bhel ccdp audit
DESCRIPTION
Energy auditTRANSCRIPT
1
Energy Auditing the Electrical Utilities BHEL CCDP
ByRenga Ramanujan CReg No. 01110548014
Guided by,Internal Guide : External Guide : Mrs. Gomathi E Mr.
Ramakrishnan D (Asst Prof Petrochemical Dept.)(AGM CCDP BHEL)
Anna University R&D BHEL
Trichy Trichy
2
Introduction A complete and comprehensive energy audit study
was conducted on the electrical utilities, BHEL CCDP in Thiruchirapalli, in the months of Jan-Apr 2012
Study was performed aiming the following objectives.
Conservation of energy, as a social responsibility, as a commercial benefit to user
Participate in the proposed, perform and achieve in trade (PAT Scheme) under, National mission on enhanced energy efficiency program
3
ObjectiveMain objective of the project is to audit the
electrical equipment's and propose suitable savings with paybacks
The following equipment's considered in Auditing :MotorPumpsCooling TowerLightingCompressorTransformer
4
BHEL CCDP(Combined Cycle Demonstration Plant) Trichy
CCDP is an IGCC(Integrated gasification combined cycle) plant type.
Installed year 1984
Total plant efficiency 58 %
Capacity of the plant is 6.25 MW 2.25 MW ( Steam Turbine ) 4.00 MW ( Gas Turbine )
2.75 MW utilized by the plant and remaining power is uploaded to the TNEB grid
5
IGCC (Integrated Gasification Combined Cycle)
Fig IGCC Plant Process
6
Gasification ReactionsExothermic
C + O2 CO2
C + ½ O2 CO
C + 2H2 CH4
CO + H2O CO2 + H2
Endothermic C + CO2 2CO
C + H2O CO + H2
Incomplete Combustion of coal forms an gas called as syn-gas (CO+H2 ).
Coal gas has the Calorific value(in CCDP) is ( 1030 Kcal/Nm3 ) . These gasification reaction is taken place in a gasifier which kept in an
high pressurized conditions.
7
PLANT
PROCESS
DIAGRAM
8
TNEB Bill for R&D Side as on ( 06-01-2012 ) :Statement of electrical energy consumption During the Month of DEC-2011 in respect of HT SC.No.58 CCDP
SI NO Description Electrical
Consumption
In Units
01 CCDP 1,20,060
02 FCB 22,200
03 Welding research institute 38,300
04 Misc.Buildings,Street Lights 3,500
Total 1,84,060
Sanctioned demand in KVA 2000Maximum demand touched in KVA during 1885.80the month of DEC 2011Power Factor 0.96 lagEnergy Supplied by TNEB 1,84,060 UnitsPer Unit rate 6.76 `Amount Paid to TNEB 12,44,245 `
Auditing Electrical Utilities
Equipment Audited
MotorsCompressorsCooling Towers LightingPumps Transformers
Motor Auditing ReportImportant Data In Motor Auditing :
% Loading – Working Power *100 Rated Power
Were, Loading of an Motor Determines;
75 % Loading- All motors designed efficiency is under this loading % only. PF factor is in the range of 0.8 -0.9 at this % loading. So its necessary step in auditing the motor to measure the
loading percentage.
Efficiency- Efficiency is measured by the losses method ,this efficiency
plays the main role in energy consumption of the device.
