Ideas & activities carried out for conservation of Energy in at thermal power plant

1. PREPARD BY:
MANOJ KUMAR MAHARANA
Sr. Engineer
Electrical [O&M]
BLA Power Pvt. Ltd

2.  Verification, Monitoring & Analysis of Use Of
Energy including submission of Technical Report
containing recommendation for improving
Energy efficiency with cost benefit analysis &
action plan to reduce Energy Consumption

3.  Turbine-Generator (TG) Heat Rate (Kcal/kwh)
 Boiler Efficiency (%)
 Auxiliary Power Consumption (%)

4. MaintenanceControl
OperationalControl
Energy Management
Standard
O&M
Practices
Technology

5.  Equipment Running Hours
 Maximizing Machine loading factor
Standardization of O&M Practices
through Energy Monitoring
Scheduled changeover of
Equipments as per energy
deviation
Most energy efficient
equipment run for
maximum time
Predictive maintenance

6.  Boiler Maintenance
 Arresting Steam leakages online
 Duct Leakages
 Duct leakages of Air and Flue gas arrested in
every opportunity

7.  Adoption of Energy Efficient Technology like
> V. F. D installation
> On-line Monitoring System.
 MVAR Management
 Compressor Loading & Unloading.
 Service Auxiliaries such as illumination etc.
 Off Peak Hour CHP running.
 Switchyard Contact thermal observation to avoid losses.

10. HT Motor
Rated Current
(Amp)
Rated KW Rated RPM
Actual current
(Amp)
Actual KW % IGV / Valve Running Hours
CWP-1 40 Amp 350 742 35.74 320.0 100 24
CWP-2 40 Amp 350 742 37.32 337.0 100 24
BFP-1 156.5 Amp
1475 2986
ID FAN-1 57 Amp
520 993 47.52 442.9
34 24
PA FAN-1 61 Amp
580 1492 50.69
492.6 14.5 24
SA FAN-1 24 Amp
210 1488 18.6 167.4
45 24
CWP-3 40 Amp 350 742
BFP-2 156.5 Amp 1475
2986
130.2 1266.0 61 24
ID FAN-2 57 Amp
520 993 47.11
442.0 24 24
PA FAN-2 61 Amp
580 1492 52.55 516.6
17.7 24
SA FAN-2 24 Amp
210 1488 18.36 164.8
41 24

12.  A 520 Kw Fan motor operating 24 hrs/day,260 Days perYr with IGV 41% Open
& assuming Rs. 2.50 per KWH.
Now,Cost of running full speed:
520x24x260x2.50=81,12,000 per yr.
After ,VFD installation as for Operation requirement
motor operates full speed(100%) for 12 hrs
80% speed for 12 hrs , with IGV 100% open
Now,Cost of running withVFD controlling the motor:
As per affinity Law: Power α (N)3
520x(1)3x12x260x2.50=40,56,000 per yr
520x(0.8) 3x 12x260x2.50=20,76,672 per yr
Annual Saving : 81,12,000-(40,56,000+20,76,672)=19,79,328 per yr

13.  Online monitoring.
 Elimination of human error
 Measurable outputs
 Compares and identifies the efficient processes &
equipment
 Different type of reports like
daily, monthly, quarterly or yearly can be generated .
 Report generation and archiving is possible.

