Power saving ideas implemented practically

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SAVINGS THROUGH
VFD’s

SAVINGS THROUGH
COMPRESSORS & CHILLING PLANT


SAVINGS BY REPLACING DYNO DRIVES MOTORS
WITH
INDUCTION MOTORS & SPEED CONTROL WITH VFD’s.

SAVINGS THROUGH
ENERGY EFFICIENT MOTORS

SAVINGS THROUGH
ENERGY EFFICIENT PUMPS


SAVINGS THROUGH
TUBE WELL RUN HRS & REPLACING INEFFICIENT WATER PUMPS


SAVINGS THROUGH
OPTIMIZATION OF EQUIPMENTS

Published in: Technology, Business

Power saving ideas implemented practically

  1. 1. ENERGY CONSERVATION INITIATIVES (TEAM Unit– Shree Gopal) ENERGY CONSERVATION INITIATIVES IMPLEMENTED
  2. 2. ENERGY SAVING IDEAS IMPLEMENTED SAVINGS THROUGH VFD’s
  3. 3. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo1. Installation of VFD at 37 KW Power saving of 11 KW Hydra treated pump PM-5,7. Power reduced from 33 to 22 KW.2. Installation of VFD at 67KW Power saving of 9 KW water supply pump to PM-5,7. Power reduced from 50 to 41 KW.3. Installation of VFD at 55KW Power saving of 16 KW Specialty back water tank pump supplying to pulp mill. Power reduced from 40 to 24 KW. Sheet Total=36kWh
  4. 4. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo4. Installed VFD for 55KW Vat Power saving = 9 kWh Dilution Pump of BSW-1 in pulp Mill and started at 45HZ. Power reduced from 33 to 24 KW.5. Installed VFD at 45KW Cooling Power saving = 18 kWh Tower pump of PM-7 and started at 42HZ. Power reduced from 40 to 22 KW.6. Installation of VFD at 67KW Power saving = 11 kWh Fan pump PM-7. Power reduced from 33 to 22 KW. Sheet Total=38kWh
  5. 5. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo7. Installed VFD at 11KW B/L Power saving of 3KW supply pump. Power reduced from 9 to 6 KW.8. Installed VFD at 45KW Couch Power saving=14 KW Pit Pump PM-4 , Average power consumption got reduced from 25KW to 11KW.9. Installed VFD at 45KW stock Power saving=6KW chest pump pulp mill. Power reduced from 30-24=6KW.10. Provided VFD at 75KW Decker Power saving of 12 KW MC pump in pulp mill. Power reduced from 60 to 48 KW. Sheet Total=35kWh
  6. 6. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo11. Provided VFD at 30KW 10m3 Power saving of 8KW FRP tank back water pump motor. Power reduced from 21 kWh to 13 kWh.12. Provided VFD at 22KW Clear Power saving of 9 KW water pump at PM-4. Power reduced from 19kWh to 10kWh.13. Provided VFD at 15KW Cloudy Power saving of 5KW water pump at PM-4. Power reduced from 10kWh to 5kWh. Sheet Total=22 kWh
  7. 7. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo14. Provided VFD at 75KW B-6 Power saving of 12KW effect pump soda recovery evaporator house. Power reduced from 52kWh to 40kWh. Sheet Total=12 kWh TOTAL SAVING THRO’ VFD’s 143 KW
  8. 8. ENERGY SAVING IDEAS IMPLEMENTED SAVINGS THROUGH COMPRESSORS & CHILLING PLANT
  9. 9. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo1. Two 1000CFM & one 500CFM Power saving of 72 kWh compressors were running for PM-5, 7&Pulp mill. Over hauled these compressor, replaced air header PM-7, plugged air leakages at various locations in plant. With this one extra running 500 CFM compressor has been stopped. Power reduced from 367 to 295KW.2. Over hauled all three 500CFM Power saving of 50 kWh compressor of Soda recovery. Plugged air leakages at various locations in plant. With this one 500 CFM 90KW compressor has been stopped. Power reduced from 142 KW to 92 KW. Sheet Total=122kWh
