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Energy Auditing the Electrical
   Utilities BHEL CCDP
                                       By
                                       Renga Ramanujan C
                                       Reg 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



                                                                   1
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

                                                      2
Objective
 Main objective of the project is to audit the
  electrical equipment's and propose suitable savings
  with paybacks
The following equipment's considered in Auditing :
 Motor
 Pumps
 Cooling Tower
 Lighting
 Compressor
 Transformer


                                                        3
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
                                                       4
IGCC (Integrated Gasification Combined
Cycle)


                  




   Fig IGCC Plant Process
                                         5
Gasification Reactions
   Exothermic
    ◦   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.

                                                                           6
P
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P
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S
S

D
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R
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    7
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                                  2000
 Maximum demand touched in KVA during            1885.80
 the month of                                    DEC 2011
 Power Factor                                    0.96 lag
 Energy Supplied by TNEB                         1,84,060 Units
 Per Unit rate                                   6.76 `
 Amount Paid to TNEB                             12,44,245 `
                                                                          8
Auditing Electrical Utilities
Equipment Audited

 Motors
 Compressors
 Cooling    Towers
 Lighting
 Pumps
 Transformers
Motor Auditing Report
Important 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
                                Efficiency vs Loading
             100

              90

              80

              70

              60
Efficiency




              50                                                75-100 HP
                                                                30-60 HP
              40                                                15-25 HP
                                                                0-10 HP
              30

              20

              10

               0
                   0%   20%   40%   60%     80%   100%   120%

                                      loading
Power factor vs Loading
                                       PF Vs Working Load
               1.2



                1



               0.8
Power Factor




               0.6                                                             75-100 HP
                                                                               30-60 HP
                                                                               15-25 HP
               0.4                                                             0-10 HP



               0.2



                0
                     35%   45%   55%      65%     75%       85%   95%   100%

                                       Full load-Amperage
Motor Details BHEL CCDP
   There 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
Motor Calculations :
   Make: NGEF(vibrator 4)
          Rated Power             : 7.5 KW
          Rated Current           : 13.7 Amps
          Rated speed             : 1440 RPM
          Insulation class        : F
          Duty cycle              : S1
          Designed efficiency ɳ   : 88%
          Number of Poles         :4
          Connection                        : Delta
          Starter                 : DOL

   No Load (15% load setting)
          Voltage            :    415 V
          Current            :    5A
          Frequency          :    50 Hz
          Stator resistance  :    1.75Ω
          Power              :    1200 W
   Load (75% load setting)
          Voltage            :    415 V
          Current            :    12.5 A
          Power              :    2900 W



                                                      16
   Solution
        Iron 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*1.75
        Pst.cu = 43.75 W
        Pi + fw=1200-43.75
                 = 1156.25 W
Stator resistance at working condition with respect to insulation
class
Stator resistance = (1.75)*(110+235/ 30+235)
                  =2.28 Ω
Stator Copper losses at Full load

        Pst.Cu(FL)=(3*(13.5/√3)2/2.28
                 = 427.67. W

                                                                    17
     Full load slip
Ns=     120f/p   S=        Ns-N/Ns



Pr=          Rated power/(1-S)       Watts




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

                                              18
 Motor Efficiency:
% ɳ=Rated output/Power Input *100
    = 7.5/9.531 *100
    =78.69%
 Power Factor
PF=Pi/√3* Rated Voltage*Rated current
PF= 9.531*1000/√3*415*13.5
  =0.968 lag


                                        19
Payback and Proposals
Proposals
       Installation of ʎ-∆ convertor
       Installation of VSD Drive
       Installation of reduced rating Motors
       Installation of DE Controllers
       Installation of Capacitors
 Payback for Installing VSD Drive :
  Motor             Energy             Costs         Payback Period
                    saved/Year         Saved/Year
                    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 `
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


                                                                21
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


                                                              22
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)
                                                                           23
Compressor Auditing
   Instrument Air
Rated 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 Air
Rated 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%
                                                      24
Compressor Auditing
   LPC
Rated 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’s
Rated 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%
                                                         25
Proposals and Payback
Observation :
 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         26
Savings Analysis (With Leakage arresting of
20%)

Compressor     Leakage    Energy Waste Energy       Cost saved
                                       Savings
Instrumentation 34.39 %   84840        60000        3,90,000
Service Air    31.70 %    294600       247465       16,08,526


Total                                  3.07,465     19,98,522.5`
                                       Units/year




                                                                 27
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.

