Smart Energy Management 1 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential Smart Energy Management 1Measure 2Detect 3Control Benefits of IT in Power Plants Presented by: R Bhatia, GM Conzerv Systems
Smart Energy Management1 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Smart Energy Management
1Measure2Detect3Control
Benefits of IT in Power Plants
Presented by: R Bhatia, GM Conzerv Systems
Smart Energy Management2 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Requirement of Energy Management in Utilities
Improvement in PLFReduction in APCReduction in T&D losses
> Improvement in Accountabilty> Improvement in Power Quality
>> Power Factor>> Harmonics
Smart Energy Management3 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Requirement of Energy Management in Utilities – Ways to Improve
Energy Audit followed by implementation of recommendations.Energy Management System: By taking action on shortcomings indicated and reports generated.
Smart Energy Management4 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
On Line Monitoring System
Smart Energy Management5 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Instrumentation for Measurement
Smart Energy Management6 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Stand-Alone Meters are not enough
Generally provide only Raw Data
Readings cannot be correlated on-line, in Real-Time
Difficult to relate Energy Consumption in Auxiliaries to Generation
Optimisation requires On-Line Data. Difficult to achieve with Stand-Alone Instruments.
Smart Energy Management7 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
EMS SYSTEM
EM 6000 Series RS 485-RS232
CONVERTORDATA
CONVERTOR
LAN NETWORK HUB
ETHERNET
CONVERTOREM 3000 Series
DATA CONVERTOR
CONZERV eLAN®
Smart Energy Management8 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Energy Management System Applications
Predictive MaintenanceRoot Cause AnalysisPower QualityMeasurement and VerificationCost AllocationSmart Power ManagementEnergy Resource PlanningEnergy BalancingBreaker Status – remote monitoringAutomated Energy Billing System for Townships
Smart Energy Management9 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Conzerv in NTPC & GencosOn Line Systems>> Singrauli, Tanda, Dadri, Vindhyachal,Ramagundam,Kawas, Jhanor, Kahalgaon, OPGC (Jharsugada), Reliance Dahanu
NTPC corporate has made On Line Monitoring standard in new power plants alsoEnergy Audits>> Dadri (twice), Talcher, Faridabad, Kayamkulam,Auraiya,Singrauli, WBWDC plants Bakreshwar and Santaldih
Smart Energy Management10 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
About Ourselves
l Incorporated in February 1988l HQ and Unit I at Electronic City, Bangalore,
India. Unit-II at Daman, l Specialized in Electrical Energy Management
& Conservation for Industrial and Commercial Complexes
l A Total Electrical solution providerl To help our customers improve their
performance through reducing energy costs
Smart Energy Management11 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Spectrum of Activities
MetersMetersIndustrial, Industrial, RevenueRevenue
SoftwareSoftware NetNet--workingworking
Training On Training On Energy Energy
EfficiencyEfficiency
Sales & Sales & Support Support NetworkNetwork
PF PF ControlControl
Demand Demand ControlControl
Energy Energy AuditsAudits
Generator Generator SynchSynch
Remote Remote MonitoringMonitoring
Harmonic Harmonic Analysis, Analysis, Reactors, Reactors,
FiltersFilters
Generator Generator AMFAMF
Smart Energy Management12 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential12 25-Dec-08 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Smart Energy Management13 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential13 25-Dec-08
Outsource the Energy Management and Energy Accounting function
On-line Energy Audits
Periodic reports with recommendations for energy cost reduction
The Conzerv Way2SaveThe Conzerv Way2SaveTM–– Energy Improvement ProgramEnergy Improvement Program
Smart Energy Management14 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
How EIP works….
