ENERGY AUDIT OF AUXILIARY POWER CONSUMPTION

ATAR SINGH Dy. DIRECTOR NPTI FARIDABAD

Energy Conservation in Power Utility

Power plant produces electrical energy

and also consumes a substantial amount of energy in the form of auxiliary consumption required for various plant equipments and services

Energy Conservation in Power Utility

Achieved mainly by:

Operating the equipments at maximum efficiency and Reduction of auxiliary Power consumption

 The auxiliary power consumption (APC) varies from 6-14% ,

depending on Size of plant ,use of TDBFP &age of plant The 500 MW units register the least APC, largely due to the incorporation of TDBFP. In some of the old 110 MW plants, APC consumption of 14% is also observed. Energy audit in a vast thermal power station (TPS) is better tackled when the thermal power plant operations are segregated into different sub-areas like: main plant auxiliaries, draft system (consisting of ID/FD/PA fans), feed water system [consisting of Boiler Fed Pumps (BFPs) / Condensate Extraction Pumps (CEPs), Circulating Water (CW) system-including Cooling Tower (CTs)], and off sites (consisting of coal handling plants, ash handling plants, air compressors, AC plants, station lightings etc.).

APC Scenario In India

Auxiliary Power Consumption in Thermal

Power Plant is major source of energy consumption. During the financial year 2007-08 total generation by coal plant was 488157.46 MUs with PLF 78.75. Auxiliary Power Consumption was 8.17%. If this APC gets reduced only by 0.17% then it is equivalent to fresh capacity addition of 120 MW without any investment.

 Trombay Station of Tata Power Co. Ltd achieved lowest

auxiliary power consumption (4.30%) in the country. Among Central Sector Stations, Talcher STPS of NTPC achieved the lowest auxiliary power consumption (5.34%).

Among State Sector Stations, Chandrapur STPS of MAHAGENCO achieved the lowest auxiliary power consumption (7.40%). Among different capacity groups, the lowest auxiliary power consumption was 6.13% in 500 MW group.

Requirement of works power with load

Factors Affecting Auxiliary Power Consumption

- Unit Generation and load Pattern - Operation of Plant Auxiliaries - Service auxiliary such as Illumination , air conditioning - Unit Startup / shutdown

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

Data collection Measurements & Observations Exploration for energy conservation measures Report preparation

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

DATA COLLECTION

Motor details requiredID code, Application, Make, Brief details of driven equipment, Type of the Motor, Motor kW, Motor frame, Duty, Rated RPM, Rated p.f., Rated motor efficiency ,Motor make, Motor voltage, Rated current of motor, Year, Operating hours, Energy meter installed or Not times the motor is rewound

, No. of

Collect the above information for all motors to be covered in the energy audit. Collect the motor efficiency curves

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

Instruments Required Power Analyzer: Used for measuring electrical parameters

such as kW, kVA, pf, V, A and Hz Infrared pyrometer (In case any heating of cable or motor is suspected) Stroboscope: To measure the speed of the driven equipment and motor The above instruments can be used in addition to the calibrated online / plant instruments

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

Parameters to be measured Energy consumption pattern of motors (daily / monthly

/yearly consumption if available) Motor electrical parameters (kW, kVA, Pf, A, V, Hz, etc.) for individual motors Equipment operational details
While conducting the measurement or performance

evaluation of any system simultaneously, the following need to be noted Unit load of the plant Date & time of measurement Instruments used for measurement Frequency of the measurement

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

MEASUREMENTSAND OBSERVATIONS

System details
Detailed interactions with the plant personnel

Energy consumption Pattern

If the plant is monitoring the energy consumption, it is suggested to record the data and monitor the daily and monthly consumption pattern

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

Equipment Annual Consumption MWH Average Load KW % of Total Generation % of total APC

Air Compressors Coal Handling Plant

Raw Water pumps DM water pumps A/C systems ESP Total

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

Equipment Annual Consumption MWH Average Load KW % of Total Generation % of total APC

Boiler Feed Pump Condensate extraction Pump CW Pumps ID Fans FD Fans PA Fans Mils CT Fans

