
Investment 0.30 Lakhs
Pay back 1 month
Activities taken up in ash handling system for reduction in air consumption:
1. Cleaning blow valve once in a week.
2.Replacing of orifice plates once in a month.
3.Ensuring cycle completing at vessel pressure at 0.35kg/cm2
4.Monitoring and arresting air leakages in the convey line.
Major projects
5.Phase density (solids to air ratio) is monitored and adjusted.
6.Identifiyng cause for line blocks and taking necessary preventive action.
7.Regular calibration of level Probes.
8.Running the system in probe mode.
Major projects
Advantages:
Power savings are 1500 Units/day
Annual savings observed @Rs.2 10.9 Lakhs
Investment 0.50 Lakhs
Pay back < 1 month
Other activities
Cleaning of bags with transvector nozzles:
Other activities
• DP across bag filters was maintained at 100-150MMWC by increasing purging cycle. Thus reducingenergy consumption.
Brief Tips
• Adopt a systematic preventive maintenance schedule with previous experience.
• Good housekeeping practices in compressors house.• Ensure condensation can be removed swiftly from
the distribution network, or does not occur. • Avoid delivering higher pressure to the entire plant
just to meet the requirements of one user.• Use high efficiency motors in place of standard motors.
Brief Tips
• Keep motor belts tight. Routinely check the compressor’s v-beltsfor proper tightness loose belts slip more frequently whichreduces compressor efficiency.
• Minimize system leaks.
Thank you
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