14 25-Dec-08 © Copyright 1986-2005, ConZerv Proprietary & Confidential
User EMS PC Conzerv Server
Broadband
Online Analysis of Plant Data
Smart Energy Management15 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential15 25-Dec-08 © Copyright 1986-2005, ConZerv Proprietary & Confidential
CONZERV HO
ISP(Internet Service Provider)
GSM/CDMA TOWER
GSM/CDMA MODEM
GSM /CDMA MODEM
DSL CONNECTION
EMS PC
EMS PC
EMS PC
Fig: Schematic diagram EIP (Way to Save)Fig: Schematic diagram EIP (Way to Save)
Online DataAnalysis
Smart Energy Management16 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
THERMAL POWER STATIONS
ENERGY CONSUMPTION IN AUXILIARY EQUIPMENT
Smart Energy Management17 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
THERMAL STATIONSAUXILIARIES MAY CONSUME 6%TO 14% OF TOTAL GENERATIONEACH ONE PERCENT REDUCTION CAN RESULT IN SAVINGS OF CRORES ANNUALLY AND RELEASE A FEW MEGAWATTS OF GENERATIONNO REDUCTION POSSIBLE UNLESS CONSUMPTION IN EACH MEASURED
Smart Energy Management18 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
THERMAL AUXILIARIESNO EXISTING SYSTEM OF MEASUREMENT OF ENERGY CONSUMPTION IN AUXILIARIESAUXILIARY CONSUMPTION CALCULATED FROM DIFFERENCE OF POWER GENERATED AND POWER TRANSMITTED
Smart Energy Management19 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
THERMAL AUXILIARIESAS NO DIRECT MEASUREMENT IS BEING DONE
APC CALCULATION IS APPROXIMATEEFFICIENCY OF EACH EQUIPMENT IS UNAVAILABLELOSS OF EFFICIENCY DUE TO TECHNICAL / MAINTENANCE REASON CANNOT BE ASCERTAINED
Smart Energy Management20 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
THERMAL AUXILIARIES
•FOR A TYPICAL 210 MW UNIT
•HT MOTORS 6.6 KV - 43 NO’S
•LT MOTORS 415 V - 510 NO’S
TOTAL CONNECTED LOAD - 36.5 MW
= 17.5%
Smart Energy Management21 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
THERMAL AUXILIARIES
PROPOSED ENERGY MONITORING
•HT MOTORS - 43 NO’S
•LT MOTORS > 50 KW - 44 NO’S
Smart Energy Management22 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
THERMAL AUXILIARIES
FOR MOTORS < 50 KW
USE OF PORTABLE ANALYSER ON
AS REQD. BASIS
Smart Energy Management23 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
RELEVANCE OF ENERGY CONSERVATION
MAXIMISE DESPATCH OF ENERGY BY MINIMISING INTERNAL USAGEENERGY USAGE CAN BE MINIMISED BY OBTAINING OPTIMUM EFFICENCY
Smart Energy Management24 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
ADVANTAGES OF ON LINE MONITORING
ENERGY CONSUMPTION OF MAJOR AUXILIARIES WILL BE AVAILABLEPROPER ACCOUNTING AND ENERGY BALANCE POSSIBLELOSSES CAN BE DETERMINEDDETERIORATION OF EFFIENCY CAN BE IDENTIFIED AND CORRECTED AT FIRST OPPORTUNITY
Smart Energy Management25 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
ADVANTAGES …PROPER COSTING OF ENERGY GENERATION ACCURATE ON LINE DATA ELIMINATING HUMAN ERRORSBENCHMARKS CAN BE SET FOR PLANT COMPARISON WITHIN AND WITHOUT POSSIBLE
Smart Energy Management26 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Requirement of Energy Management System in Utilities
Improvement in PLFReduction in APCReduction in T&D losses
> Improvement in Accountabilty> Improvement in Power Quality
>> Power Factor>> Harmonics
Smart Energy Management27 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
CASE STUDYBOILER FEED PUMP
Smart Energy Management28 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
NTPC Unit ( 210 MW ) ITEM KWH KWH / DAYBFP-1B 2085 55938BFP-1C 2312 62285FD Fan-1A 380 10797FD Fan-1B 383 10879ID Fan-1A 770 21280ID Fan-1B 800 22820PA Fan-1A 780 18210PA Fan-1B 780 18135
Smart Energy Management29 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Case Study – Boiler Feed PumpBoiler feed pump 1C showed higher energy consumption.This pump was overhauled in recent past by manufacturer.The pump internals ( cartridge ) was also replaced recently.New technology valve was also fitted in this pump.
