energy conserve tpc
TRANSCRIPT
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Energy ConservationTechniques
By
R. V. Ghate
Tata Power Company ,
Mumbai.
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Energy Conservation in PowerUtility
A power plant produces electrical energy andalso consumes a substantial amount ofenergy in the form of auxillary consumptionrequired for various plant equipments andservices
Management attitude -The top managementof the company is committed to, and has
the right attitude towards energyconservation.This is passed on to the theplant staff for ensuring success by Quality
Management Systems such as Tata BusinessExcellence Model and ISO
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Tata Power
Consistent achiever of Business Results.
Vision Statement-To be an Excellentand Efficient organisation.
Focus on enhancing Business andCustomer Orientation.
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Trombay Generating Station
Installed Capacity-1350 MW
ISO 9001:2000 Certified
Perception has changed to strike a
balance between reliability and energy
conservation
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Trombay Generating Station
Key Drivers for change-
Tata Business Excellence Model
(TBEM )-Leadership
-Customer and Market Focus-Process Management
-Business Results
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Energy Conservation in PowerUtility
Energy conservation in Power Utility isachieved mainly by-
1) Operating the equipments at maximum
efficiency.
2) Reduction of Auxiliary Power Consumption
Energy Conservation Measures adopted atTata Power Company Limited have taken
both these factors into consideration
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Factors affecting AuxiliaryConsumption
Unit Generation and Load Pattern
Operation of Plant Auxiliaries
Service auxiliary such as Illumination,
Air Conditioning etc
Unit startups / shutdowns
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Criteria used for adopting newenergy saving methods
Reliability
Sustainability
Method and Quality of verification
Investment required
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Energy Saving Techniques
Energy saving Techniques adopted are
classified in the following categories -
Design and Conceptual Stage Techniques developed through O&M
experience
Energy auditing by external agencies
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Design and Conceptual Stage
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Design and Conceptual Stage
Use of Steam Turbine driven BoilerFeed Pumps. ( 2 X 9 MW)
Pioneered concept of using Variable
Speed Drives for Large Motors by usingLCI drives for 4 X 2 MW ID Fan Motor
of 500MW Unit Use of Fluid Coupling for Motor Driven
Boiler Feed Pump
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Techniques developedthrough O&M Experience
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In addition to techniques adopted at designstage various initiatives have been taken overthe years to optimise the Auxiliary PowerConsumption. These are Monitoring of Aux Power Consumption
continuously improving the levels and accuracy
Formation of Cross Functional Teams to analyse
and optimise process Modification in Operation Strategy to achieve
Optimisation
Knowledge sharing and benchmarking with other
power utilities
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Snapshot of Aux Power ofUnit 5 at 500 MW11-07-02 11:00 hr
20.25
3.57
0
5
10
15
20
25
MW
TOTAL AUXILIARY CONSUMPTION
HT consLT cons
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0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
HT CONSUMPTION(kW)
ID FANS
CWP
FD FANS
PA FANS
CEP
FGD
AWP
SGWCP
MILLS
HTR DRIPPUMPACW
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0
50
100
150200
250
300
350
400
450
500
550
600650
700
750
LT CO NS UMPTION
(kW)
DMPT5B
SST5A
SST5CUST5B
CLPT5B
UST5A
VST
COMPT5BCWPT5A
COMPT5A
ESP5A
CLPT5A
ESPT5CCHPT5B
CWPT5B
ASHPT5A
ASHPT5B
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Prioritisation
Ideas and suggestions captured from
various initiatives are then prioritised
into three categories - Without investment
With minor investment With major investment
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Blue
Print
No
Date of
Idea
Ideas for which detailed blueprint were made
(Ideas indicated in blue were implemented)
Original
Idea by
Est Annual
Saving Rs
in Lakhs
Actual
saving Rs
in Lakhs
till 31.03.03
Status
1 Jul-99 Running of 3 nos SGWCP motors in Unit 5 instead of 4
motors
Mr APW
& team
53.00 7.57 Implemented since 19/02/2003
2 Jul-99 Running of 2 nos SGWCP motors in Unit 6 instead of 3
motors
Mr APW
& team
38.00 19.15 Implenented since 24/08/2002
3 Jul-02 Operation of Unit 5 ESP thyristor panel in Charge Ratio
mode
TRAC 45.30 Not found feasible in view of
increased coal firing.
4 Jul-02 Operation of fewer Coal Mills at Unit 5 with higher
loading
TRAC 42.00 Implemented since Sep 02.
Less coal mills operated with
higher loadings (presently
increased to 70% from 40%)
Actual savings could not be
captured.
5 Jul-02 Stopping of steam supply to Station B Tank Farm during
daytime
TRAC 117.00 63.88 Implemented since September
02.
6 Jul-02 Ship Receipt line one of the heat tracing circuit to beswitched Off during non-receipt
TRAC 2.62 Not found feasible.
