MR Gaurang Bhatt-Yantra

REDUCTION IN APC & ACHIEVING PAT
TARGET IN POWER PLANTS

BY
GAURANG BHATT
DIRECTOR TECHNICAL
YANTRA HARVEST ENERGY PVT LTD
CII GBC Forum Aug 2011
Yantra Harvest Energy India
India Power Scenario

Indias Power requirement Scenario.
2500
298
218
1915
GW
BU
1500
1000
500
100
q 64% Power Generation = Thermal
250
200
153
1392
150
969
100
690
50
q 2009 Thermal Power Generation 81.6GW
350
300
2000
2006-07 10th
2011-12 11th
Plan End (actual)
Plan End
2016-17 12th
plan End
Energy Re quirement (BU)
13th Plan
Peak Load (GW)
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

2
Approach for Setting Targets Depends upon the Objective of the

Scheme
Total Saving Objective = 8.97 MTOE
SN
1
2
3
4
5
7
6
8
Total
Sector
Power (Thermal)
Iron & Steel
Cement
Fertilizers
Aluminium
Paper & pulp
Textile
Chlor-Alkali
No. of
Identified DCs
Reported
Share of Apportioned
Energy
Consumptio
Energy
Consumption
n
reduction
(MTOE)
104.14
28.00
11.87
7.86
7.73
2.09
1.62
0.84
164.15
145
80
65
28
10
31
85
18
462
(%)
63.44%
17.06%
7.23%
4.79%
4.71%
1.27%
0.99%
0.51%
100%
(MTOE)
5.691
1.530
0.649
0.430
0.422
0.114
0.089
0.046
8.97
3
AUX POWER CONSUMPTION
Induced Draft Fan ( ID Fan )
Forced Draft Fan ( FD Fan )30%
Primary Air Fan ( PA Fan )
q Circulating Water Pump
4%1%
HT MOTOR
LT MOTOR
MISC
95%
30%
( CWP )
q Condensate Extraction Pumps ( CEP )

q
Water Supply Pumps
Boiler Feed Water Pump ( BFW Pump )
High Pressure Boiler Feed Pump (PBFP )
33%
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
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
0.5MW
Coal Handling Plant

And common aux.
Approximate
2.0MW
TOTAL ( 8.5% )
18.0MW
6
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
ABOUT YANTRA- Energy Saving Solutions History
2009-11
2007-2009
2006
a) Introduction .
a) Reliance Dahanu
3 nos .
CEP ,PA Fan.
b) Reliance Goa,Samalkot
2 nos .
c) Monnett Ispat CWP
2 nos .
d) APGENCO 1 no
e) Cell Bypass Feature
Implemented .
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 HPCL
e) Introduction of Vector Control
Synchronous Transfer ,GPRS
Remote Diagnostics
Target Energy Saving 2011 15MW
Majority Retrofit
9
Savings
Projects
MW
MWh/Yr
Tons CO2
Completed
2.932
23456
25801
Under Execution
4.990
39920
43921
Target 2011-12
15
10
Eg : Power Plant
System Desired Pressure & Flow are Imp Factors in Determining

Operating Point- especially in Power Plant Applications
11
Centrifugal Load Affinity- Law
12
Fan Systems
Pumping Systems
Control Valve
VFD
Variable Fluid -Coupling
15-20% Effeciency Diff depending on

Speed .
13
Note : Above are Indicative Data
Reliance Energy Dahanu

CEP Case Study
CEP Process Flowchart
Dahanu Thermal Power Station
Data of CEP Before MV Drive Installation - DOL Operation
TURN-KEY PROJECT SCOPE OF WORK
CEP-2A discharge pressure ( Head )

Dearator Pressure
Flow
Motor speed
Current
Power consumed by CEP without MV drive
: 21.3 Kg/cm^2
: 6.9 Kg/cm^2
: 640 T/hr
: 50 Hz = 1480 rpm
: 59.2 Amp
: 590KWH
CEP-2A discharge pressure

Dearator Pressure
Flow
Motor Speed
Control Valve CD14 Position
Current
Power consumed by CEP with MV drive
: 16.5 Kg/cm^2
: 6.9 Kg/cm^2
: 640 T/hr
: 45.4 Hz = 1362 rpm
: 86% open
: 40.4 Amp
: 415KWH
MV Drive with Bypass Panel

Civil room for MV drive system
Necessary Cooling arrangement
Cable Laying & Terminations
Data of CEP after Installation of MV drive
Interfacing with existing DCS system
ENERGY SAVING OF 150KW TO 175KW PER HOUR ACHIEVED ( 25% )

14
APGENCO Vijayawada
ID Fan Case Study
Fan Process Flowchart

TURN-KEY PROJECT SCOPE OF WORK Data of ID Fan Before MV DriveIDInstallation
- DOL Operation
Scoop Position
: 60-65% Open
Air Flow
: 700 TPH
Civil room for MV drive system
Fan Speed
: 640 rpm
Suction Pressure
: -130 mmwc
Necessary Cooling arrangement
Furnace Pressure
: -10 to -15 mmwc
Motor Speed
: 50 Hz 740 rpm
Supply of All Cables
Current
: 155 160 Amp
Power Consumption without MV Drive : 1500 KW
Interfacing with existing DCS system Data of CEP after Installation of MV drive
Scoop Position
Hydraulic Coupling kept in Line

