ENERGY AUDIT OF AUXILIARY POWER CONSUMPTION

ATAR SINGH
Dy. DIRECTOR
NPTI FARIDABAD
Energy Conservation in Power
Utility

 Power plant produces electrical energy

and also consumes a substantial amount
of energy in the form of auxiliary
consumption required for various plant
equipments and services
Energy Conservation in Power Utility

Achieved mainly by:

 Operating the equipments at maximum
efficiency and
 Reduction of auxiliary Power
consumption
 The auxiliary power consumption (APC) varies from 6-14% ,
depending on Size of plant ,use of TDBFP &age of plant
 The 500 MW units register the least APC, largely due to the
incorporation of TDBFP.
 In some of the old 110 MW plants, APC consumption of 14%
is also observed.
 Energy audit in a vast thermal power station (TPS) is better
tackled when the thermal power plant operations are
segregated into different sub-areas like:
main plant auxiliaries, draft system (consisting of ID/FD/PA
fans), feed water system [consisting of Boiler Fed Pumps
(BFPs) / Condensate Extraction Pumps (CEPs), Circulating
Water (CW) system-including Cooling Tower (CTs)], and off
sites (consisting of coal handling plants, ash handling plants,
air compressors, AC plants, station lightings etc.).
 APC Scenario In India

 Auxiliary Power Consumption in Thermal

Power Plant is major source of energy
consumption.
 During the financial year 2007-08 total
generation by coal plant was 488157.46 MUs
with PLF 78.75.
• Auxiliary Power Consumption was 8.17%.
• If this APC gets reduced only by 0.17%
then it is equivalent to fresh capacity addition
of 120 MW without any investment.
  Trombay Station of Tata Power Co. Ltd achieved lowest
auxiliary power consumption (4.30%) in the country.

Among Central Sector Stations, Talcher

STPS of NTPC achieved the lowest auxiliary
power consumption (5.34%).

Among State Sector Stations, Chandrapur

STPS of MAHAGENCO achieved the lowest
auxiliary power consumption (7.40%).

Among different capacity groups, the lowest

auxiliary power consumption was 6.13% in 500
MW group.
Requirement of works power with load
Factors Affecting Auxiliary Power
Consumption

- Unit Generation and load Pattern

- Operation of Plant Auxiliaries
- Service auxiliary such as Illumination , air
conditioning
- Unit Startup / shutdown
STEPS INVOLVED IN CONDUCTING
ENERGY AUDIT

 Data collection
 Measurements & Observations
 Exploration for energy conservation
measures
 Report preparation
STEPS INVOLVED IN CONDUCTING
ENERGY AUDIT
 DATA COLLECTION
Motor details required-
ID code, Application, Make, Brief details of driven
equipment, Type of the Motor, Motor kW, Motor frame,
Duty, Rated RPM, Rated p.f., Rated motor efficiency ,Motor
make, Motor voltage, Rated current of motor, Year,
Operating hours, Energy meter installed or Not , No. of
times the motor is rewound

 Collect the above information for all motors to be covered in

the energy audit.
 Collect the motor efficiency curves
STEPS INVOLVED IN CONDUCTING
ENERGY AUDIT
Instruments Required-

 Power Analyzer: Used for measuring electrical parameters

such as kW, kVA, pf, V, A and Hz
 Infrared pyrometer (In case any heating of cable or
motor is suspected)
 Stroboscope: To measure the speed of the driven
equipment and motor
 The above instruments can be used in addition to the
calibrated online / plant instruments
STEPS INVOLVED IN CONDUCTING
ENERGY AUDIT
Parameters to be measured-

 Energy consumption pattern of motors (daily / monthly

/yearly consumption if available)
 Motor electrical parameters (kW, kVA, Pf, A, V, Hz, etc.)
for individual motors
 Equipment operational details

 While conducting the measurement or performance

evaluation of any system simultaneously, the following
need to be noted
 Unit load of the plant
 Date & time of measurement
 Instruments used for measurement
 Frequency of the measurement
STEPS INVOLVED IN CONDUCTING
ENERGY AUDIT

 MEASUREMENTSAND OBSERVATIONS

System details
Detailed interactions with the plant personnel

Energy consumption Pattern

If the plant is monitoring the energy consumption, it
is suggested to record the data and monitor the daily and
monthly consumption pattern
STEPS INVOLVED IN CONDUCTING
ENERGY AUDIT
Equipment Annual Average Load % of Total % of total APC
Consumption KW Generation
MWH

Air Compressors

Coal Handling
Plant

Raw Water
pumps

DM water pumps

A/C systems

ESP

Total
STEPS INVOLVED IN CONDUCTING
ENERGY AUDIT
Equipment Annual Average Load % of Total % of total APC
Consumption KW Generation
MWH

Boiler Feed Pump

Condensate
extraction Pump

CW Pumps

ID Fans

FD Fans

PA Fans

Mils

CT Fans
STEPS INVOLVED IN CONDUCTING ENERGY AUD

MW %
Total Generation 1305.57 81.60 (of installed capacity)
Auxiliary Power Consumption 111.7 8.56 (of actual generation)