7 Jul-02 Optimisation of Lighting of O&S Bldg and provision to
switch off during nightime to be made
TRAC 3.00 1.41 Implemented by SGA-28 since
Dec 02.
8 Sep-02 Changing and cleaning of LC Oil gun in Unit 6 to be
reviewed and optimised
R B More -
Opn B
2.39 Implemented since April 03.
Savings to be computed.
9 Sep-02 Plant area lighting in Unit 5 and 6 inside the building to
be switched off (except emergency lights)
V M
Dinkar -
Opn B
10.00 Implemented since April 03.
Savings to be computed.
10 Sep-02 Optimisation of operation of screen wash pumps at jetty M H Takle 2.34 Not found feasible
11 Sep-02 Saving service water used for ai r compressors BR Agaj 11.00 Not found feasible
12 Sep-02 Providing solenoid valve in cooling lines of blend oil
pumps
M H Takle No found cost effective.
13 Oct-02 Scavenging of oil guns to be optimised TRAC 39.00 Implemented since April 03.
Savings to be computed.
Actual Saving upto 31.03.03 (Items 1,2,5,7) Rs 92.01 LakhsSavings of Item no 4,8,9,13 are not included.
Savings upto 31.03.03Without Investment
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With minor investment Installation of Vacuum Pumps in Fly Ash
Removal system in place of Hydro ejectorbased Ash Water Pumps
Replacement of conventional Central Air
Conditioning System by Vapour Absorptionsystem to utilise waste steam
Improving efficiency of ElectrochlorinationPlant by regular acid cleaning
Replacement of ESP controllers by improvedversion having option of energy efficientmode
Use of energy efficient lighting system
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With major investment
Replacement of HP Turbine Module of
500 MW Unit
Proposal of Retrofitting of Constant
speed ID Fan motor with Variable speed
drives.
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Energy Audit by ExternalAgency
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External Audit
Detailed energy audit of TrombayThermal Power Station was conducted
by CII in Nov-Dec 2002 CII studied various main and sub
processes
Good energy conservation practices at
TPCL as per CIIs viewpoint are
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Encon at Tata Power
Installation of Load commutator invertors
(LCI) for ID fans
Optimisation of auxiliary consumption
during non-peak hours
Good excess air control in boilers Optimum loading of motors
Efficient lighting systems Optimum T in condensing water system Excellent control systems
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Some of the CII Proposals under
consideration forimplementation
Annual
Saving
Invest-
ment
required
Simple
Payback
period
Rs.Lakhs
Rs. Lakhs Months
Install next lower size impeller forthe FGD spray pumps
10.48 2.50 3
Install Variable Frequency Drive
for Hot-well make-up water pumpin Unit # 7 0.65 1.00 19
Avoid daytime lighting and install
transmission roofing sheets in LC
oil pressure filter area
0.34 0.20 7
Replace conventional chokes
with electronic chokes influorescent lamps
4.95 8.75 21
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Conclusion
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No Optimisation of Aux Power in Savings in MU1 ESP 0.241
2 FGD 0.236
3 FAA 0.302
4 Ash Plant 2.510
5 GR Fans 4.180
6 CW Pumps 2.460
7 SGWCPs 1.070Total 11.000
Total saving in FY 02 03 11 MUSaving Rs 2.23 Crores
Reduction in Cost 0.25 Paise / KWH
Savings due to Energy Conservation Measures for FY 02 -03
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TROM BAY AUXILIARY POWER CONSUM PTIO N TREND
9 .6
10 .2
9 .0
9 .8
7.8
7.4 7.4
5.05.4
5.2
5.7
5.25.4
5.0
3 .5 3 .5
4 .1 4 .2
3 .8 3 .73 .3
1.91.5
2 .1 2 .2
2 .63 .0
2 .7
4 .3 4 .34 .5
4 .84 .5 4 .6
4 .3
0 .0
2 .0
4 .0
6 .0
8 .0
10 .0
12 .0
9 6 -9 7 9 7-9 8 9 8 -9 9 9 9 -0 0 0 0 -0 1 0 1-0 2 0 2 -0 3
Y E A R
U N IT-4 U N IT-5 U N IT-6 U N IT-7 S TA TIO N
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3.66
4.84.54.5 4.6 4.3
7.057.4
6.52
3
4
5
6
7
8
9
1998-99 1999-00 2000-01 2001-02 2002-03IB Trombay SEB
Nat Avg Comptr NB
Graph 7.4.18 Trombay Aux. Cons. (%
BENCHMARKING OF UTILITIES
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Conclusion
Comparison of auxiliary power consumption ofThermal Power Utilities
India benchmark 6.33%
International benchmark 3.99% TPCL 4.33 %
TPCLs Auxiliary Power Consumption has been
acknowledged by CEA as one of the best in
India
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Thank You