Efficiency vs Loading graph
0% 20% 40% 60% 80% 100% 120%0
10
20
30
40
50
60
70
80
90
100
Efficiency vs Loading
75-100 HP30-60 HP15-25 HP0-10 HP
loading
Eff
icie
ncy
Power factor vs Loading
35% 45% 55% 65% 75% 85% 95% 100%0
0.2
0.4
0.6
0.8
1
1.2
PF Vs Working Load
75-100 HP30-60 HP15-25 HP0-10 HP
Full load-Amperage
Pow
er F
acto
r
Motor Details BHEL CCDPThere are about 139 Motors
running in the Plant including motor and compressor drives
The loading % is calculated in all the motors its found that 25 motors are running in under loading conditions among which 6 motors are high rated Motors which has been taken and efficiency has been calculated for that Motors
Under-Loading Motors
Vibrator-4( Rated Power-7.5 kW)
% Loading - 38.667 %
Working Efficiency - 78.69 %
PF - 0.92
Belt Conveyor( Rated Power- 5.5 kW)
% Loading - 41.81 %
Working Efficiency - 80.13 %
PF - 0.88
Bucket Elevator (Rated Power-5.5 kW)
% Loading - 47.27 %
Working Efficiency - 78.52 %
PF - 0.85
Under loading Motors
Crusher (Rated Power-30 kW)
% Loading - 46.67 %
Working Efficiency - 77.02 %
PF - 0.92
Belt Conveyor(Rated Power-15 kW)
% Loading - 47.27%
Working Efficiency - 81.00%
PF - 0.86
Ash conveyor(Rated Power-3.5kW)
% Loading - 42.85%
Working Efficiency - 73.11%
PF - 0.48
16
Make: NGEF(vibrator 4)Rated Power : 7.5 KWRated Current : 13.7 AmpsRated speed : 1440 RPMInsulation class : FDuty cycle : S1Designed efficiency ɳ : 88%Number of Poles : 4Connection : DeltaStarter : DOL
No Load (15% load setting)Voltage : 415 VCurrent : 5AFrequency : 50 HzStator resistance : 1.75ΩPower : 1200 W
Load (75% load setting)Voltage : 415 VCurrent : 12.5 APower : 2900 W
Motor Calculations :
17
SolutionIron Loss with friction Windage loss
Pi + fw=Pnl-Pst.cu (Stator Cu loss)
Pst.cu= 3*(No load current/√3) 2*Stator Resistance =3*(5/√3)2*1.75Pst.cu = 43.75 WPi + fw=1200-43.75
= 1156.25 WStator resistance at working condition with respect to insulation classStator resistance = (1.75)*(110+235/ 30+235)
=2.28 ΩStator Copper losses at Full load
Pst.Cu(FL)=(3*(13.5/√3)2/2.28 = 427.67. W
18
Full load slip
Ns =120*50/4 = 1500 RPM
S= (1500-1440)/1500
S=0.04
Rotor Power Pr= 7500/(1-0.04)
=7812.5W
Power Input Pi=Pr+pst.Cu(FL)+(Pi+fW)+Pstray
= 7500+427.67+1156.25+0.018
= 9.531 KW
Ns= 120f/p S= Ns-N/
Ns
Pr= Rated power/(1-S) Watts
19
Motor Efficiency:% ɳ=Rated output/Power Input *100
= 7.5/9.531 *100=78.69%
Power FactorPF=Pi/√3* Rated Voltage*Rated currentPF= 9.531*1000/√3*415*13.5 =0.968 lag
Payback and ProposalsProposals
Installation of ʎ-∆ convertor
Installation of VSD Drive
Installation of reduced rating Motors
Installation of DE Controllers
Installation of Capacitors
Motor Energy saved/Year
Costs Saved/Year
Payback Period
kWh ` Months
Vibrator 4 16386 1,06,509 10.7
Belt conveyor 20184 1,31,196 4.1
Bucket Elevator
18600 1,20,900 4.8
Crusher 104682 6,80,433 2.6
Belt Conveyor 3
60240 3,91,560 6
Total 220092 kWh 14,30,598 `
Payback for Installing VSD Drive :
21
Compressor Auditing Report
The Compressor is an Least efficient device the compressor is major electrical consumption device on the plant.
The compressor air is used in an plant for the Instrumentation air , service air ,an heatless dryer compressor ,and LPC for Gas turbine, Plant AC.