                                                               28
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
                                                                 29
Lighting Auditing Report

   Lighting consumption data at different
    sections
Gasifier Section              -     105.36
units/day
Gas Cleaning System           -     71.16
units/day
Coal yard          -          84.42
units/day
Engineering Building          -     46.72
units/day                                    30
Lighting calculations
   Turbine & Crane Hall:
   Length                     :        70 m
   Width                      :        30 m
   Height                     :        6m
   Average Lux                :        92
   Target Lux                 :        50
   Number of workers          :        32
   Total Watts Utilized       :        (400*21) = 8.4   kW


   Floor area             :   Length * Width
                               110*45 = 4950 m2

   Room index             :   floor area / (height-0.83)*(length +
    Width)
                               4950 / (6-0.83) * (110 + 45)
                               = 3.48
                                                                      31
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
                                                     32
Light Auditing
Place              Area     TotalWatts   ILER
Gasifier Section   375m2    1.155kW      0.74
(Ground Floor)

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         875m2    1.28kW       0.892
House
Stores and         2800m2   3.295 kW     0.93
Instrumentation
room
Reference room     600m2    920W         0.93
Gas Cleaning       400m2    2.12 kW      0.297
Ground floor
                                                 33
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 `                                         34
Proposals and Savings
   Gasifier 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
                                                            35
Savings
Place              Energy Waste   Energy saved     Costs saved
                   units          with new         `
                                  settings units
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 `




                                                                 36
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
                                                                            37
Formula used
   Range (°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
                                                  38
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%


                                                                39
CCDP Cooling Tower(1)
                 4.88 ϕ m 4.88 ϕ m 4.88 ϕ m

                                                                                              Calculated Values:
                                                                     No of Fans: 4

                                                                     No of blades: 3
              Fan Motor: 15 KW
                                                                                              Range       : 11oC
                                                                                 Fan Blades
                                                                                 3.6 ϕ m      Approach             : 5oC
                                                           44oC                               Effectiveness : 68.75%
                                                                                              Evaporation : 31.64m3.hr
               Rate of Flow 1880 m3/hr                                                        Loss
                                              Tower Frame: Treated timber
                                                                                              Blow down :10.54 m3/hr
                                                                                              Loss
8.39 ϕ m                                                                                      Connected :
                                                         Wet Bulb Temp: 28oC

                                                         Dry Bulb Temp: 30.5oC
                                                                                              Pumps
                                                                                              ACW1,2(45kW),
                                                                                                          CW 1,2 (150
                       103.7 ϕ m                   33o                                        kW)
                                                   C                                                   HP Aux pump(30
                         125 ϕ m                                                              kW)

                                                                                              Fan        : CT fans     40
CCDP Cooling Tower (2)
                4.88 ϕ m 4.88 ϕ m 4.88 ϕ m
                                                                                            Calculated Values:
                                                                   No of Fans: 4


             Fan Motor: 20 KW
                                                                   No of blades: 3
                                                                                            Range       : 9oC
                                                                               Fan Blades
                                                                               3.8 ϕ m      Approach             : 8oC
                                                         45oC                               Effectiveness : 52.95%
                                                                                            Evaporation : 33.6m3.hr
              Rate of Flow2440 m3/hr
                                             Tower Frame: Treated timber
                                                                                            Loss
                                                                                            Blow down :11.196 m3/hr
8.50 ϕ m                                                                                    Loss
                                                       Wet Bulb Temp: 28oC

