7/18/2019 Mr Gaurang Bhatt-Yantra
1/13
1
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
Yantra Harvest Energy India
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
7/18/2019 Mr Gaurang Bhatt-Yantra
2/13
3
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
4
Yantra Harvest Energy India
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%
7/18/2019 Mr Gaurang Bhatt-Yantra
3/13
5
Yantra Harvest Energy India
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
6
Yantra Harvest Energy India
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
7/18/2019 Mr Gaurang Bhatt-Yantra
4/13
7
Yantra Harvest Energy India
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
8
Yantra Harvest Energy India
7/18/2019 Mr Gaurang Bhatt-Yantra
5/13
9
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
Yantra Harvest Energy India
ABOUT YANTRA- Energy Saving Solutions History
10
Yantra Harvest Energy India
Projects MW MWh/Yr Tons CO2
Completed 2.932 23456 25801
Under Execution 4.990 39920 43921
Target 2011-12 15
Savings
7/18/2019 Mr Gaurang Bhatt-Yantra
6/13
11
Yantra Harvest Energy India
System Desired Pressure & Flow are Imp Factors in Determining
Operating Point- especially in Power Plant Applications
Eg : Power Plant
12
Yantra Harvest Energy India
Centrifugal Load Affinity- Law
7/18/2019 Mr Gaurang Bhatt-Yantra
7/13
13
Yantra Harvest Energy India
Fan Systems Pumping Systems
Control Valve
VFD
Variable Fluid -Coupling
15-20% Effeciency Diff depending on
Speed .
Note : Above are Indicative Data
14
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
Yantra Harvest Energy India
7/18/2019 Mr Gaurang Bhatt-Yantra
8/13
15
APGENCO Vijayawada
ID Fan Case Study
TURN-KEY PROJECT SCOPE OF WORK
MV Drive with Bypass Panel
Civil room for MV drive system
Necessary Cooling arrangement
Supply of All Cables
Cable Laying & Terminations
Interfacing with existing DCS system
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
Data of CEP after Installation of MV drive
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
Yantra Harvest Energy India
16
Reliance Energy SamalkotHPBFP Case Study
TURN-KEY PROJECT SCOPE OF WORK
MV Drive with Bypass Panel
Supply of All Cables
Cable Laying & Terminations
Interfacing with existing DCS system
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
Data of CEP after Installation of MV drive
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
Yantra Harvest Energy India
7/18/2019 Mr Gaurang Bhatt-Yantra
9/13
17
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
Yantra Harvest Energy India
INDEPTH PROCESS KNOWLEDGE HELPS TO MAXIMISE ENERGY SAVING
18
Yantra Harvest Energy India
Concept :
7/18/2019 Mr Gaurang Bhatt-Yantra
10/13
19
Yantra Harvest Energy India
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 :
20
Yantra Harvest Energy India
7/18/2019 Mr Gaurang Bhatt-Yantra
11/13
21
Yantra Harvest Energy India
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 .
22
.
Yantra Harvest Energy India
YANTRA HARVEST MV DRIVE
7/18/2019 Mr Gaurang Bhatt-Yantra
12/13
23
.
Yantra Harvest Energy India
YANTRA HARVEST MV DRIVE
24
Yantra Harvest Energy India
MV Drive Ratings
3300V Series:
Rated motor 300 ~ 7000KW
6600V Series:
Rated motor 300 ~ 14000KW
11000V Series:
Rated motor 300 ~ 24000KW
7/18/2019 Mr Gaurang Bhatt-Yantra
13/13
25
Summary
Yantra Harvest Energy India
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
26
Yantra Harvest Energy India
ENERGY SAVED
IS
ENERGY GENERATED