The compressor audited to find out the leakage, Actual FAD
and the volumetric efficiency is calculated and the efficient enviornment is proposed in this auditing
22
Data Collection Name Plate data
Design CFM
Rated Power W
Storage tank Capacity m3
Cut in Pressure kg/cm2
Cut off Pressure kg/cm2
Measured data
Time taken by compressor to reach cutoff pressure sec
Loading and unloading time sec Calculated Data
% Leakage
Volumetric ɳ ; Isothermal Efficiency
Actual FAD CFM
Specific energy consumption Watts/CFM
23
Formula used Correction factor = [(273+ambient air temperature)/ (273+temperature of discharge air)]
Actual FAD (m3/s) = [(P2-P1)/P0 x (total vol of receiver / time taken) x correction factor]
FAD (m3/hr) = FAD (m3/s) x 3600
FAD (Nm3/hr) = FAD (m3/hr) x (atm pressure / 1.013) x (273 / (273 + ambient air T))
FAD (cfm) = FAD (Nm3/hr) x 0.588
Volumetric efficiency = (Actual FAD / Design value) x 100
Sp.energy consumption= (actual power consumption /actual FAD in cfm)
24
Compressor AuditingInstrument AirRated power : 37 kW
Design CFM : 162.5087
Actual CFM : 103.596
Specific Energy Consumption : 0.24 kW/CFM
% Volumetric ɳ : 63.75 %
% Leakage : 34.49%
Service AirRated power : 90 kW
Design CFM : 528.1536 CFM
Actual CFM : 319.22 CFM
Specific Energy Consumption : 0.235 kW/CFM
% Volumetric ɳ : 60.47%
% Leakage : 31.70%
25
Compressor AuditingLPCRated power : 1.07 MW
Design CFM : 36034.56 CFM
Actual CFM : 29337 CFM
Specific Energy Consumption : 0.41 kW/CFM
% Volumetric ɳ : 67.54 %
% Leakage : 35.06%
Plant AC Compressor 2 No’sRated power : 20 kW ; 20kW
Design CFM : 70 CFM ; 60 CFM
Actual CFM : 54 CFM ; 42 CFM
Specific Energy Consumption : 0.21 kW/CFM ; 0.21 kW/CFM
% Volumetric ɳ : 64% ; 64.7%
26
Proposals and PaybackObservation : Instrument ,service air compressors are installed in the air 1985 and LPC
installed in 1990 and Plant AC compressors installed in 1994.Its been found that the Volumetric efficiency is around 60% in all compressors represents the age doesn’t the performance of compressors.
Problem exists in the leakage between the compressor and the receiver tank.
Found out Leakage areas : Damaged Valve seperating the drier unit and service air
compressor. Leakage in pipe joints of pipes at the room corner ends
leaving the compressor room to the outside storage tank. Bypass Valve present near the tank were the pipe
connceted to the storage tank
For precision leak detection ultrasonic leak detectors are recommended
27
Savings Analysis (With Leakage arresting of 20%)
Compressor Leakage Energy Waste
Energy Savings
Cost saved
Instrumentation
34.39 % 84840 60000 3,90,000
Service Air 31.70 % 294600 247465 16,08,526
Total 3.07,465Units/year
19,98,522.5`
28
Lighting Auditing Report The CCDP Plant utilize Mercury vapor lamps (125 W &
400W),FTL 40W and rare Sodium vapour (250W) is used.
The data has to be gathered is the length ,breadth and
width of the room and lux at different corners of room
and average lux is taken.
With the gathered data ILER has been calculated and
propose whether the room is at underlight or overlight
conditions.
29
Formula Used Total Watts utilized:
With the help of power analyzer the total watts utilized by the room is measured. Room Index:
Floor area (height-0.83)*(Length + Width) Watts/Square metre :
Total Watts/Floor area Actual Lux :
Average lux / W/m2
ILER(installed load efficacy ratio) = Actual Lux /Target Lux
30
Lighting Auditing Report
Lighting consumption data at different sections
Gasifier Section - 105.36 units/dayGas Cleaning System - 71.16 units/dayCoal yard - 84.42 units/dayEngineering Building - 46.72 units/dayStreet Lighting - 159 units/dayOther areas - 326.34 units/day
31
Lighting calculations Turbine & Crane Hall:
Length : 70 m Width : 30 m Height : 6 m Average Lux : 92 Target Lux : 50 Number of workers : 32 Total Watts Utilized : (400*21) = 8.4 kW
Floor area : Length * Width110*45 = 4950 m2
Room index : floor area / (height-0.83)*(length + Width)4950 / (6-0.83) * (110 + 45)= 3.48
32
Contd..Watts / Sq.m : Total Watts / Floor area
8.4*103 / 4950 = 1.7 W/m2
Actual lux / (W/m2) : Average lux / W/m2
92 / 1.7 = 54.214
Installed load efficacy ratio: Actual lux / Target lux
54.214 / 50= 1.08
33
Light AuditingPlace Area TotalWatts ILER