  10. 10. ENERGY SAVING IDEAS IMPLEMENTEDS. Description Gain PhotoNo.3. Installed Elgi compressor 5 HP for sludge Power saving of filter soda recovery separately. Where 5Kg 18kWh pressure was required, where as for other areas of soda recovery 3Kg pressure was required. This has reduced working pressure of one compressors of 90KW. Power reduced from 92 to 74 KW.4. Old inefficient chilling unit replaced with Power saving of energy efficient chilling unit at PM-7 and 18 KW by changing its location just below machine calendars for reducing losses in line bends and line length. Power reduced from 34 to 16 KW Sheet Total= 36 kWh TOTAL SAVING THRO’ COMPRESSORS & CHILLING PLANT 158 KW
  11. 11. ENERGY SAVING IDEAS IMPLEMENTED SAVINGS BY REPLACING DYNO DRIVES MOTORS WITH INDUCTION MOTORS & SPEED CONTROL WITH VFD’s.
  12. 12. ENERGY SAVING IDEAS IMPLEMENTEDS.No Description Gain Photo .1. Replaced 20 Nos. variable speed inefficient Power saving dyno drive motors with energy efficient =30 KW normal induction motors by controlling its speed with VFD at following locations:- (a) 6 No Silo Screw extractors of chipper house 7.5KW each power saving 12KW (b) 5 No. Wire shaker motors of 3.7KW of all 5 paper machines Power saving 7.5 KW (c) 6 No. Rectifier rolls motors 2.2KW each of PM-4, 5 & 7 power saving 3 KW (d) 3 No Maloney filters motors 11KW each of Soda recovery, PM-4 & PM-5 power saving 7.5 KW TOTAL SAVING BY REPLACING DYNO DRIVE MOTORS 30 KW
  13. 13. ENERGY SAVING IDEAS IMPLEMENTED SAVINGS THROUGH ENERGY EFFICIENT MOTORS
  14. 14. ENERGY SAVING IDEAS IMPLEMENTEDNo. Description Gain Photo1 Replaced A class open type inefficient Power saving of motors with F class energy efficient motors 26KW at 17 locations mill wide after reconsidering their actual power requirement of equipment.2. Replaced Broke Refiner open type A class Power saving of motor 65KW 1000 RPM with F class 37 KW 20KW 750RPM after taking trial with VFD of PM 4. Power reduced from 42kWh to 22kWh. Sheet Total= 46 kWh TOTAL SAVING THRO’ ENERGY EFFICIENT MOTORS 46 KW
  15. 15. ENERGY SAVING IDEAS IMPLEMENTEDLIST OF MOTORS REPLACED WITH NEW ENERGY EFFICIENT MOTORS IN FY_-2010-11No. EQUIPMENT NAME RATING SAVING NO. EQUIPMENT NAME RATING SAVING THICK BLACK LIQ TANK AGIT 1 10 CAUSTIC PUMP OLD EVAP.HOUSE 0.7 S/R 22 1.2 7.5 BLEACHED STOCK CHEST 2 11 PULP TRANSFER PUMP PM-4 PUMP 11 0.8 55 2.5 MIXING CHEST -1 AGITATOR PM- 3 STOCK CHEST-5 AGIT PM-4 12 22 1 4. 22 1.2 4 STUFF PUMP-1 PM-2 13 SMALL W.L.PUMP-1 DOOR PLANT 15 0.6 7.5 0.5 SERVICE PUMP NO.2 PUMP LIME TANK-1 AGIT. CHEMICAL 5 14 HOUSE 75 3.5 HOUSE 7.5 0.75 LIME TANK-2 AGIT.CHEMICAL 6 B.W.PUMP-2 PM-1 15 22 1 HOUSE 7.5 0.75 7 STUFF PUMP PM-1 16 REFINER PM-2 18.5 1 63.75 3.5 8 PULPER NO.1 PM-2 17 COMPRESSOR SODA RECOVERY 37 1.5 90 4 TOTAL 26 9 PULPER NO.2 PM-2 37 1.5
  16. 16. ENERGY SAVING IDEAS IMPLEMENTED SAVINGS THROUGH ENERGY EFFICIENT PUMPS
  17. 17. ENERGY SAVING IDEAS IMPLEMENTEDS. Description Gain PhotoNo.1. Replaced inefficient 67KW pump of water Power saving = 18 supply to PM-5,7 with energy efficient kWh pump & with new lines. Also started VFD in close loop by providing pressure control switch with setting of 2.1Kg pressure. Power reduced from 50 to 32KW2. Replaced inefficient 75KW water supply Power pump of PM-1,2 with energy efficient saving=9KW pump and started in close loop with pressure of 1.5Kg. Power reduced from 50 to 41KW3. Replaced inefficient pump of 110KW Blow Power saving of tank stock pump pulp mill with new 10KW efficient one Power reduced from 80 to 70 KW. Sheet Total= 37 kWh