                                                       Dry Bulb Temp: 30.5oC
                                                                                            Connected :
                                                                                            Pumps      PFBG 1&2
                                                                                            (75kW)
                      130 ϕ m                   36oC                                                   MHD 1,2 (40 kW)
                                                                                                     HP Aux pump(30
                        160 ϕ m
                                                                                            kW)

                                                                                            Fan        : CT fans
                                                                                            3*15kW                  41
Cooling tower pump analysis
   Cooling Tower -1
ACW 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


                                                                                    42
   Cooling Tower -1
CW Pump 1 & II
       These 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


                                                             43
   Cooling Tower -2
       PFBG pump I & II
      Both 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


                                             44
   Cooling Tower -2
       MHD I & II
      These 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              45
   Cooling Tower -2
       HP Aux Pump
      These 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
                                                 46
Proposals
   Water 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%


                                                            47
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




                                                     48
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


                                                                   49
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 Loading
Power factor management                                50
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/Annum
29% lossed in transformer
                                                                      51
1500 kVA Best loading
Best loading-√(no load loss/FL loss)*Rated kVA
             = √ (1.32/1.85)*1500
             = 766.94 kVA
             = 51 %

500 kVA Transformer
No load loss-1.05
FL Loss        - 6.5
Total loss    - 15.507 kWh/day
Currently Loaded – 39%
Annual Loss during working days – 5815 kVA
Annual loss during Non Workin – 4704 kVA
Total loss in years - 9653 kVA
Best Loading % - 40.91%                          52
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.




                                        53
Power Factor Management
Apr-11-0.85
May-11-0.67   NEED For PF Correction
Jun-11-0.78
              AVG PF : 0.8 lag
Jul-11-0.77
Aug-11-0.8    Converting KVA to KW
Sep-11-0.9     640*0.8 = 512 KWh
Oct-11-0.88
              With 0.9 PF
Nov-11-0.76   640 *0.9 = 576 KWh
Dec-11-0.92
Jan-12-0.96   64 units saved per hour
Feb-12-0.78
Mar-12-0.7
Apr-12-0.8



                                        54
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
                                                                                       55
Transformer Summary
   Costs Saved
PF Correction      - 39,260 `/year
Increase Loading %       - Increasing loading from
42 % to                            51%




                                                 56
Pump Auditing
 The Main data to be found out during
  pump auditing is
     Hydraulic Power
     Shaft Power
     Pump Efficiency
For calculating these data's
Flow Rate
Head
Power Consumption
Is measured


                                         57
Pump Audit
Formula Used :
   Hydraulic (kW) = Q x Total Head, (hd – hs) x   xg
                                  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

                                                        58
Auditing Calculations
Motor name plate details: (Liquor Pump –Quench Column)
      Make :Kriloskar
      Power : 75 kW
      Current : 128 A
      Speed : 2970 RPM
      Insulation Class : F
      Duty : S1
      Voltage : 415 V
      %ɳ       : 85 %
Pump name plate details :
      Make : VK Pump industries
      Type : Triplex Plunger
      Capacity Q : 61 m3/hr (or) 0.016944 m3/sec
      Head         : 238 m
      Speed        : 2970 RPM
      %ɳ           : 57.5 %
                                                    59
Datas

   Motor consumption details :
       Power input Pi : 86.34 kW
       Motor working ɳ: 80%

Pump :
     Capacity : 59.8 m3/hr (or) 0.016611
m3/sec
     Density of liquid : 1000 Kg/m3
     Gravity      : 9.81 m/sec2

                                           60
Calculations
Pump 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                                     61
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%

                                          62
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%

                                   63
Condensate Pump
Capacity Q : 30 m3/hr (or) 0.00833 m3/sec
Head        : 100 m
Hydraulic 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
                                            64
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
 consumption
 Proposed Power consumption         : 76 kW
 One time motor
  Implementation cost        : 68000 `
                                                            65
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