14. Date
Time
(Hours)
Total
Generation
MWH
Plant Auxilary Consumption
Aux.
Consumption Constrction
Power
MWH
Actual Import
MWH
Actual Export
MWH
Max. Demand
MW
Plant
Utilization
Factor %
(PUF)
Rev.
BLA
Rev.
SLDCNET CONSUMP.
[GEN+IMPORT]-
EXPO
%
[SAT+UAT]
MWH
01-Aug-12 00 hr-24 hr 187.9102 45.8375 24.39 45.2517 0.5513 23.5986 165.6713 45.26 17.40 R-1 R-1
02-Aug-12 00 hr-24 hr 0.0000 23.7488 N.A. 23.6113 0.5941 23.7488 0.0000 0 0.00 R-0 R-0
03-Aug-12 00 hr-24 hr 0.0000 21.6696 N.A. 21.4206 0.5188 21.6696 0.0000 0 0.00 R-0 R-0
04-Aug-12 00 hr-24 hr 0.0000 21.4956 N.A. 21.3391 0.5363 21.4956 0.0000 0 0.00 R-0 R-0
05-Aug-12 00 hr-24 hr 0.0000 14.2380 N.A. 14.0888 0.5730 14.2380 0.0000 0 0.00 R-0 R-0
06-Aug-12 00 hr-24 hr 0.0000 15.1342 N.A. 14.9954 0.5521 15.1342 0.0000 0.0000 0.00 R-0 R-0
07-Aug-12 00 hr-24 hr 0.0000 32.9980 N.A. 32.3800 0.5507 32.9980 0.0000 0.0000 0.00 R-0 R-0
08-Aug-12 00 hr-24 hr 842.4411 129.4173 15.36 120.8759 0.9089 11.2774 724.3012 45.2900 78.00
09-Aug-12 00 hr-24 hr 1053.6027 128.0791 12.16 126.6573 0.6385 0.0000 925.5236 45.3000 97.56 R-0 R-0
10-Aug-12 00 hr-24 hr 1048.5206 131.1004 12.50 126.6944 0.5255 0.0000 917.4202 45.3000 97.09 R-1 R-0
11-Aug-12 00 hr-24 hr 681.4661 118.9805 17.46 114.9359 0.5133 0.0000 562.4856 44.3062 63.10 R-0 R-0*
12-Aug-12 00 hr-24 hr 653.8169 116.5612 17.83 114.2477 0.6135 0.0000 537.2557 44.4200 60.54 R-0 R-0*
13-Aug-12 00 hr-24 hr 781.7993 117.7024 15.06 115.4830 0.3110 0.0000 664.0969 38.2202 72.39 R-2 R-2
14-Aug-12 00 hr-24 hr 615.2586 115.3600 18.75 113.0708 0.3113 16.1626 516.0612 40.5771 56.97 R-5 R-3
15-Aug-12 00 hr-24 hr 1007.4397 124.1597 12.32 121.4729 0.2356 0.0000 883.2800 45.3260 93.28 R-0 R-0
16-Aug-12 00 hr-24 hr 1029.1149 126.9881 12.34 121.9607 0.2285 0.0000 902.1268 45.2500 95.29 R-1 R-1
17-Aug-12 00 hr-24 hr 1053.6539 132.9391 12.62 124.5252 0.1753 0.0000 920.7148 45.3109 97.56 R-0 R-0
18-Aug-12 00 hr-24 hr 1045.7193 129.3059 12.37 125.5823 0.2040 0.0000 916.4134 45.3083 96.83 R-1 R-0
19-Aug-12 00 hr-24 hr 1010.5977 129.7518 12.84 124.9794 0.3614 0.0000 880.8459 45.3537 93.57 R-1 R-0
20-Aug-12 00 hr-24 hr 789.4197 124.4742 15.77 118.8999 0.3071 7.8875 672.8330 45.2680 73.09 R-5 R-5
21-Aug-12 00 hr-24 hr 900.6403 123.6932 13.73 122.4100 0.1602 0.0000 776.9471 45.2630 83.39 R-3 R-3
22-Aug-12 00 hr-24 hr 977.1813 131.1305 13.42 126.2523 0.3858 0.0000 846.0508 45.3839 90.48 R-2 R-2
23-Aug-12 00 hr-24 hr 962.7620 126.6416 13.15 125.4549 0.3496 0.0000 836.1204 45.3159 89.14
24-Aug-12 00 hr-24 hr 1033.4637 135.8749 13.15 126.5416 0.3434 0.0000 897.5888 45.8472 95.69 R-0 R-0
25-Aug-12 00 hr-24 hr 797.6023 119.5955 14.99 115.3832 0.2501 16.4098 694.4166 45.2800 73.85 R-2 R-0
26-Aug-12 00 hr-24 hr 1078.7355 135.5828 12.57 129.2128 0.3438 0.0000 943.1527 45.2700 99.88 R-0 R-0
27-Aug-12 00 hr-24 hr 1078.9963 130.5336 12.10 128.8854 0.3392 0.0000 948.4627 45.2907 99.91 R-0 R-0
28-Aug-12 00 hr-24 hr 1080.3202 132.5365 12.27 128.9368 0.3303 0.0000 947.7837 45.3461 100.03 R-0 R-0
29-Aug-12 00 hr-24 hr 1084.6341 135.2539 12.47 128.2091 0.5166 0.0000 949.3805 45.3537 100.43 R-0 R-0
30-Aug-12 00 hr-24 hr 1066.1845 134.8903 12.65 127.9227 0.4280 0.0000 931.2942 45.2835 98.72 R-0 R-0
31-Aug-12 00 hr-24 hr 1084.0267 135.7393 12.52 128.5743 0.4198 0.0000 948.2874 45.3310 100.37 R-0 R-0

15. TR-1 I/C TR-3 I/C TR-5 I/C
Date KW KVA KVAR VOLT AMP KW KVA KVAR VOLT AMP KW KVA KVAR VOLT AMP
12 Nov 197 217.1 92.96 424 293 313.6 374 201.8 438 419 336.1 456 341 435 709.2
13 Nov 198.2 219.2 93.42 424 297 296.5 354.7 196.3 438.2 466.9 283.8 436.1 326.8 438.1 574
TR-2 I/C TR-4 I/C TR-6 I/C
Date KW KVA KVAR VOLT AMP KW KVA KVAR VOLT AMP KW KVA KVAR VOLT AMP
12 Nov 142.4 166.2 85.37 425 225 220.6 274.7 163.2 440 359 410.4 494.5 267.3 420.3 630.3
13 Nov 141.6 165.3 84.97 424 224.4 217.6 271.8 162.2 440 357 364.1 486.1 264.4 420 560
2 MVA TR-1 = appox. 10.85 to 12 % Loading
2 MVA TR-2 = appox. 08.31 to 10 % Loading
2 MVA TR-3 = appox. 17.77 to 20 % Loading At Full Load 45 MW Generation
2 MVA TR-4 = appox. 13.55 to 15 % Loading
2 MVA TR-5 = appox. 21.85 to 25 % Loading
2 MVA TR-6 = appox. 24.31 to 27 % Loading

