Energy Conservation Techniques

By R. V. Ghate Tata Power Company , Mumbai.

Energy Conservation in Power Utility

A power plant produces electrical energy and also consumes a substantial amount of energy in the form of auxillary consumption required for various plant equipments and services Management attitude -The top management of the company is committed to, and has the right attitude towards energy conservation.This is passed on to the the plant staff for ensuring success by Quality Management Systems such as Tata Business Excellence Model and ISO

Tata Power
Consistent achiever of Business Results. Vision Statement-To be an Excellent and Efficient organisation. Focus on enhancing Business and Customer Orientation.

Trombay Generating Station

Installed Capacity-1350 MW ISO 9001:2000 Certified Perception has changed to strike a balance between reliability and energy conservation

Trombay Generating Station

Key Drivers for changeTata Business Excellence Model (TBEM ) -Leadership -Customer and Market Focus -Process Management -Business Results

Energy Conservation in Power Utility

Energy conservation in Power Utility is achieved mainly by1) Operating the equipments at maximum efficiency. 2) Reduction of Auxiliary Power Consumption Energy Conservation Measures adopted at Tata Power Company Limited have taken both these factors into consideration

Factors affecting Auxiliary Consumption

Unit Generation and Load Pattern Operation of Plant Auxiliaries Service auxiliary such as Illumination, Air Conditioning etc Unit startups / shutdowns

Criteria used for adopting new energy saving methods

Reliability Sustainability Method and Quality of verification Investment required

Energy Saving Techniques

Energy saving Techniques adopted are classified in the following categories Design and Conceptual Stage Techniques developed through O&M experience Energy auditing by external agencies

Design and Conceptual Stage

Design and Conceptual Stage

Use of Steam Turbine driven Boiler Feed Pumps. ( 2 X 9 MW) Pioneered concept of using Variable Speed Drives for Large Motors by using LCI drives for 4 X 2 MW ID Fan Motor of 500MW Unit Use of Fluid Coupling for Motor Driven Boiler Feed Pump

Techniques developed through O&M Experience

In addition to techniques adopted at design stage various initiatives have been taken over the years to optimise the Auxiliary Power Consumption. These are
Monitoring of Aux Power Consumption continuously improving the levels and accuracy Formation of Cross Functional Teams to analyse and optimise process Modification in Operation Strategy to achieve Optimisation Knowledge sharing and benchmarking with other power utilities

Snapshot of Aux Power of Unit 5 at 500 MW

11-07-02 11:00 hr

TOTAL AUXILIARY CONSUMPTION

25 20 15 10 5 0 MW 20.25 HT cons LT cons 3.57

HT CONSUMPTION (kW) 5500 5000 4500 4000 3500 3000 2500 2000 1500 1000 500 0 ID FANS CWP FD FANS PA FANS CEP FGD AWP SGWCP MILLS HTR DRIP PUMP ACW

LT C O NS UMP T IO N (kW)

750 700 650 600 550 500 450 400 350 300 250 200 150 100 50 0

DMPT5B SST5A SST5C UST5B CLPT5B UST5A VST COMPT5B CWPT5A COMPT5A ESP5A CLPT5A ESPT5C CHPT5B CWPT5B ASHPT5A ASHPT5B

Prioritisation
Ideas and suggestions captured from various initiatives are then prioritised into three categories Without investment With minor investment With major investment

Without Investment
Blue Date of Print Idea No 1 2

Savings upto 31.03.03 Ideas for which detailed blueprint w ere made Original Est Annual Actual (Ideas indicated in blue were implemented) Idea by Saving Rs saving Rs in Lakhs in Lakhs till 31.03.03 Mr APW & team Mr APW & team TRAC TRAC 53.00 38.00

Status

Jul-99 Running of 3 nos SGWCP motors in Unit 5 instead of 4 motors Jul-99 Running of 2 nos SGWCP motors in Unit 6 instead of 3 motors Jul-02 Operation of Unit 5 ESP thyristor panel in Charge Ratio mode Jul-02 Operation of fewer Coal Mills at Unit 5 with higher loading

7.57 Implemented since 19/02/2003 19.15 Implenented since 24/08/2002

3 4

45.30 42.00

5 6 7 8 9

Jul-02 Stopping of steam supply to Station B Tank Farm during daytime Jul-02 Ship Receipt line one of the heat tracing circuit to be switched Off during non-receipt Jul-02 Optimisation of Lighting of O&S Bldg and provision to switch off during nightime to be made Sep-02 Changing and cleaning of LC Oil gun in Unit 6 to be reviewed and optimised Sep-02 Plant area lighting in Unit 5 and 6 inside the building to be switched off (except emergency lights)

TRAC TRAC TRAC

117.00 2.62 3.00 2.39 10.00

Not found feasible in view of increased coal firing. Implemented since Sep 02. Less coal mills operated w ith higher loadings (presently increased to 70% from 40%) Actual savings could not be captured. 63.88 Implemented since September 02. Not found feasible. 1.41 Implemented by SGA-28 since Dec 02. Implemented since April 03. Savings to be computed. Implemented since April 03. Savings to be computed. Not found feasible Not found feasible No found cost effective. Implemented since April 03. Savings to be computed.