  18. 18. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo4. Replaced inefficient 55KW Power saving of 10 KW pump of Bleached stock chest PM-4 with energy efficient pump. Average power consumption got reduced from 34KW to 24KW.5. Replaced inefficient 30KW Power saving of 5 KW pump of back water PM-4 with energy efficient pump. Power reduced from 22 to 17KW. Sheet Total= 15 kWh TOTAL SAVING THRO’ ENERGY EFFICIENT PUMPS 52 KW
  19. 19. ENERGY SAVING IDEAS IMPLEMENTED SAVINGS THROUGHTUBE WELL RUN HRS & REPLACING INEFFICIENT WATER PUMPS
  20. 20. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo1. Unit SGU was meeting its Power saving 93 KW BEFORE water demand thro’ installed 19 No. bore wells (130M3/Ton of Paper) by running 16 bore wells continuously. Through various actions on water conservation & by replacing inefficient vertical 45KW bore wells with 37KW submersible water pumps at new locations AFTER with increased water flow, we are now meeting our water demand by running 13 bore wells only. 1) Water conservation actions. 2) Waste water management. 3) Utilization of treated effluent Sheet Total=93kWh
  21. 21. ENERGY SAVING IDEAS IMPLEMENTED FOLLOWING INITIATIVES WERE TAKEN FOR WATER CONSERVATION MILL WIDE1 Re-use of pope reel & 6 Re-use of vacuum pump 11 Push button type taps compressor cooling water. water by passing thro’ provided in bath rooms & cooling tower. toilets of mills.2 Re-use of barometric 7 Re-use of machine back 12 Re-use of treated effluent in condenser water Clo2 in water for pulp dilution. jet condenser chemical pulp mill. house.3 Use of disc save all clear 8 Wood log washing with 13 Installed level controllers in water on wire showers PM-4. treated effluent water. pumps to avoid overflow.4 Re-use of treated effluent for 9 Ash quenching with treated 14 Thickener shower of PM-1,2 gardening in mills & colony. effluent water. replaced with new showers.5 Re-use of D1 filtrate on E/O 10 Use of Macstar packing in TOTAL POWER SAVING = 93kWh screw conveyor for pulp pump glands for reduction WATER CONS.100M3/TON PAPER dilution. in water consumption. TOTAL SAVING THRO’ TUBE WELL RUN HRS & REPLACING INEFFICIENT WATER PUMPS 93 KW
  22. 22. ENERGY SAVING IDEAS IMPLEMENTED SAVINGS THROUGH OPTIMIZATION OF EQUIPMENTS
  23. 23. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo1. Filtrate tank pump made shut at PM- Power saving 5 KW 1,2 by transferring back water by gravity with modification in pipe line.2. Speed reduction of Pressure Screen Power saving 19KW PM-4 by changing motor pulley.3. Started KVM-600 Vacuum pump PM- Power saving 36KW 4 and stopped KVM-900 Vacuum pump. Consumption reduced from 110kWh to 74kWh.4. Decreased run time of two Foam Power saving 2 KW breakers in NPM of running 6KW each. These were running for 30 min and shut for 30min. Now these are running for 30min & shut for 1 Hr. Saving 4 HrsX6X2KW Sheet Total = 62 kWh