Contribution Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Over All

To APC By

MW % MW % MW % MW % MW % MW %
BFP's 4.52 2.78 4.29 2.98 4.52 3.39 - - - - 13.34 1.02%
CEP's 0.43 0.26 0.43 0.30 0.41 0.31 1.69 0.45 1.78 0.42 4.73 0.36%
FD's 0.35 0.22 0.31 0.22 0.30 0.23 1.21 0.29 1.26 0.29 3.43 0.26%
ID's 2.26 1.38 2.08 1.44 2.34 1.51 8.18 2.24 7.25 1.51 22.12 1.69%
PA's 2.31 1.41 2.38 1.65 2.36 1.52 4.85 1.34 4.82 1.00 16.72 1.28%
Coal Mills 1.21 0.74 1.53 1.06 1.69 1.08 2.92 0.81 2.92 0.61 10.25 0.79%
CHP 0.57 0.35 0.57 0.39 0.57 0.36 1.11 0.31 1.11 0.23 3.92 0.30%
AHP 0.47 0.29 0.47 0.33 0.47 0.30 0.52 0.14 0.52 0.11 2.45 0.19%
Air 0.42 0.26 0.42 0.29 0.42 0.27 0.38 0.11 0.38 0.08 2.04 0.16%
Compressors
Others 3.89 2.37 4.21 2.92 4.11 2.64 10.28 2.84 10.22 2.13 32.70 2.50%
(CWP’s,
RWP’s, DM
Plant, etc )
Total 16.42 10.06 16.67 11.58 17.18 11.61 31.14 8.53 30.26 6.38 111.70 8.56%
Motor loading survey

 Details
 Rated Kw
 Rated Efficiency
 Rated Speed
 Measurement of parameters
 Power factor
 kVA
 KW drawn
 Frequency
 Harmonics
 Motor speed
 Driven Voltage
 Current
 Power equipment speed
 Driven equipment parameters
 Operational observations Transmission
 % loading on the motor

STEPS INVOLVED IN CONDUCTING
ENERGY AUDIT
 Motor loading can be estimated by:

% Loading =

Input kW to motor x 100

---------------------------------------------------------------------

Name plate kW /Name plate full load motor efficiency

STEPS INVOLVED IN CONDUCTING
ENERGY AUDIT
 While conducting motor load survey,
observations on machine side:

 parameters such as speed, load, pressure,

temperature, etc., (as relevant) are also taken

 availability of load-end capacitors for PF

correction & energy meters for monitoring is
also looked into for each case.
STEPS INVOLVED IN CONDUCTING
ENERGY AUDIT
Motor Rewinding History

comparison of no load current and stator resistance

per phase of a rewound motor with the original no-load

current and stator resistance at the same voltage can be one

of the indicators to assess the efficacy of rewinding.

STEPS INVOLVED IN CONDUCTING
ENERGY AUDIT
Power Factor Correction

Induction motors are characterized by power factors

less than unity, leading to lesser efficiency (higher
overall operating cost) associated with a plant's
electrical system.

 Capacitors connected in parallel (shunted) with the

motor are typically used to improve the power factor

 The impacts of PF correction include reduced kVA

drawn , KVAR & current, reduction of transformer load,
 Reduction of cable losses, reduction of switch gear rating,
 Enhanced life of equipment
STEPS INVOLVED IN CONDUCTING
ENERGY AUDIT
 EXPLORATION OF ENERGY CONSERVATION
MEASURES

 Replacement / sizing of motors Opting for

energy efficient motors, Use of high efficiency
motors,
 Use of energy efficient transmission
 Replacement of pulleys
 Direct coupling
STEPS INVOLVED IN CONDUCTING
ENERGY AUDIT
 Analysis of observations
o Loading pattern - % loading
o Comments of power supply quality –
The BIS standards specify that a motor should be
capable of delivering its rated output with a voltage
variation of ± 6 % and frequency variation of ±3 %. Motor
o Identified motors with less than 50 % loading, 50 – 75 %
loading, 75- 100 % loading, over 100 % loading
o Identified motors with machine side losses / inefficiencies
like idle operations, throttling/damper operations
o Motor load survey is aimed not only as a measure to
identify motor efficiency areas but equally importantly, as a
means to check combined efficiency of the motor, driven
machine and controller
AUXILIARY POWER CONSUMPTION

 Operating only 4 mills instead of 5 mills in 210 MW units

 Shutting of CTs’ cells in conjunction with favorable weather

conditions and replacing existing aluminum cast and GRP blades
with FRP

 avoiding idle running of conveyors & crushers

 incorporating soft starter - energy savers etc.

AUXILIARY POWER CONSUMPTION

 STRATEGY
 Variable frequency drive for PA Fans & ID Fans & CEPs
 Air in-leaks in draft system (O2 measurement) blanketing
 Replacement of inefficient BFPs as a part of R& M of the old
plants.
 Clipping of one stage from the multi stage BFPs to balance the
pressure drop requirements between HP heaters, economizer and
boiler drum etc.
 Use of higher pressure in the deareator to commensurately reduce
BFP power consumption (reduced head developed)
 Running of two CEPs instead of 3 CEPs (3 CEPs are run to avoid
tripping due to lower frequency in some of the power plants)
 Application of variable speed drives
 Installation of hydraulic turbine instead of feed regulating section
to avoid pressure drops and to generate additional power