                                                                   66
Savings in Pumps
Pump               Energy         Cost           Return of
                   Savings/year   savings/year   investment
Auxillary Boiler   10318 kWh      67067 `        9.3 Months
Feed Pump
Back wash Pump     4200 kWh       27300 `        17 months
Condensate         11340 kWh      73710 `        7.5 months
Pump
Liquor Pump        62040 kWh      403260 `       2.4
Total              87898 kWh      5,71,337 `




                                                              67
Conclusion
 On auditing the electrical utilities of the
  plant I am concluding the project with
  savings summary
Motors          - 220092 kWh
Compressor      – 307465 kWh
Lighting        – 111331.69 kWh
Cooling Tower – 316099 kWh
Transformer     – 10000 kWh
Pumping         – 87898 kWh
Total             736786.69 kWh saved
/year
                                                68
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                                           69
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
                                                                          70
71

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BHEL CCDP audit

  • 1. Energy Auditing the Electrical Utilities BHEL CCDP By Renga Ramanujan C Reg 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 1
  • 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 2
  • 3. Objective  Main objective of the project is to audit the electrical equipment's and propose suitable savings with paybacks The following equipment's considered in Auditing :  Motor  Pumps  Cooling Tower  Lighting  Compressor  Transformer 3
  • 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 4
  • 5. IGCC (Integrated Gasification Combined Cycle)   Fig IGCC Plant Process 5
  • 6. Gasification Reactions  Exothermic ◦ 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. 6
  • 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 2000 Maximum demand touched in KVA during 1885.80 the month of DEC 2011 Power Factor 0.96 lag Energy Supplied by TNEB 1,84,060 Units Per Unit rate 6.76 ` Amount Paid to TNEB 12,44,245 ` 8
  • 9. Auditing Electrical Utilities Equipment Audited  Motors  Compressors  Cooling Towers  Lighting  Pumps  Transformers
  • 10. Motor Auditing Report Important 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.
  • 11. Efficiency vs Loading graph Efficiency vs Loading 100 90 80 70 60 Efficiency 50 75-100 HP 30-60 HP 40 15-25 HP 0-10 HP 30 20 10 0 0% 20% 40% 60% 80% 100% 120% loading
  • 12. Power factor vs Loading PF Vs Working Load 1.2 1 0.8 Power Factor 0.6 75-100 HP 30-60 HP 15-25 HP 0.4 0-10 HP 0.2 0 35% 45% 55% 65% 75% 85% 95% 100% Full load-Amperage
  • 13. Motor Details BHEL CCDP  There 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
  • 14. 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
  • 15. 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. Motor Calculations :  Make: NGEF(vibrator 4) Rated Power : 7.5 KW Rated Current : 13.7 Amps Rated speed : 1440 RPM Insulation class : F Duty cycle : S1 Designed efficiency ɳ : 88% Number of Poles :4 Connection : Delta Starter : DOL  No Load (15% load setting) Voltage : 415 V Current : 5A Frequency : 50 Hz Stator resistance : 1.75Ω Power : 1200 W  Load (75% load setting) Voltage : 415 V Current : 12.5 A Power : 2900 W 16
  • 17. Solution Iron 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*1.75 Pst.cu = 43.75 W Pi + fw=1200-43.75 = 1156.25 W Stator resistance at working condition with respect to insulation class Stator resistance = (1.75)*(110+235/ 30+235) =2.28 Ω Stator Copper losses at Full load Pst.Cu(FL)=(3*(13.5/√3)2/2.28 = 427.67. W 17
  • 18. Full load slip Ns= 120f/p S= Ns-N/Ns Pr= Rated power/(1-S) Watts 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 18