Gasifier Section(Ground Floor)
375m2 1.155kW 0.74
Power house 2100m2 3.2kW 1.05
Turbine Hall 4950m2 8.4 kW 1.08
Control Room 600m2 2.24 kW 0.51
Pump House 1000m2 1.32 kW 1.004
Compressor House
875m2 1.28kW 0.892
Stores and Instrumentation room
2800m2 3.295 kW 0.93
Reference room
600m2 920W 0.93
Gas CleaningGround floor
400m2 2.12 kW 0.297
34
Proposals and Savings Turbine and Crane Operating Hall : This room consist of an two turbines(gas and steam turbine ) were
gas turbine operating in an steel guarded closed room and an condenser with vacuum pumps and pumps from condenser to cooling tower and the boost compressors of LPC and HPC in steel guarded closed room .32 workers are always present in the hall so the proper lighting is necessary for this room
Proposals :The 21 No’s of 400 W high pressure mercury vapour lamps can be replaced with 180W Induction lamp
Energy savings = Total watts utilized per hour previously* (operating hours) – Total Watts utilized in present*(operating hours) Energy Savings / year = ( 8.4*4380 ) – (3.78*4380) = 20236 kWh Cost saved / year = 20236* 6.5= 131,534 `
35
Proposals and SavingsGasifier section and gas cleaning section mostly
uses an Mercury vapour lamp in most of the places
this light can be replaced with induction lamps
Street lamp is mainly an 125 W Mercury vapour
lamp which and 250 w sodium vapour lamps these
lamps can be replace with the CFL Lamps
40W FTL lamps equals 18 W CFL so FTL lamps are
replaced with CFL Lamps
Motivating green energy with Solar Street
lighting
36
SavingsPlace Energy
Wasteunits
Energy saved with new settings units
Costs saved`
Gasifier Section
8079 5885 38,255
Street lighting 58035 37120 2,41,312
Power House 14016 13889 90,279
Turbine Hall 36792 16556.4 1,31,534
Control Room 3205 2809.3 18,260
Gas Cleaning 35838 31130 2,02,345
Reference room
282 257 1671
Total 111331.69 723656 `
37
Cooling Tower Cooling towers are heat removal devices used to transfer
process waste heat to the atmosphere. Cooling towers may either use the evaporation of water to remove process heat or, rely solely on air to cool the working fluid to near the dry-bulb air temperature.
Auditing the cooling tower:
While auditing the cooling tower
Data Gathered:
Hot water inlet
Cold Water outlet
circulation rate
Dry bulb and Wet bulb Temperature
electrical equipment's data associated with cooling tower
Calculated
Effectiveness of cooling tower
Make up Water Requirement
Pump working efficiency
38
Formula usedRange (°C) = [CW inlet temp (°C) – CW outlet temp (°C)]
Approach (°C) = [CW outlet temp (°C) – Wet bulb temp (°C)]
Effectiveness= Range / (Range + Approach)
• Blow down = Evaporation loss / (C.O.C. – 1) m3/hr
• Make up water requirement= Evaporation loss + Blow down loss m3/hr
39
Cooling Tower in CCDP The plant uses 2 cooling towers .
The cooling tower type used is the Induced draft counter flow cooling tower.
Cooling Tower 1 The water used to cool the external surface of condenser
Cooling Tower 2 The water used to cool the gasifier
Annual power utilized for cooling tower is 72 lakhs ` Pumps 80% Fans 20%
40
CCDP Cooling Tower(1)
Fan Motor: 15 KW
Rate of Flow 1880 m3/hr
44oC
33o
C
Wet Bulb Temp: 28oC
Dry Bulb Temp: 30.5oC
125 ϕ m
103.7 ϕ m
8.39 ϕ m
Fan Blades
3.6 ϕ m
Tower Frame: Treated timber
No of Fans: 4
No of blades: 3
4.88 ϕ m 4.88 ϕ m 4.88 ϕ m
Calculated Values:
Range : 11oCApproach : 5oCEffectiveness : 68.75%Evaporation : 31.64m3.hrLossBlow down :10.54 m3/hrLossConnected :Pumps ACW1,2(45kW),
CW 1,2 (150 kW) HP Aux pump(30 kW)
Fan : CT fans 3*15kW
Air Flow Rate : 138700 m3/hr
41
CCDP Cooling Tower (2)
Fan Motor: 20 KW
Rate of Flow2440 m3/hr
45oC
36oC
Wet Bulb Temp: 28oC
Dry Bulb Temp: 30.5oC
160 ϕ m
130 ϕ m
8.50 ϕ m
Fan Blades
3.8 ϕ m
Tower Frame: Treated timber
No of Fans: 4
No of blades: 3
4.88 ϕ m 4.88 ϕ m 4.88 ϕ m Calculated Values:
Range : 9oCApproach : 8oCEffectiveness : 52.95%Evaporation : 33.6m3.hrLossBlow down :11.196 m3/hrLossConnected :Pumps PFBG 1&2 (75kW)
MHD 1,2 (40 kW) HP Aux pump(30 kW)
Fan : CT fans 3*15kW
Air Flow Rate : 138700 m3/hr
42
Cooling tower pump analysis
Cooling Tower -1ACW Pump 1 & II
These pumps are working under interval basis if one pump operated other been at stand by.
