Energy Conserve Tpc

8/3/2019 Energy Conserve Tpc

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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.


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.


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

Energy Conserve Tpc

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