Smart Energy Management30 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Case Study contd.All factors stated should have resulted in lower energy consumption .Obvious conclusion was that measurements were incorrect.Meter was rechecked and recalibrated.Software for on line monitoring was also checked but no fault could be located.Pump continued to show higher consumption.
Smart Energy Management31 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Case Study contd.As running 210 MW unit could not be shut down, checks were carried out on motor as well as the pump in operation.Results were inconclusive as no defects could be ascertained.Plant authorities decided to wait till next scheduled shut down.For over two months pump operated with excess consumption of 6500 units per day.
Smart Energy Management32 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Case Study - ConclusionDuring shut down, the pump was dismantled.Observed that on the recirculating valve side there was excess clearance or gap resulting in higher energy for same pumping requirement.On line monitoring system could payback in less than two months.Analogue ammeter of say 500 Amp full scale may not show noticeable difference between 228 and 252 Amps
Smart Energy Management33 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Case StudyCoal Mill
Smart Energy Management34 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
COAL MILLIn the Coal mills power consumption increases with wear of grind rolls. Thus it should be possible to establish a relation between run hours and power consumption.Actual spot readings taken with energy meters in a coal mill are shown in the next slide with attempt to establish some pattern in the next two slides.
Smart Energy Management35 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
COAL MILL
Smart Energy Management36 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Coal Mill
Smart Energy Management37 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Coal MillRun Hours Vs Power Consumpt ion and Speci f ic Power Consumpt ion
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
1 A 1 B 1 C 1 D 1 E 1 F 2 A 2 B 2 C 2 D 2 E 2 F 3 A 3 B 3 C 3 D 3 E 3 F 4 A 4 B 4 C 4 D 4 E0.00
2.00
4.00
6.00
8.00
10.00
12.00
Run Hours
Power Consumption
Specific Power Consumption
Smart Energy Management38 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Coal Mill - AnalysisFrom energy meter readings it is not possible to establish any relationship .Noting Specific Power Consumption trend on line from 0 to 2500 hrs can enable extrapolation to say 3500 hrs or even 4000 hrs.Prediction of Specific power consumption at 4000 hrs and consequently extra power consumption vs cost can provide an optimum replacement point in no of hours for each mill as characterstics for each are different.
Smart Energy Management39 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Coal Mill - AnalysisWhen Bullring replacement is done it is necessary to know whether Specific power consumption has changed as compared to original state.If not, there could be other causes also which contribute to higher consumption.Actual power consumption of a coal mill is shown in next slide. Mill E is showing unusually high consumption.
Smart Energy Management40 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
DAILY POWER CONSUMPTION & AVG.KW
EQUIPMENT NAME
UNIT-1 UNIT-2 UNIT-3 UNIT-4
AVG. KW AVG. KW AVG. KW AVG. KW
MILL-A 139 160 161 153
MILL-B 135 147 166 148
MILL-C 148 141 163 151
MILL-D 131 144 158 157
MILL-E 173 0 159 142
MILL-F 148 139 138 145
Av.Kw 146 146 158 149
Case : 1
Smart Energy Management41 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Coal MillLooking at high consumption mill E is attended to for necessary repair and maintenance.Results of correct operation can be seen in the next slide – a reduction of over 50 KW in one mill.