Flow 220 m3/hr
Measured flow 208 m3/hr
Head 40 m
Power consumed 55.47 kW
Hydraulic power 22.67 kW
Shaft Power 45 KW
ɳPump 50.38%
Power consumption /year 22180 units/year
43
Cooling Tower -1
CW Pump 1 & IIThese pumps are working under interval basis if one
pump operated other been at stand by.
Flow 800 m3/hr
Measured flow 235 m3/hr
Head 235 m
Power consumed 100 kW
Hydraulic power 49.6 kW
Shaft Power 76.65 KW
ɳPump 65%
Power consumption/year 400000 units/year
44
Cooling Tower -2
PFBG pump I & IIBoth pumps are running.
Flow 450 m3/hr
Measured flow 420 m3/hr
Head 40.7 m
Power consumed 91.9 kW
Hydraulic power 46.58 kW
Shaft Power 74.9 KW
ɳPump 62.11%
pump consumption/year- 367600 units
45
Cooling Tower -2
MHD I & IIThese pumps are working under interval basis if
one pump operated other been at stand by.
Flow 75 m3/hr
Measured flow 66 m3/hr
Head 100 m
Power consumed 48.316 kW
Hydraulic power 17.985 kW
Shaft Power 40 KW
ɳPump 44%
pump consumption/year- 193264 units
46
Cooling Tower -2
HP Aux PumpThese pumps are working under interval
basis if one pump operated other been at stand by.
Flow 25 m3/hr
Measured flow 20 m3/hr
Head 250 m
Power consumed 36.8 kW
Hydraulic power 13.625 kW
Shaft Power 29.91 KW
ɳPump 57.5%
pump consumption/year- 147200 units
47
ProposalsWater used is found to be contaminated ,will cause
slates on the surface condenser. maintainance of water solid levels is necessary
Tower frame in cooling tower 1 is damaged its recommended to works on damage or install an new cooling tower frame
Cooling tower pumps all pumps except ACW and PFBG pumps are operated just above 50 % its recommended to install high efficient pumps around 60-70%
48
Payback analysis Reduction of make up water by changing the tower
frame
Power consumption on Hp Aux is greatly varies
Old Energy consumption : 73,688kWh
New Energy Expected: 40,256 kWh
Annual Energy Saved : 200592 kWh
Annual Cost Saved : 13,03,848
Payback period : 8 months
49
Installing an efficient pump By installing efficient pumps 2% of current energy consumption is
reduced. Old consumption 362644 units
New consumption 362644*0.8 =290115.2
Cost saved=(362644-290115.2)*6.5 = 4,71,438 `
Investment = 7,50,800
Payback = 19.11 Months
Energy and cost saved
By Repairing Tower Frame : 13,03,848
Installation of efficient pumps : 7,50,800
Cost Saved /year in 2054648 `
Cooling tower
50
Transformer Auditing report:Transformer :
BHEL CCDP Uses 2 transformer which has been installed as per the norms of TNEB,as CCDP is sanctioned with 2000KVA demand
Transformer 1 - 500 KVA Transformer 2 – 1500 KVA
Transformer is an static device hence the losses are low.While performing performance analysis of an transformer these data to be find out,Losses(Both No load , Load Losses)Best LoadingPower factor management
51
Transformer Audit 1500 kVA Transformer
No load loss - 1.32 KW
Full Load Loss - 8.5 kW
Total loss - (NL Loss +FL Loss*(Act KVA/Rated KVA)
3.21 KVA
Operating hours - 9hrs
Currently loaded -42.13%
Calculating Annual Loss during Working Days:
Loss-(3.21*9)*300*1.85 =10833 kWh/Annum
Calculating annual loss during Non-Working days
Loss-(3.21*12)*365*1.32=10128.75 kWh/Annum
Total 12 month Transformer loss-10833 + 10128=20961 KVA/Annum
Present Energy utilization from TNEB – 964,952 kVA/Annum29% lossed in transformer
52
1500 kVA Best loadingBest loading-√(no load loss/FL loss)*Rated kVA
= √ (1.32/1.85)*1500 = 766.94 kVA = 51 %
500 kVA TransformerNo load loss-1.05FL Loss - 6.5Total loss - 15.507 kWh/dayCurrently Loaded – 39%Annual Loss during working days – 5815 kVAAnnual loss during Non Workin – 4704 kVATotal loss in years - 9653 kVABest Loading % - 40.91%
53
Proposals
Currently the 1500 KVA is running under 42% loading but the best efficiency 51% its recommended to increase the loading %
Install 20 KVAR cpacitor.
