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Smart Energy Management1 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential

Smart Energy Management

1Measure2Detect3Control

Benefits of IT in Power Plants

Presented by: R Bhatia, GM Conzerv Systems


Requirement of Energy Management in Utilities

Improvement in PLFReduction in APCReduction in T&D losses

> Improvement in Accountabilty> Improvement in Power Quality

>> Power Factor>> Harmonics


Requirement of Energy Management in Utilities – Ways to Improve

Energy Audit followed by implementation of recommendations.Energy Management System: By taking action on shortcomings indicated and reports generated.


On Line Monitoring System


Instrumentation for Measurement


Stand-Alone Meters are not enough

Generally provide only Raw Data

Readings cannot be correlated on-line, in Real-Time

Difficult to relate Energy Consumption in Auxiliaries to Generation

Optimisation requires On-Line Data. Difficult to achieve with Stand-Alone Instruments.


EMS SYSTEM

EM 6000 Series RS 485-RS232

CONVERTORDATA

CONVERTOR

LAN NETWORK HUB

ETHERNET

CONVERTOREM 3000 Series

DATA CONVERTOR

CONZERV eLAN®


Energy Management System Applications

Predictive MaintenanceRoot Cause AnalysisPower QualityMeasurement and VerificationCost AllocationSmart Power ManagementEnergy Resource PlanningEnergy BalancingBreaker Status – remote monitoringAutomated Energy Billing System for Townships


Conzerv in NTPC & GencosOn Line Systems>> Singrauli, Tanda, Dadri, Vindhyachal,Ramagundam,Kawas, Jhanor, Kahalgaon, OPGC (Jharsugada), Reliance Dahanu

NTPC corporate has made On Line Monitoring standard in new power plants alsoEnergy Audits>> Dadri (twice), Talcher, Faridabad, Kayamkulam,Auraiya,Singrauli, WBWDC plants Bakreshwar and Santaldih


About Ourselves

l Incorporated in February 1988l HQ and Unit I at Electronic City, Bangalore,

India. Unit-II at Daman, l Specialized in Electrical Energy Management

& Conservation for Industrial and Commercial Complexes

l A Total Electrical solution providerl To help our customers improve their

performance through reducing energy costs


Spectrum of Activities

MetersMetersIndustrial, Industrial, RevenueRevenue

SoftwareSoftware NetNet--workingworking

Training On Training On Energy Energy

EfficiencyEfficiency

Sales & Sales & Support Support NetworkNetwork

PF PF ControlControl

Demand Demand ControlControl

Energy Energy AuditsAudits

Generator Generator SynchSynch

Remote Remote MonitoringMonitoring

Harmonic Harmonic Analysis, Analysis, Reactors, Reactors,

FiltersFilters

Generator Generator AMFAMF

Smart Energy Management13 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential13 25-Dec-08

Outsource the Energy Management and Energy Accounting function

On-line Energy Audits

Periodic reports with recommendations for energy cost reduction

The Conzerv Way2SaveThe Conzerv Way2SaveTM–– Energy Improvement ProgramEnergy Improvement Program


How EIP works….

14 25-Dec-08 © Copyright 1986-2005, ConZerv Proprietary & Confidential

User EMS PC Conzerv Server

Broadband

Online Analysis of Plant Data

Smart Energy Management15 Apr 1, 2005 © Copyright 1986-2005, ConZerv Proprietary & Confidential15 25-Dec-08 © Copyright 1986-2005, ConZerv Proprietary & Confidential

CONZERV HO

ISP(Internet Service Provider)

GSM/CDMA TOWER

GSM/CDMA MODEM

GSM /CDMA MODEM

DSL CONNECTION

EMS PC

EMS PC

EMS PC

Fig: Schematic diagram EIP (Way to Save)Fig: Schematic diagram EIP (Way to Save)

Online DataAnalysis


THERMAL POWER STATIONS

ENERGY CONSUMPTION IN AUXILIARY EQUIPMENT


THERMAL STATIONSAUXILIARIES MAY CONSUME 6%TO 14% OF TOTAL GENERATIONEACH ONE PERCENT REDUCTION CAN RESULT IN SAVINGS OF CRORES ANNUALLY AND RELEASE A FEW MEGAWATTS OF GENERATIONNO REDUCTION POSSIBLE UNLESS CONSUMPTION IN EACH MEASURED


THERMAL AUXILIARIESNO EXISTING SYSTEM OF MEASUREMENT OF ENERGY CONSUMPTION IN AUXILIARIESAUXILIARY CONSUMPTION CALCULATED FROM DIFFERENCE OF POWER GENERATED AND POWER TRANSMITTED