  • 19.  Motor Efficiency: % ɳ=Rated output/Power Input *100 = 7.5/9.531 *100 =78.69%  Power Factor PF=Pi/√3* Rated Voltage*Rated current PF= 9.531*1000/√3*415*13.5 =0.968 lag 19
  • 20. Payback and Proposals Proposals Installation of ʎ-∆ convertor Installation of VSD Drive Installation of reduced rating Motors Installation of DE Controllers Installation of Capacitors Payback for Installing VSD Drive : Motor Energy Costs Payback Period saved/Year Saved/Year 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 `
  • 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 21
  • 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 22
  • 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) 23
  • 24. Compressor Auditing  Instrument Air Rated 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 Air Rated 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% 24
  • 25. Compressor Auditing  LPC Rated 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’s Rated 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% 25
  • 26. Proposals and Payback Observation :  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 26
  • 27. Savings Analysis (With Leakage arresting of 20%) Compressor Leakage Energy Waste Energy Cost saved Savings Instrumentation 34.39 % 84840 60000 3,90,000 Service Air 31.70 % 294600 247465 16,08,526 Total 3.07,465 19,98,522.5` Units/year 27
  • 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. 28
  • 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 29
  • 30. Lighting Auditing Report  Lighting consumption data at different sections Gasifier Section - 105.36 units/day Gas Cleaning System - 71.16 units/day Coal yard - 84.42 units/day Engineering Building - 46.72 units/day 30
  • 31. Lighting calculations  Turbine & Crane Hall:  Length : 70 m  Width : 30 m  Height : 6m  Average Lux : 92  Target Lux : 50  Number of workers : 32  Total Watts Utilized : (400*21) = 8.4 kW  Floor area : Length * Width 110*45 = 4950 m2  Room index : floor area / (height-0.83)*(length + Width) 4950 / (6-0.83) * (110 + 45) = 3.48 31
  • 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 32
  • 33. Light Auditing Place Area TotalWatts ILER Gasifier Section 375m2 1.155kW 0.74 (Ground Floor) 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 875m2 1.28kW 0.892 House Stores and 2800m2 3.295 kW 0.93 Instrumentation room Reference room 600m2 920W 0.93 Gas Cleaning 400m2 2.12 kW 0.297 Ground floor 33
  • 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 ` 34
  • 35. Proposals and Savings  Gasifier 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 35
  • 36. Savings Place Energy Waste Energy saved Costs saved units with new ` settings units 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 ` 36
  • 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 37
  • 38. Formula used  Range (°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 38
  • 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% 39
  • 40. CCDP Cooling Tower(1) 4.88 ϕ m 4.88 ϕ m 4.88 ϕ m Calculated Values: No of Fans: 4 No of blades: 3 Fan Motor: 15 KW Range : 11oC Fan Blades 3.6 ϕ m Approach : 5oC 44oC Effectiveness : 68.75% Evaporation : 31.64m3.hr Rate of Flow 1880 m3/hr Loss Tower Frame: Treated timber Blow down :10.54 m3/hr Loss 8.39 ϕ m Connected : Wet Bulb Temp: 28oC Dry Bulb Temp: 30.5oC Pumps ACW1,2(45kW), CW 1,2 (150 103.7 ϕ m 33o kW) C HP Aux pump(30 125 ϕ m kW) Fan : CT fans 40
  • 41. CCDP Cooling Tower (2) 4.88 ϕ m 4.88 ϕ m 4.88 ϕ m Calculated Values: No of Fans: 4 Fan Motor: 20 KW No of blades: 3 Range : 9oC Fan Blades 3.8 ϕ m Approach : 8oC 45oC Effectiveness : 52.95% Evaporation : 33.6m3.hr Rate of Flow2440 m3/hr Tower Frame: Treated timber Loss Blow down :11.196 m3/hr 8.50 ϕ m Loss Wet Bulb Temp: 28oC Dry Bulb Temp: 30.5oC Connected : Pumps PFBG 1&2 (75kW) 130 ϕ m 36oC MHD 1,2 (40 kW) HP Aux pump(30 160 ϕ m kW) Fan : CT fans 3*15kW 41
  • 42. Cooling tower pump analysis  Cooling Tower -1 ACW 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 42