With Scoop Tube position
At 100% open
: 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
ENERGY SAVING OF 350KW PER HOUR PER FAN ACHIEVED ( 24% )
15
Reliance Energy Samalkot

HPBFP Case Study
HPBFP Process Flowchart
Data of ID Fan Before MV Drive Installation - DOL Operation

HPBFP Discharge Pressure
Samalkot Combined Cycle Plant

TURN-KEY PROJECT SCOPE OF WORK
HPBFP Flow
HP ECO outlet Pressure
HP Drum Pressure
Operating Frequency
Power Consumption
: 121 bar
: 207 TPH
: 86 bar
: 76 bar
: 50 Hz
: 1100 KW
Data of CEP after Installation of MV drive

Supply of All Cables
Interfacing with existing DCS system
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
ENERGY SAVING OF 300KW PER HOUR ACHIEVED ( 27% )
16
ENERGY CONSUMPTION PATTERN

BEFORE INSTALLATION
AFTER INSTALLATION
DATE
I D FAN -1 (in KWH)
N.O HEATS
KWH / HEAT
DATE
I D FAN -1 (in KWH)
N.O HEATS
KWH / HEAT
10/09/2010
22600
27
837.037
16/09/2010
23520
29
811.034
12/09/2010
23160
26
859.230
18/09/2010
20920
26
804.615
13/09/2010
21780
28
777.857
20/09/2010
21740
28
776.428
14/09/2010
23300
25
932
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
MODIFICATION # 1
MODIFICATION # 2
MODIFICATION # 3
MODIFICATION # 4
MODIFICATION # 5
INDEPTH PROCESS KNOWLEDGE HELPS TO MAXIMISE ENERGY SAVING

17
Concept :
18
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
Service Back up :
a) Post Warranty AMC
b) Service Spares at Plant Level during Warranty
19
20
Pay on Performance / Guaranteed Energy Basis .
Guaranteed Energy Basis Outright Payment
Guaranteed Energy Basis Pay out of Saving
1) Energy Saving Guarantee Decided .

2) Payback within agreed limits
3) Price Negotiated
4) Penalty for non achievement decided .
1) Energy Saving Guarantee Decided .

2) Payback within agreed limits
3) Finance Cost included
4) EMI Decided within stipulated time
5) Penalty for non achievement decided .
21
YANTRA HARVEST MV DRIVE
22
YANTRA HARVEST MV DRIVE
23
MV Drive Ratings
3300V Series:
Rated motor 300 ~ 7000KW
6600V Series:
11000V Series:
24
Summary
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
25
ENERGY SAVED
IS
ENERGY GENERATED
26

MR Gaurang Bhatt-Yantra

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REDUCTION IN APC & ACHIEVING PAT

TARGET IN POWER PLANTS

CII GBC Forum Aug 2011

Yantra Harvest Energy India

India Power Scenario

q 64% Power Generation = Thermal

q 2009 Thermal Power Generation 81.6GW

Energy Re quirement (BU)

Peak Load (GW)

q Aux Power = 8-10% = 6-7GW

Majority of Aux Power = MV Motor

Yantra Harvest Energy India

Approach for Setting Targets Depends upon the Objective of the

AUX POWER CONSUMPTION

Induced Draft Fan ( ID Fan )

Forced Draft Fan ( FD Fan )30%

Primary Air Fan ( PA Fan )

q Circulating Water Pump

q Condensate Extraction Pumps ( CEP )

Water Supply Pumps

Boiler Feed Water Pump ( BFW Pump )

High Pressure Boiler Feed Pump (PBFP )

Yantra Harvest Energy India

How to Become more Effecient

Yantra Harvest Energy India

TYPICAL AUXILIARY CONSUMPTION

Boiler Feed Pump

Coal Handling Plant

Yantra Harvest Energy India

Expected Saving After

Expected saving = 3.6MW 4 MW

Yantra Harvest Energy India

Yantra Harvest Energy India

ABOUT YANTRA- Energy Saving Solutions History

a) Green Field Cement Plant

Target Energy Saving 2011 15MW

Yantra Harvest Energy India

Yantra Harvest Energy India

System Desired Pressure & Flow are Imp Factors in Determining

Yantra Harvest Energy India

Centrifugal Load Affinity- Law

Yantra Harvest Energy India

Variable Fluid -Coupling

15-20% Effeciency Diff depending on

Note : Above are Indicative Data

Yantra Harvest Energy India

Reliance Energy Dahanu

CEP Process Flowchart

Dahanu Thermal Power Station

Data of CEP Before MV Drive Installation - DOL Operation

TURN-KEY PROJECT SCOPE OF WORK

CEP-2A discharge pressure ( Head )

CEP-2A discharge pressure

MV Drive with Bypass Panel

ENERGY SAVING OF 150KW TO 175KW PER HOUR ACHIEVED ( 25% )

Fan Process Flowchart

Hydraulic Coupling kept in Line

ENERGY SAVING OF 350KW PER HOUR PER FAN ACHIEVED ( 24% )

Yantra Harvest Energy India

Reliance Energy Samalkot

HPBFP Process Flowchart

Data of ID Fan Before MV Drive Installation - DOL Operation

Samalkot Combined Cycle Plant