mr gaurang bhatt-yantra

7/18/2019 Mr Gaurang Bhatt-Yantra

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Yantra Harvest Energy India

REDUCTION IN APC & ACHIEVING PAT

TARGET IN POWER PLANTS

BY

GAURANG BHATT

DIRECTOR TECHNICAL

YANTRA HARVEST ENERGY PVT LTD

CII GBC Forum Aug 2011

2


India Power Scenario

690

969

1392

1915

100

153

218

298

0

500

1000

1500

2000

2500

2006-07 10th

Plan End (actual)

2011-12 11th

Plan End

2016-17 12th

plan End

13th Plan

BU

0

50

100

150

200

250

300

350

GW

E ne rg y Re qu ir ement (BU) Pe ak Loa d (GW )

Indias Power requirement Scenario.

q 2009 Thermal Power Generation 81.6GW

q 64% Power Generation = Thermal

q Aux Power = 8-10% = 6-7GW

1.0% REDUCTION IN Aux Power = 800MW Power Saved in Current Generation .

= 1600MW considering Future !

Majority of Aux Power = MV Motor


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Approach for Setting Targets Depends upon the Objective of the

SchemeTotal Saving Objective = 8.97 MTOE

SN SectorNo. of

Identified DCs

Reported

Energy

Consumption

Share of

Consumptio

n

Apportioned

Energy

reduction

(MTOE) (%) (MTOE)

1 Power (Thermal) 145 104.14 63.44% 5.691

2 Iron & Steel 80 28.00 17.06% 1.530

3 Cement 65 11.87 7.23% 0.649

4 Fertilizers 28 7.86 4.79% 0.430

5 Aluminium 10 7.73 4.71% 0.422

7 Paper & pulp 31 2.09 1.27% 0.1146 Textile 85 1.62 0.99% 0.089

8 Chlor-Alkali 18 0.84 0.51% 0.046

Total 462 164.15 100% 8.97

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AUX POWER CONSUMPTION

95%

4%1%

HT MOTORLT MOTORMISC

q Induced Draft Fan ( ID Fan )

q Forced Draft Fan ( FD Fan )30%

q Primary Air Fan ( PA Fan )

q Circulating Water Pump ( CWP )

q Condensate Extraction Pumps ( CEP )

q Water Supply Pumps

q Boiler Feed Water Pump ( BFW Pump )

q High Pressure Boiler Feed Pump (PBFP )

30%

33%


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How to Become more Effecient

n Maximum capacity Utilization Lower energy consumption

n Changes in Production Process

n Use of Substitutes

n Using more Energy Efficient machine

n Recovery of energy that is wasted

n Use of Energy saving Devices

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TYPICAL AUXILIARY CONSUMPTION

FOR Thermal Power Plant OF 210MW

AUXILIARY QTY POWER IN

MW

Boiler Feed Pump 02 8.0MW

ID Fan 02 3.0MW

PA Fan 02 2.5MW

FD Fan 02 1.0MW

CW Pump 02 1.0MW

CE Pump 02 0.5MWCoal Handling Plant

And common aux.

Approximate 2.0MW

TOTAL ( 8.5% ) 18.0MW


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Expected Saving After

Installation of MV Drive to Aux

AUXILIARY Rated POWER

IN MW

Present

Consumption in

MW **

Expexted

Consumption with

MV Drive

TOTAL ( 8.5% ) 18.0MW 16.0 MW 12.0MW- 12.40MW

Expected saving = 3.6MW 4 MW

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2009-11

2007-2009

2006

a) Green Field Cement Plant

-21 nos .

b) Power Plants Retrofits 30 nos

- Lanco

- GMR

- CESC

- Kota TPS

- APGENCO

c) Metals 7 nos

- JSW Steel

- Hindalco .

d) Oil & Gas HPCLe) Introduction of Vector Control

Synchronous Transfer ,GPRS

Remote Diagnostics

a) Reliance Dahanu

3 nos .

CEP ,PA Fan.

b) Reliance Goa,Samalkot

2 nos .

c) Monnett Ispat CWP

2 nos .

d) APGENCO 1 noe) Cell Bypass Feature

Implemented .

a) Introduction .

Target Energy Saving 2011 15MW Majority Retrofit


ABOUT YANTRA- Energy Saving Solutions History

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Projects MW MWh/Yr Tons CO2

Completed 2.932 23456 25801

Under Execution 4.990 39920 43921

Target 2011-12 15

Savings


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System Desired Pressure & Flow are Imp Factors in Determining

Operating Point- especially in Power Plant Applications

Eg : Power Plant

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Centrifugal Load Affinity- Law


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Fan Systems Pumping Systems

Control Valve

VFD

Variable Fluid -Coupling

15-20% Effeciency Diff depending on

Speed .

Note : Above are Indicative Data

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Reliance Energy Dahanu

CEP Case Study

Data of CEP Before MV Drive Installation - DOL Operation

CEP-2A discharge pressure ( Head ) : 21.3 Kg/cm^2 Dearator Pressure : 6.9 Kg/cm^2 Flow : 640 T/hr Motor speed : 50 Hz = 1480 rpm Current : 59.2 Amp Power consumed by CEP without MV drive : 590KWH

Data of CEP after Installation of MV drive

CEP-2A discharge pressure : 16.5 Kg/cm^2

Dearator Pressure : 6.9 Kg/cm^2 Flow : 640 T/hr Motor Speed : 45.4 Hz = 1362 rpm Control Valve CD14 Position : 86% open Current : 40.4 Amp Power consumed by CEP with MV drive : 415KWH