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

Total Generation Auxiliary Power Consumption Contribution To APC By BFP's CEP's FD's ID's PA's Coal Mills CHP AHP Air Compressors Others (CWPs, RWPs, DM Plant, etc ) Unit 1 MW 4.52 0.43 0.35 2.26 2.31 1.21 0.57 0.47 0.42 3.89 % 2.78 0.26 0.22 1.38 1.41 0.74 0.35 0.29 0.26 2.37 Unit 2 MW 4.29 0.43 0.31 2.08 2.38 1.53 0.57 0.47 0.42 4.21 % 2.98 0.30 0.22 1.44 1.65 1.06 0.39 0.33 0.29 2.92 MW 1305.57 111.7 Unit 3 MW 4.52 0.41 0.30 2.34 2.36 1.69 0.57 0.47 0.42 4.11 % 3.39 0.31 0.23 1.51 1.52 1.08 0.36 0.30 0.27 2.64 Unit 4 MW 1.69 1.21 8.18 4.85 2.92 1.11 0.52 0.38 10.28 % 0.45 0.29 2.24 1.34 0.81 0.31 0.14 0.11 2.84 % 81.60 (of installed capacity) 8.56 (of actual generation) Unit 5 MW 1.78 1.26 7.25 4.82 2.92 1.11 0.52 0.38 10.22 % 0.42 0.29 1.51 1.00 0.61 0.23 0.11 0.08 2.13 Over All MW 13.34 4.73 3.43 22.12 16.72 10.25 3.92 2.45 2.04 32.70 % 1.02% 0.36% 0.26% 1.69% 1.28% 0.79% 0.30% 0.19% 0.16% 2.50%

Total 16.42

10.06

16.67

11.58

17.18

11.61

31.14

8.53

30.26

6.38

111.70

8.56%

Motor loading survey

Details Rated Kw Rated Efficiency Rated Speed Measurement of parameters Power factor kVA KW drawn Frequency Harmonics Motor speed Driven Voltage Current Power equipment speed Driven equipment parameters Operational observations Transmission % loading on the motor

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

Motor loading can be estimated by:

Loading =

Input kW to motor x 100 --------------------------------------------------------------------Name plate kW /Name plate full load motor efficiency

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

While conducting motor load survey,

observations on machine side:

parameters such as speed, load, pressure, temperature, etc., (as relevant) are also taken

availability of load-end capacitors for PF

correction & energy meters for monitoring is also looked into for each case.

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

Motor Rewinding History
comparison of no load current and stator resistance per phase of a rewound motor with the original no-load current and stator resistance at the same voltage can be one of the indicators to assess the efficacy of rewinding.

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

Power Factor Correction
Induction motors are characterized by power factors less than unity, leading to lesser efficiency (higher overall operating cost) associated with a plant's electrical system.

Capacitors connected in parallel (shunted) with the motor are typically used to improve the power factor

The impacts of PF correction include reduced kVA drawn , KVAR & current, reduction of transformer load, Reduction of cable losses, reduction of switch gear rating, Enhanced life of equipment

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

EXPLORATION OF ENERGY CONSERVATION

MEASURES Replacement / sizing of motors Opting for energy efficient motors, Use of high efficiency motors, Use of energy efficient transmission Replacement of pulleys Direct coupling

STEPS INVOLVED IN CONDUCTING ENERGY AUDIT

Analysis of observations o o

Loading pattern % loading Comments of power supply quality

The BIS standards specify that a motor should be capable of delivering its rated output with a voltage variation of 6 % and frequency variation of 3 %. Motor o Identified motors with less than 50 % loading, 50 75 % loading, 75- 100 % loading, over 100 % loading o Identified motors with machine side losses / inefficiencies like idle operations, throttling/damper operations o Motor load survey is aimed not only as a measure to identify motor efficiency areas but equally importantly, as a means to check combined efficiency of the motor, driven machine and controller

AUXILIARY POWER CONSUMPTION

Operating only 4 mills instead of 5 mills in 210 MW units Shutting of CTs cells in conjunction with favorable weather

conditions and replacing existing aluminum cast and GRP blades with FRP
avoiding idle running of conveyors & crushers

incorporating soft starter - energy savers etc.

AUXILIARY POWER CONSUMPTION

STRATEGY
Variable frequency drive for PA Fans & ID Fans & CEPs

Air in-leaks in draft system (O2 measurement) blanketing Replacement of inefficient BFPs as a part of R& M of the old plants. Clipping of one stage from the multi stage BFPs to balance the pressure drop requirements between HP heaters, economizer and boiler drum etc. Use of higher pressure in the deareator to commensurately reduce BFP power consumption (reduced head developed) Running of two CEPs instead of 3 CEPs (3 CEPs are run to avoid tripping due to lower frequency in some of the power plants) Application of variable speed drives Installation of hydraulic turbine instead of feed regulating section to avoid pressure drops and to generate additional power