Smart Energy Management42 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
DAILY POWER CONSUMPTION & AVG.KW
UNIT-1 UNIT-2 UNIT-3 UNIT-4
EQUIPMENT NAME AVG. KW AVG. KW AVG. KW AVG. KW
MILL-A 134 139 142 149
MILL-B 119 124 133 131
MILL-C 138 117 159 149
MILL-D 0 130 153 138
MILL-E 121 119 0 120
MILL-F 124 0 102 0
Av.KW 127 126 138 137
Smart Energy Management43 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
CASE STUDYCOAL HANDLING PLANT
Smart Energy Management44 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Case Study – Coal Handling PlantNTPC had taken over Thermal Station from Electricity Board against dues.Station had low PLF and high auxiliary power consumption.NTPC made substantial improvements on both achieving PLF better than 85 % and auxiliary consumption at approx 12 %.Station has 4 x 210 MW units
Smart Energy Management45 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Case Study contd.Plateauing of further gains in Auxiliary Power consumption occurred.Unit auxiliaries were in focus for reduction but station auxiliaries not given adequate attention.Coal Handling plant tended to be neglected being out of sight.Plant authorities decided to focus on CHP.
Smart Energy Management46 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Case Study contd.Energy meters were installed in CHP.Consumption was measured in conveyors and crushers.No opportunity for reduction could be established.Use of power analyser also could not result in substantial reduction.It was decided to have a demo energy management system.
Smart Energy Management47 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Case Study - ConclusionEMS provided on line data of consumption with relation to time.Conveyor was observed to be consistently underloaded.Crusher was actually operating for only a few hours per day but remained on all the time.With improvements in operation indicated by EMS the station has achieved further gains.
Smart Energy Management48 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Operation of CrusherNext slide shows from actual coal crusher the trend of energy consumption on a particular day.On line data shows crusher operation is proper in the beginning and towards the later part.In the middle portion for considerable period the crusher is not optimally loaded
Smart Energy Management49 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Case : 2
Smart Energy Management50 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Ash Slurry PumpsCase Study
Smart Energy Management51 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Case Study - NTPC PlantAfter On line monitoring system was operated for 2-3
months, the plant managers one key finding was that there were huge number of START & STOPS in their Ash slurry pumps. After analysis it was found that there are a lot of leakages at the pumps on the output side. After sealing of these leakages the requirement of running the Ash slurry pump for the same process drastically came down from 6 pumps to 3 pumps. Each pump consumes a total of 120-130kw/hrNet Saving = 120*3=360kw/hr*24hr = 8640kwh.
Smart Energy Management52 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Earlier
Smart Energy Management53 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
After
Smart Energy Management54 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
CW PumpsCase Study
Smart Energy Management55 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
CW System – Observations in Power plants
Specific Cooling water consumption cubic meters per MW higher than norm.Specific energy consumption (pumping efficiency) KWH per cubic meter higher.Ash water consumption higher.DM water make up pumps running even if there is no demand – energy savings possibility with VFD.High back pressure in condenser – can be improved by condenser tube cleaning. High TTD indicates low heat transfer efficiency.
Smart Energy Management56 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
CW System – Some Audit Observations
Low efficiency of CW pumpsHead higher than requiredWastage of water in auxiliary heatingRecovery of waste water from clarifier etc
Smart Energy Management57 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Smart Energy Management58 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Smart Energy Management59 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
Smart Energy Management60 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
SPECIFIC ENERGY CONSUMPTION REPORT
System Fan Unit -1 Unit-2 Unit-3 Unit-4
ID Fans
Fan-A 1.61 1.86 1.75
Fan-B 1.57 1.81 1.64
Fan-C 1.92 1.67
FD FansFan-A 1.45 1.35 1.14 1.42
Fan-B 1.25 1.24 1.12 1.50
PA FansFan-A 9.69 9.21 10.52 8.77
Fan-B 9.55 9.48 10.10 8.85
BFPs
Pump-A 7.91 8.07 9.0 7.15
Pump-B
Smart Energy Management61 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential
THANK YOU