  24. 24. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo5. Replaced suction fan of Power saving=1KW secondary conveyor of Sheeter no.2 BCP from 2.2KW to 0.55KW and has saved 1KW. OLD NEW6. Optimized speed of white Power saving of 5 KW liquor supply pump after taking trial with VFD & replaced pulley of motor accordingly. Sheet Total=6 kWh TOTAL POWER SAVING BY OPTIMIZING EQUIPMENTS 68 KW
  25. 25. ENERGY SAVING IDEAS IMPLEMENTED SAVINGS THROUGH STOPPING EQUIPMENT AFTER OPTIMIZATION OF OTHERS RUNNING
  26. 26. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo1. Connected water lines of high Power saving of 21 KW pressure pump PM-7 with PM- 5 high pressure pump & stopped PM-7 H.P.Pump . PM-5 H.P.Pump running for PM-5 only= 25 KW PM-7 H.P.Pump= 22 KW PM-5 H.P.Pump running for PM-5 & 7 M/C = 26 KW2. Installed new 132 KW KVM Power saving of 15 KW 900 Vacuum pump at PM-7 resulted to shut of two inefficient 90 KW vacuum pumps consuming 65KW each. Power saved 15 KW.3. Shut one1000KVA transformer Power saving of 4 KW of finishing house running at 30% load by shifting its load to other under loaded transformer at PM-4. Power saving 4 KW. Sheet Total=40kWh
  27. 27. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo4. Stopped one paper rewinder Power saving of 25KW no.1 of PM-4 which was consuming average 25KW power by optimizing production at other three rewinders.5. Stopped trim nozzle pump at Power saving of 4KW PM-2 by connecting line with H. P. Oscillating shower PM-1. With this common operation saved 4 KW.6. Three 250KW refiners were Power saving of 148KW running for common operation of PM-1, 2 (178KW + 190 KW + 200 KW). Stopped DDR 2 (20”) 250KW refiner permanently which was consuming 190 KW power, by optimizing refining on other two 250KW refiners. Net power saving 148KW. Sheet Total=177 kWh
  28. 28. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo7. Two refiners 250 & 110KW Power saving=40KW were running for PM-7 (158KW + 90 KW). Stopped 110KW refiner permanently by increasing refining on 250KW refiner. Net power saving achieved = 40KW. Sheet Total=40kWh TOTAL POWER SAVING BY STOPPING EQUIPMENT AFTER OPTIMIZATION OF OTHERS RUNNING 257 KW
  29. 29. ENERGY SAVING IDEAS IMPLEMENTED SAVINGS THROUGH AUTO CONTROL OF EQUIPMENTS INSTEAD OF MANUAL CONTROLS
  30. 30. ENERGY SAVING IDEAS IMPLEMENTEDFOLLOWING VFD’s OF PULP MILL HAS BEEN STARTED IN CLOSE LOOP IN DCS TO SAVE POWER S. Description Gain Photo No.1. CD tower launder dilution pump Power saving of 1.3 KW pulp mill 30KW.Saving= 26.3-25 = 1.3KW2. EO tower dilution pump pulp mill Power saving of 1.7 KW 37KW.Saving=26-24.3= 1.7KW.3. EO tower stock pump pulp mill Power saving of 1.3 KW 37KW.Saving=15-13.7=1.3KW4. EO washer Vat dilution pump pulp Power saving of 2.7 KW mill. Saving=25-22.3= 2.7KW5. D2 tower launder dilution pump Power saving of 5.0 KW pulp mill. Saving=27-22= 5.0KW.6. P4 warm water BHR area pulp mill Power saving of 1.7 KW 30KW. Saving=16-14.3= 1.7KW.7. D1 launder dilution pump P.Mill Power saving of 1.3 KW 45KW. Saving=30.7-29.4= 1.3KW. Sheet Total=15kWh
  31. 31. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo8. Started VFD of P.Mill fresh Power saving of 6.0 KW water supply pump in close loop of pressure. Saving=62-56= 6KW.9. Provided emergency stop for Power saving of 2.0 KW stopping cooling fan PM-7 rewinder DC motor when not in use. Saving=2-0= 2 KW.10. Modified control circuit of Power saving=6 KW warm water pump P.Mill & hooked up with level from DCS. Saving = 18-12=6 KW. Sheet Total=14kWh