54
Power Factor Management Apr-11-0.85May-11-0.67Jun-11-0.78Jul-11-0.77Aug-11-0.8Sep-11-0.9Oct-11-0.88Nov-11-0.76Dec-11-0.92Jan-12-0.96Feb-12-0.78Mar-12-0.7Apr-12-0.8
NEED For PF Correction
AVG PF : 0.8 lag
Converting KVA to KW 640*0.8 = 512 KWh With 0.9 PF640 *0.9 = 576 KWh
64 units saved per hour
55
PF Correction 1500 KVA Installed with 150 KVAR to maintain 0.8 PF its recommended to increase from 0.8
to 0.9
From BEE book PF correction table to maintain 0.9 Multiply with 0.266
Avg 640 kVA drawn so 640*0.266-170 kVAR Required further 20 more KVAR needed
1 kVAR costs 700 rs
20 kVAR costs 20*700
Investment on Capacitor = 14,000
By installing 20 kVAR 6040 KWh is saved
Cost Saved = 6.5*6040 = 39260`
Payback = 14000*12 / 39260
= 4.27 Months
56
Transformer SummaryCosts Saved PF Correction - 39,260 `/yearIncrease Loading % - Increasing loading from 42 % to 51%
57
Pump AuditingThe Main data to be found out during
pump auditing isHydraulic PowerShaft PowerPump Efficiency
For calculating these data'sFlow RateHeadPower ConsumptionIs measured
58
Pump Audit
Formula Used : Hydraulic (kW) = Q x Total Head, (hd – hs) x x g
1000
• Pump shaft power= Hydraulic power X ɳ Motor
Pump efficiency, ɳ Pump = Hydraulic power
Pump shaft power
Were
Q-Flow Rate m3/sec
H-Head m
- Density kg/m3
g- Acceleration due to gravity m2/ s
59
Auditing CalculationsMotor name plate details: (Liquor Pump –Quench Column)
Make :KriloskarPower : 75 kWCurrent : 128 ASpeed : 2970 RPMInsulation Class : FDuty : S1Voltage : 415 V% ɳ : 85 %
Pump name plate details :Make : VK Pump industriesType : Triplex PlungerCapacity Q : 61 m3/hr (or) 0.016944 m3/secHead : 238 mSpeed : 2970 RPM% ɳ : 57.5 %
60
Datas
Motor consumption details : Power input Pi : 86.34 kW
Motor working ɳ: 80%
Pump :Capacity : 59.8 m3/hr (or)
0.016611 m3/secDensity of liquid : 1000 Kg/m3
Gravity : 9.81 m/sec2
61
CalculationsPump calculations (with measured values) :Hydraulic power = Q*H*ρ*g / 1000
= 59.8 * 238 *1000*9.81/1000 = 38.78 kW
Pump Shaft power = Motor input * motor ɳ = 86.34* 0.80 = 69.08 kW
% Pump ɳ = Hydraulic power*100 / Shaft power
= 38.78*100 / 69.08 = 56 %
62
Pump Report Auxiliary Boiler Feed Pump:
Hydraulic Power = 3.374 kW
Shaft Power = 9.3 kW
Pump ɳ = 36%
Auxiliary Boiler Hot water Feed Pump:
Hydraulic Power = 310.92 W
Shaft Power = 712.5 W
Pump ɳ = 43%
Auxiliary Boiler FO Injection Pump :
Hydraulic Power = 85.247 W
Shaft Power = 172.5W
Pump ɳ = 49%
63
Pump Report DM Plant back Wash Pump:
Hydraulic Power = 3.345 kW
Shaft Power = 6.885 kW
Pump ɳ = 49%
DM Plant Drinking Water Pump :
Hydraulic Power = 1.002 kW
Shaft Power = 2.002 kW
Pump ɳ = 50.08 %
DM Plant Make Water Pump:
Hydraulic Power = 546.075 W
Shaft Power = 1.258 kW
Pump ɳ = 45%
64
Condensate PumpCapacity Q : 30 m3/hr (or) 0.00833 m3/secHead : 100 mHydraulic Power =7.685kW
Shaft Power =15.309 kW
Pump ɳ = 50.02 %
Proposals:
These pump working at the 50% efficiency so increase the efficiency to 65-70% Will reduce the power consumption
65
Savings and Payback Liquor pump: Rated flow : 61 m3/hr Flow Measured : 59.8 m3/hr Power consumption : 86.34 kW Pump current Efficiency : 56 % Motor current efficiency : 80 % Annual working hours : 6000
Proposals:
The pump is working under the 56 % Efficiency, Replacing the pump with the 70% Efficiency will decrease power required hydraulic power, hence reducing the power consumptionProposed Power consumption : 76 kWOne time motor Implementation cost : 68000 `
66
Payback: Annual Energy Savings : (Present power – Expected power) * Annual working hours (86.34-76)*6000 62040 kWh Annual power cost savings: Annual energy savings * cost of 1 unit 62040 * 6.5 403260 ` Payback period : One time implementation cost*12 /Annual power cost savings 68000*12 / 403260 2.4 Months
67
Savings in PumpsPump Energy
Savings/yearCost savings/year
Return of investment
Auxillary Boiler Feed Pump
10318 kWh 67067 ` 9.3 Months
Back wash Pump
4200 kWh 27300 ` 17 months
Condensate Pump
11340 kWh 73710 ` 7.5 months
Liquor Pump 62040 kWh 403260 ` 2.4
Total 87898 kWh 5,71,337 `
68
ConclusionOn auditing the electrical utilities of
the plant I am concluding the project with savings summary
Motors - 220092 kWhCompressor – 307465 kWhLighting – 111331.69 kWhCooling Tower – 316099 kWhTransformer – 10000 kWhPumping – 87898 kWhTotal 736786.69 kWh saved /year
69
Bibiliography Bibliography Handbook on Energy Audit and Environment
Managementby Abbi The Codes Guidebook for Interiorsby Sharon Koomen
Harmon, Katherine E. Kennon Technical Guide of BHEL CCDP Plantby Mithoshi Ken Shu
Wang,Yaspal singh and Karthikeyan. Hispanic Engineer & IT- Winter-Energy Auditing magazine. Keeping the Lights on: Nuclear, Renewables and Climate
Change-Great Britain: Parliament: House of Commons: Environmental
Audit Committee Investment Grade Energy Audit: Making Smart Energy
Choices-Shirley J. Hansen, James W. Brown Energy Audit of Building Systems-An Engineering Approach-
Moncef Krarti Commercial Energy Auditing Reference Handbook-Steve
Doty
70
Bibiligraphy Handbook of Energy Engineering-Albert Thumann, D. Paul Mehta Energy Management-Dr. Parag Diwan & Mohammed Yaqoot Turbines Compressors And Fans (4th Edition)- S. M. Yahya Reciprocating Compressors: Operation & Maintenance-Heinz P. Bloch, John J. Hoefner Lighting dimensions: Volume 20-Magazine Lighting Retrofit and Relighting: A Guide to Energy Efficient
Lighting-James R. Benya, Donna J. Leban Pump User's Handbook: Life Extension-Heinz P. Bloch, Allan R.
Budris Variable Speed Pumping:A Guide To Successful Applications-
Magazine BHEL CCDP Electrical equipments Installation Data- Departmental
Copy Cooling Tower Performance-Meera Bai,Lakshmi and Naryan Manual on coating and lining methods for cooling water systems-
Dr.Chandrasekaran
71
THANK YOU