THERMAL AUXILIARIESAS NO DIRECT MEASUREMENT IS BEING DONE

APC CALCULATION IS APPROXIMATEEFFICIENCY OF EACH EQUIPMENT IS UNAVAILABLELOSS OF EFFICIENCY DUE TO TECHNICAL / MAINTENANCE REASON CANNOT BE ASCERTAINED


THERMAL AUXILIARIES

•FOR A TYPICAL 210 MW UNIT

•HT MOTORS 6.6 KV - 43 NO’S

•LT MOTORS 415 V - 510 NO’S

TOTAL CONNECTED LOAD - 36.5 MW

= 17.5%


THERMAL AUXILIARIES

PROPOSED ENERGY MONITORING

•HT MOTORS - 43 NO’S

•LT MOTORS > 50 KW - 44 NO’S


THERMAL AUXILIARIES

FOR MOTORS < 50 KW

USE OF PORTABLE ANALYSER ON

AS REQD. BASIS


RELEVANCE OF ENERGY CONSERVATION

MAXIMISE DESPATCH OF ENERGY BY MINIMISING INTERNAL USAGEENERGY USAGE CAN BE MINIMISED BY OBTAINING OPTIMUM EFFICENCY


ADVANTAGES OF ON LINE MONITORING

ENERGY CONSUMPTION OF MAJOR AUXILIARIES WILL BE AVAILABLEPROPER ACCOUNTING AND ENERGY BALANCE POSSIBLELOSSES CAN BE DETERMINEDDETERIORATION OF EFFIENCY CAN BE IDENTIFIED AND CORRECTED AT FIRST OPPORTUNITY


ADVANTAGES …PROPER COSTING OF ENERGY GENERATION ACCURATE ON LINE DATA ELIMINATING HUMAN ERRORSBENCHMARKS CAN BE SET FOR PLANT COMPARISON WITHIN AND WITHOUT POSSIBLE


Requirement of Energy Management System in Utilities

Improvement in PLFReduction in APCReduction in T&D losses

> Improvement in Accountabilty> Improvement in Power Quality

>> Power Factor>> Harmonics


CASE STUDYBOILER FEED PUMP


NTPC Unit ( 210 MW ) ITEM KWH KWH / DAYBFP-1B 2085 55938BFP-1C 2312 62285FD Fan-1A 380 10797FD Fan-1B 383 10879ID Fan-1A 770 21280ID Fan-1B 800 22820PA Fan-1A 780 18210PA Fan-1B 780 18135


Case Study – Boiler Feed PumpBoiler feed pump 1C showed higher energy consumption.This pump was overhauled in recent past by manufacturer.The pump internals ( cartridge ) was also replaced recently.New technology valve was also fitted in this pump.


Case Study contd.All factors stated should have resulted in lower energy consumption .Obvious conclusion was that measurements were incorrect.Meter was rechecked and recalibrated.Software for on line monitoring was also checked but no fault could be located.Pump continued to show higher consumption.


Case Study contd.As running 210 MW unit could not be shut down, checks were carried out on motor as well as the pump in operation.Results were inconclusive as no defects could be ascertained.Plant authorities decided to wait till next scheduled shut down.For over two months pump operated with excess consumption of 6500 units per day.


Case Study - ConclusionDuring shut down, the pump was dismantled.Observed that on the recirculating valve side there was excess clearance or gap resulting in higher energy for same pumping requirement.On line monitoring system could payback in less than two months.Analogue ammeter of say 500 Amp full scale may not show noticeable difference between 228 and 252 Amps


Case StudyCoal Mill


COAL MILLIn the Coal mills power consumption increases with wear of grind rolls. Thus it should be possible to establish a relation between run hours and power consumption.Actual spot readings taken with energy meters in a coal mill are shown in the next slide with attempt to establish some pattern in the next two slides.


COAL MILL


Coal Mill


Coal MillRun Hours Vs Power Consumpt ion and Speci f ic Power Consumpt ion

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

1 A 1 B 1 C 1 D 1 E 1 F 2 A 2 B 2 C 2 D 2 E 2 F 3 A 3 B 3 C 3 D 3 E 3 F 4 A 4 B 4 C 4 D 4 E0.00

2.00

4.00

6.00

8.00

10.00

12.00

Run Hours

Power Consumption

Specific Power Consumption


Coal Mill - AnalysisFrom energy meter readings it is not possible to establish any relationship .Noting Specific Power Consumption trend on line from 0 to 2500 hrs can enable extrapolation to say 3500 hrs or even 4000 hrs.Prediction of Specific power consumption at 4000 hrs and consequently extra power consumption vs cost can provide an optimum replacement point in no of hours for each mill as characterstics for each are different.