10 11 12 13

R B More Opn B VM Dinkar Opn B Sep-02 Optimisation of operation of screen wash pumps at jetty M H Takle BR Agaj M H Takle TRAC

2.34 11.00

Sep-02 Saving service water used for air compressors Sep-02 Providing solenoid valve in cooling lines of blend oil pumps Oct-02 Scavenging of oil guns to be optimised

39.00

Actual Saving upto 31.03.03 (Items 1,2,5,7)

Savings of Item no 4,8,9,13 are not included.

Rs

92.01 Lakhs

With minor investment

Installation of Vacuum Pumps in Fly Ash Removal system in place of Hydro ejector based Ash Water Pumps Replacement of conventional Central Air Conditioning System by Vapour Absorption system to utilise waste steam Improving efficiency of Electrochlorination Plant by regular acid cleaning Replacement of ESP controllers by improved version having option of energy efficient mode Use of energy efficient lighting system

With major investment

Replacement of HP Turbine Module of 500 MW Unit Proposal of Retrofitting of Constant speed ID Fan motor with Variable speed drives.

Energy Audit by External Agency

External Audit
Detailed energy audit of Trombay Thermal Power Station was conducted by CII in Nov-Dec 2002 CII studied various main and sub processes Good energy conservation practices at TPCL as per CIIs viewpoint are

Encon at Tata Power

Installation of Load commutator invertors (LCI) for ID fans Optimisation of auxiliary consumption during non-peak hours Good excess air control in boilers Optimum loading of motors Efficient lighting systems Optimum T in condensing water system Excellent control systems

Some of the CII Proposals under consideration for implementation

Annual Saving Rs. Lakhs

Investment required Rs. Lakhs

Simple Payback period Months

Install next lower size impeller for the FGD spray pumps Install Variable Frequency Drive for Hot-well make-up water pump in Unit # 7 Avoid daytime lighting and install transmission roofing sheets in LC oil pressure filter area Replace conventional chokes with electronic chokes in fluorescent lamps

10.48

2.50

0.65

1.00

19

0.34

0.20

4.95

8.75

21

Conclusion

Savings due to Energy Conservation Measures for FY 02 -03

No 1 2 3 4 5 6 7

Optimisation of Aux Power in ESP FGD FAA Ash Plant GR Fans CW Pumps SGWCPs Total

Savings in MU 0.241 0.236 0.302 2.510 4.180 2.460 1.070 11.000

Total saving in FY 02 03 11 MU Saving Rs 2.23 Crores Reduction in Cost 0.25 Paise / KWH

TROM BAY AUXILIARY POWER CONSUM PTION TREND

12 .0

10 .0

10 .2 9 .6 9 .0

9 .8

8 .0

7.8

7.4

7.4

6 .0 5.0 4 .0 4 .3 3 .5 5.4 4 .3 3 .5 2 .1 1.5 5.2 4 .5 4 .1

5.7 4 .8 4 .2 5.2 4 .5 3 .8 2 .6

5.4 4 .6 3 .7 3 .0

5.0 4 .3 3 .3 2 .7

2 .0

1.9

2 .2

0 .0 9 6 -9 7 9 7-9 8 9 8 -9 9 9 9 -0 0 Y EA R UNIT-4 UNIT-5 UNIT-6 UNIT-7 STATIO N 0 0 -0 1 0 1-0 2 0 2 -0 3

BENCHMARKING OF UTILITIES

Graph 7.4.18

Trombay Aux. Cons. (%

9 8 7 6 5 4 3
1998-99 IB 1999-00 2000-01 2001-02 2002-03 Trombay SEB
4.5 4.8 4.5 4.6 4.3

7.05

7.4 6.52

3.66

Nat Avg

Comptr

NB

Conclusion
Comparison of auxiliary power consumption of Thermal Power Utilities
India benchmark 6.33% International benchmark 3.99% TPCL 4.33 %

TPCLs Auxiliary Power Consumption has been acknowledged by CEA as one of the best in India

Thank You