16.  Compressed air is very energy intensive. Only 5% of electrical
energy is converted to useful energy. Use of compressed air for
cleaning is rarely justified.
 Ensure low temperature of inlet air. Increase in inlet air
temperature by 3°C increases power consumption by 1%.
 It should be examined whether air at lower pressure can be used in
the process. Reduction in discharge pressure by 10% saves energy
consumption upto 5%.
 A leakage from a ½” diameter hole from a compressed air line
working at a pressure of 6.5kg/cm2 can drain almost Rs. 2500 per
day.

17.  Quality of power supply judged from two factors i.e. voltage and
frequency.
a. All generators having defined capability to generate reactive
/active power. If export of reactive power increases
correspondingly reduces active power.
b. Transmission line generates the reactive power according to
voltage level. Higher the voltage level will be the generation of
reactive power.
132 KV Lines - 0.05 MVAR/KM
 MVAR balancing minimizes I2R Losses and increases capacity
utilizations of transformers/lines.
 BLA Power, Line Voltage Fluctuates frequently from
125.4 KV to 132KV to 140 KV
So MVAR should maintain 25 MVAR to 20 MVAR to -8 MVAR
accordingly.

18.  Lighting conservation done mainly in two Parts:
a. Operational Area
b. Office / Service Area & street Lighting
• Use of CFL lamp in place of GLS lamp can save energy
upto 70%.
• Clean the lamps and fixtures regularly. Illumination
levels fall by 20-30% due to collection of dust.
• Use of sodium vapour lamps for area lighting in place of
mercury vapour lamps saves electricity upto 40%.

19. BEFORE AFTER

20. BEFORE AFTER

21. BEFORE AFTER

22. BEFORE AFTER

23. BEFORE AFTER

24. BEFORE AFTER

25. BEFORE AFTER

26. BEFORE AFTER

27. Energy Saving
Light Load Area Quantity watt Consu KW / Hr Running hr Daily Consum. In KWH Daily KWH Monthly KWH Yearly KWH
TG floor 15 mtr
Before 12 250 3 12 36.0
27.0 810 9720
After 3 250 0.75 12 9.0
AC package
Before 12 36 0.432 24 10.4
8.6 258 3096
After 2 36 0.072 24 1.7
6.6 KV
Before 114 36 4.104 24 98.5
43.2 1296 15552
After 64 36 2.304 24 55.3
0 mtr TG floor
Before 6 250 1.5 12 18.0
9.0 270 3240
After 3 250 0.75 12 9.0
PMCC-3
Before 64 36 2.304 12 27.6
14.7 441 5292
After 30 36 1.08 12 13.0
Compressor
house
Before 14 250 3.5 12 42.0
33.0 990 11880
After 3 250 0.75 12 9.0
wtp mcc & Hall
Before 40 250 10 12 120.0
75.0 2250 27000
After 15 250 3.75 12 45.0
cable celler
room
Before 114 36 4.104 12 49.2
40.6 1218 14616
After 20 36 0.72 12 8.6
DG room
Before 12 250 3 12 36.0
27.0 810 9720
After 3 250 0.75 12 9.0
DM plant MCC
Before 36 36 1.296 12 15.6
6.9 207 2484
After 20 36 0.72 12 8.6
cooling Tower
Before 8 250 2 12 24.0
24.0 720 8640
After 0 250 0 12 0.0
Swith Yard
Before 24 400 9.6 12 115.2
115.2 3456 41472
After 0 400 0 12 0.0
Net Saving per Day/Month/Yr In KWH 424.2 12726 152712

28. DATE A-Shift B-Shift C-Shift Total Running Hrs
15-Nov-12 2:40 2:10 3:10 8
16-Nov-12 0:30 4:15 2:20 7:30
17-Nov-12 2:20 3:30 2:15 8:05
18-Nov-12 2:37 3:15 3:00 8:52
19-Nov-12 0:50 3:00 2:50 6:40
20-Nov-12 2:40 2:50 2:05 7:35
21-Nov-12 1:25 4:50 2:35 8:50
Peak Hours – 18:00 Hrs to 22:00 Hrs

29.  LT consumption metering & monitoring
 Capacitor Bank Implementation.
 ESP Efficiency & monitoring.
Target
≥ 10.5%
Aux. Consumption

30. THANKS
Prepared By:
MANOJ KUMAR MAHARANA
Sr. Engineer
Electrical [O&M]
BLA Power Pvt. Ltd