Coal Mill - AnalysisWhen Bullring replacement is done it is necessary to know whether Specific power consumption has changed as compared to original state.If not, there could be other causes also which contribute to higher consumption.Actual power consumption of a coal mill is shown in next slide. Mill E is showing unusually high consumption.


DAILY POWER CONSUMPTION & AVG.KW

EQUIPMENT NAME

UNIT-1 UNIT-2 UNIT-3 UNIT-4

AVG. KW AVG. KW AVG. KW AVG. KW

MILL-A 139 160 161 153

MILL-B 135 147 166 148

MILL-C 148 141 163 151

MILL-D 131 144 158 157

MILL-E 173 0 159 142

MILL-F 148 139 138 145

Av.Kw 146 146 158 149

Case : 1


Coal MillLooking at high consumption mill E is attended to for necessary repair and maintenance.Results of correct operation can be seen in the next slide – a reduction of over 50 KW in one mill.


DAILY POWER CONSUMPTION & AVG.KW

UNIT-1 UNIT-2 UNIT-3 UNIT-4

EQUIPMENT NAME AVG. KW AVG. KW AVG. KW AVG. KW

MILL-A 134 139 142 149

MILL-B 119 124 133 131

MILL-C 138 117 159 149

MILL-D 0 130 153 138

MILL-E 121 119 0 120

MILL-F 124 0 102 0

Av.KW 127 126 138 137


CASE STUDYCOAL HANDLING PLANT


Case Study – Coal Handling PlantNTPC had taken over Thermal Station from Electricity Board against dues.Station had low PLF and high auxiliary power consumption.NTPC made substantial improvements on both achieving PLF better than 85 % and auxiliary consumption at approx 12 %.Station has 4 x 210 MW units


Case Study contd.Plateauing of further gains in Auxiliary Power consumption occurred.Unit auxiliaries were in focus for reduction but station auxiliaries not given adequate attention.Coal Handling plant tended to be neglected being out of sight.Plant authorities decided to focus on CHP.


Case Study contd.Energy meters were installed in CHP.Consumption was measured in conveyors and crushers.No opportunity for reduction could be established.Use of power analyser also could not result in substantial reduction.It was decided to have a demo energy management system.


Case Study - ConclusionEMS provided on line data of consumption with relation to time.Conveyor was observed to be consistently underloaded.Crusher was actually operating for only a few hours per day but remained on all the time.With improvements in operation indicated by EMS the station has achieved further gains.


Operation of CrusherNext slide shows from actual coal crusher the trend of energy consumption on a particular day.On line data shows crusher operation is proper in the beginning and towards the later part.In the middle portion for considerable period the crusher is not optimally loaded


Case : 2


Ash Slurry PumpsCase Study


Case Study - NTPC PlantAfter On line monitoring system was operated for 2-3

months, the plant managers one key finding was that there were huge number of START & STOPS in their Ash slurry pumps. After analysis it was found that there are a lot of leakages at the pumps on the output side. After sealing of these leakages the requirement of running the Ash slurry pump for the same process drastically came down from 6 pumps to 3 pumps. Each pump consumes a total of 120-130kw/hrNet Saving = 120*3=360kw/hr*24hr = 8640kwh.


Earlier


After


CW PumpsCase Study


CW System – Observations in Power plants

Specific Cooling water consumption cubic meters per MW higher than norm.Specific energy consumption (pumping efficiency) KWH per cubic meter higher.Ash water consumption higher.DM water make up pumps running even if there is no demand – energy savings possibility with VFD.High back pressure in condenser – can be improved by condenser tube cleaning. High TTD indicates low heat transfer efficiency.


CW System – Some Audit Observations

Low efficiency of CW pumpsHead higher than requiredWastage of water in auxiliary heatingRecovery of waste water from clarifier etc


SPECIFIC ENERGY CONSUMPTION REPORT

System Fan Unit -1 Unit-2 Unit-3 Unit-4

ID Fans

Fan-A 1.61 1.86 1.75

Fan-B 1.57 1.81 1.64

Fan-C 1.92 1.67

FD FansFan-A 1.45 1.35 1.14 1.42

Fan-B 1.25 1.24 1.12 1.50

PA FansFan-A 9.69 9.21 10.52 8.77

Fan-B 9.55 9.48 10.10 8.85

BFPs

Pump-A 7.91 8.07 9.0 7.15

Pump-B


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1measure 2detect 3control - india core...vindhyachal,ramagundam,kawas, jhanor, kahalgaon, opgc...

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