TURN-KEY PROJECT SCOPE OF WORK

MV Drive with Bypass Panel

Civil room for MV drive system

Necessary Cooling arrangement

Cable Laying & Terminations

Interfacing with existing DCS system

ENERGY SAVING OF 150KW TO 175KW PER HOUR ACHIEVED ( 25% )

Dahanu Thermal Power Station CEP Process Flowchart



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APGENCO Vijayawada

ID Fan Case Study



Civil room for MV drive system

Necessary Cooling arrangement

Supply of All Cables



ENERGY SAVING OF 350KW PER HOUR PER FAN ACHIEVED ( 24% )

ID Fan Process FlowchartData of ID Fan Before MV Drive Installation - DOL Operation

Scoop Position : 60-65% Open Air Flow : 700 TPH Fan Speed : 640 rpm Suction Pressure : -130 mmwc Furnace Pressure : -10 to -15 mmwc Motor Speed : 50 Hz 740 rpm Current : 155 160 Amp Power Consumption without MV Drive : 1500 KW


Scoop Position : 100% Open Air Flow : 700 TPH Fan Speed : 640 rpm Suction Pressure : -130 mmwc Furnace Pressure : -10 to -15 mmwc Motor Speed : 43 Hz 645 rpm Current : 104 Amp Power Consumption using MV Drive : 1150 KW

Hydraulic Coupling kept in LineWith Scoop Tube position

At 100% open


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Reliance Energy SamalkotHPBFP Case Study



Supply of All Cables



ENERGY SAVING OF 300KW PER HOUR ACHIEVED ( 27% )

HPBFP Process Flowchart

Data of ID Fan Before MV Drive Installation - DOL Operation

HPBFP Discharge Pressure : 121 bar HPBFP Flow : 207 TPH HP ECO outlet Pressure : 86 bar HP Drum Pressure : 76 bar Operating Frequency : 50 Hz Power Consumption : 1100 KW


HPBFP Discharge Pressure : 90 bar HPBFP Flow : 207 TPH HP ECO outlet Pressure : 86 bar HP Drum Pressure : 76 bar Operating Frequency : 43 Hz Power Consumption : 800 KW

Samalkot Combined Cycle Plant



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ENERGY CONSUMPTION PATTERN

DATE I D FAN -1 (in KWH) N.O HEATS KWH / HEAT

16/09/2010 23520 29 811.034

18/09/2010 20920 26 804.615

20/09/2010 21740 28 776.428

22/09/2010 20770 28 741.785

24/09/2010 20960 25 838.444

26/09/2010 21280 26 818.461

28/09/2010 21720 29 748.965

01/10/2010 20400 29 703.44

03/10/2010 20570 29 709.310

05/10/2010 20100 27 744.444

07/10/2010 19230 25 769.2

09/10/2010 19060 27 705.925

10/10/2010 18390 27 681.111

11/10/2010 17320 26 666.153

12/10/2010 17230 26 662.692

13/10/2010 13720 26 527.692

14/10/2010 13870 26 533.46

15/10/2010 14800 27 548.148

16/10/2010 13500 25 540.00

17/10/2010 15330 26 589.615

DATE I D FAN -1 (in KWH) N.O HEATS KWH / HEAT

10/09/2010 22600 27 837.037

12/09/2010 23160 26 859.230

13/09/2010 21780 28 777.857

14/09/2010 23300 25 932

BEFORE INSTALLATION AFTER INSTALLATION

MODIFICATION # 2

MODIFICATION # 3

MODIFICATION # 5

MODIFICATION # 1

MODIFICATION # 4


INDEPTH PROCESS KNOWLEDGE HELPS TO MAXIMISE ENERGY SAVING

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Concept :


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Yantra Harvest : Total Value Added Approach

a)MV VFD System

b)Bypass System

c)Airconditioning System

d)Cable Laying /Cable Schedule

e)Civil Room VFD Panel

f)Interfacing /Tuning with DCS PLC

a) Post Warranty AMC

b) Service Spares at Plant Level during Warranty

Service Back up :

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Pay on Performance / Guaranteed Energy Basis .

Guaranteed Energy Basis Outright Payment

1) Energy Saving Guarantee Decided .

2) Payback within agreed limits

3) Price Negotiated

4) Penalty for non achievement decided .

Guaranteed Energy Basis Pay out of Saving

1) Energy Saving Guarantee Decided .

2) Payback within agreed limits

3) Finance Cost included

4) EMI Decided within stipulated time5) Penalty for non achievement decided .

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YANTRA HARVEST MV DRIVE


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YANTRA HARVEST MV DRIVE

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MV Drive Ratings

3300V Series:

Rated motor 300 ~ 7000KW

6600V Series:


11000V Series:



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Summary


q Popularity of MV Drives has substantially Increased in last 2-3 years

- Great Contribution to Energy Saving and Smart Equipment Control .

q Payback -2 years in many cases : Pay Out of Saving Schemes becoming Popular .

q Main Customers Requirements :

a) Assured Savings with Guarantees .

b) No Change in Process Conditions Infact Chance to Make it Better .

c) Smooth Changeover from existing systems .Turnkey Retrofits .

- No Effect of Harmonics / Effects on Existing Motors .

- Ease of Installation ,Ease of Use .

d) Fault Tolerance and Increased Availability through

- Advanced Cell Bypass Systems ( Multi Cell Technology )

- Suitable Bypass Systems to Existing Systems .

- Management of Grid Disturbances .

c) Long Term Assured Service Backups with AMCs

Recommended to Look at Performance Criterion rather than Topology

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ENERGY SAVED

IS

ENERGY GENERATED

mr gaurang bhatt-yantra

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