  32. 32. ENERGY SAVING IDEAS IMPLEMENTED TOTAL SAVING THRO’ AUTO CONTROL OF EQUIPMENTS INSTEAD OF MANUAL CONTROLS 29 KW
  33. 33. ENERGY SAVING IDEAS IMPLEMENTED SAVINGS THROUGH VOLTAGE & FREQUENCY OPTIMIZATION
  34. 34. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo1. Earlier many motors in plant were open type Power ‘A’ class having voltage rating 425-440V. But saving of now maximum motors are replaced with ‘F’ 150 KW class rating having voltage level 415V and will give maximum efficiency at 415V. Reduced voltage from 11KV to 10.7KV & 6.6 to 6.4 KV and frequency from 49.9 HZ to 49.3 HZ of both sources 11KV TG & 6.6KV BTH turbines. Also adjusted transformer tap changer switches at few locations as per required voltage. Power saving 90 + 60 = 150 KW. Sheet Total=150 kWh TOTAL SAVING THRO’ VOLTAGE & FREQUENCY OPTIMIZATION 150 KW
  35. 35. ENERGY SAVING IDEAS IMPLEMENTED SAVINGS THROUGH LIGHTING & OTHERS
  36. 36. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo1. Provided MCB for putting of all Power saving of 5 KW lights of pulp mill, PM-5,7 mech. workshop, drive rooms, electrical centers & transformer rooms. etc. Total 10KW load will be saved for 12 Hrs. Net Saving=5KW2. Provided MCB in cable gallery Power saving of 2.0 KW & HT switchboard of pulp mill. 2KW will remain shut for 24Hrs.Net saving = 2KW3. Replaced 120 chokes of Power saving of 2.0 KW fluorescent tubes with electronic chokes. Power saving 2KW BEFORE AFTER Sheet Total=9 kWh
  37. 37. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo4. Interacted with workmen of Power saving of 3.0 KW various departments mill wide after identification and marking lights to be put off when not required in day time. Power saving = 6 KW for 12 Hrs. Net power saving = 3KW.5. Restructured street light Power saving of 2.0 KW circuits in mills near canteen PM-1, mechanical workshop pulp mill & chipper house area. Saving = 2KW6. 1000 Watt Halogen lights for Power saving=4 KW Load Break Switches removed after installation of OCBs at four transformers. Saving = 4 KW. Sheet Total = 9 kWh
  38. 38. ENERGY SAVING IDEAS IMPLEMENTEDS. No. Description Gain Photo7. Provide 20 MCBs for main Power saving of 1.0KW power supply at the doors of offices, halls, So that complete power can be switched off while moving out. Power saving = 1KW8. Transparent fiber sheets on Power saving of 6.0KW roof sheds at Pulp godown, New syn. Sheeter area, new dispatch section, stores etc. Power saving 12KW for 12 Hrs. Net power saving = 6KW Sheet Total=7 kWh TOTAL SAVING THRO’ LIGHTING & OTHERS 25 KW
  39. 39. TOTAL SAVING WITH ENERGY SAVING IDEAS IMPLEMENTEDSR. SAVING SAVING THROUGHNO. IN kWh1. VFD’s 1432. Compressors & Chilling plant. 1583. Replacing Dyno Drive motors with induction motors & 30 speed control with VFD’s4. Energy efficient motors. 465. Energy efficient pumps. 526. Tube wells run hrs reduced thro’ water saving & by 93 replacing inefficient water pumps mill wide.7. Optimization of equipments 688. Stopping equipment after optimization of others running. 2579. Auto control of equipments instead of manual controls. 2910. Voltage & Frequency optimization 15011. Lighting & Others. 25 TOTAL = 1051 kWh

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