  • 43. Cooling Tower -1 CW Pump 1 & II These 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 43
  • 44. Cooling Tower -2 PFBG pump I & II Both 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 44
  • 45. Cooling Tower -2 MHD I & II These 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 45
  • 46. Cooling Tower -2 HP Aux Pump These 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 46
  • 47. Proposals  Water 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% 47
  • 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 48
  • 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 49
  • 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 Loading Power factor management 50
  • 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/Annum 29% lossed in transformer 51
  • 52. 1500 kVA Best loading Best loading-√(no load loss/FL loss)*Rated kVA = √ (1.32/1.85)*1500 = 766.94 kVA = 51 % 500 kVA Transformer No load loss-1.05 FL Loss - 6.5 Total loss - 15.507 kWh/day Currently Loaded – 39% Annual Loss during working days – 5815 kVA Annual loss during Non Workin – 4704 kVA Total loss in years - 9653 kVA Best Loading % - 40.91% 52
  • 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. 53
  • 54. Power Factor Management Apr-11-0.85 May-11-0.67 NEED For PF Correction Jun-11-0.78 AVG PF : 0.8 lag Jul-11-0.77 Aug-11-0.8 Converting KVA to KW Sep-11-0.9 640*0.8 = 512 KWh Oct-11-0.88 With 0.9 PF Nov-11-0.76 640 *0.9 = 576 KWh Dec-11-0.92 Jan-12-0.96 64 units saved per hour Feb-12-0.78 Mar-12-0.7 Apr-12-0.8 54
  • 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 55
  • 56. Transformer Summary  Costs Saved PF Correction - 39,260 `/year Increase Loading % - Increasing loading from 42 % to 51% 56
  • 57. Pump Auditing  The Main data to be found out during pump auditing is Hydraulic Power Shaft Power Pump Efficiency For calculating these data's Flow Rate Head Power Consumption Is measured 57
  • 58. Pump Audit Formula Used :  Hydraulic (kW) = Q x Total Head, (hd – hs) x xg 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 58
  • 59. Auditing Calculations Motor name plate details: (Liquor Pump –Quench Column) Make :Kriloskar Power : 75 kW Current : 128 A Speed : 2970 RPM Insulation Class : F Duty : S1 Voltage : 415 V %ɳ : 85 % Pump name plate details : Make : VK Pump industries Type : Triplex Plunger Capacity Q : 61 m3/hr (or) 0.016944 m3/sec Head : 238 m Speed : 2970 RPM %ɳ : 57.5 % 59
  • 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/sec Density of liquid : 1000 Kg/m3 Gravity : 9.81 m/sec2 60
  • 61. Calculations Pump 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 61
  • 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% 62
  • 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% 63
  • 64. Condensate Pump Capacity Q : 30 m3/hr (or) 0.00833 m3/sec Head : 100 m Hydraulic 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 64
  • 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 consumption Proposed Power consumption : 76 kW One time motor Implementation cost : 68000 ` 65
  • 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 66
  • 67. Savings in Pumps Pump Energy Cost Return of Savings/year savings/year investment Auxillary Boiler 10318 kWh 67067 ` 9.3 Months Feed Pump Back wash Pump 4200 kWh 27300 ` 17 months Condensate 11340 kWh 73710 ` 7.5 months Pump Liquor Pump 62040 kWh 403260 ` 2.4 Total 87898 kWh 5,71,337 ` 67
  • 68. Conclusion  On auditing the electrical utilities of the plant I am concluding the project with savings summary Motors - 220092 kWh Compressor – 307465 kWh Lighting – 111331.69 kWh Cooling Tower – 316099 kWh Transformer – 10000 kWh Pumping – 87898 kWh Total 736786.69 kWh saved /year 68
  • 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 69
  • 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 70
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