AP Cement Works Captive Power plant
A Unit of UltraTech Cement
Integrity - commitment- Passion -Seamlessness -Speed 1
Welcome to all
2
APCW Cluster
B
A
D
B- ARCW – G.U. 1.1 Million Ton
Cement
C
D - SBT – B.T. 1.0 Million Ton
Cement
A - APCW – I.P. Phase 1 Clinker – 2.7 Million
Ton Phase 2 Clinker – 3.4 Million
Ton Total Cement – 6.4 Million
Ton
A B
C- GICW – G.U. 1.2 Million Ton
Cement
C
D
Total Clinker : 6.1 Million
Ton Cement : 9.7 Million
Ton
First ISO:50001:2011 certified unit
Achieved 28206 ESCERTS in PAT cycle-1
Established first of its kind(in India) WHRPP
GreenCo Gold Award Unit
Day lights installation for all machinery buildings
Successfully completed Steam blowing with coal in place of HSD for Boiler#4 (first time in the history of Thyssen Krupp Boilers).
Energy Policy implemented in Dec – 2011
Energy Policy states unit’s
commitment towards continual energy performance improvement.
Energy policy is communicated at all levels.
Energy policy is regularly reviewed and last reviewed on 1st March’16.
To Reduce TPP Power Cost to the cement plant by means :
To reduce the auxiliary consumption
To reduce the Plant heat rate .
Responsibility Chart:-
FH –CPP
DH-Operation
SH Operation
DH-Mechanical
SH Mech
DH-E&I
SH-Electrical
SH-Instrument
SH-Energy
Step Project Initiation SH
(Opern)
Engineer
(E)
Engineer
(Electrical)
Project
leader
Hods/
FH
(TPP)
1 Data collection I R I A I
2 Equipment wise power consumption data
analysis R R R A / C I
3 Identifying Power saving potential area R R R A C
4 Conduct Brain storming session R R R A C
5 Project Execution -PROCESS R I I A I
6 Project Execution -E&I I R I A I
7 Project Execution -MECH I I R A I
8 Post Evaluation R R R A C
9 Sharing of Outcome R R R A I
Unit-1 Aux.
Boiler Fans
BFP
ESP
TG Aux
ACC Fans
ACC CEP
Unit-2 Aux.
Boiler Fans
BFP
ESP
TG Aux
ACC Fans
ACC CEP
Unit-3 Aux.
Boiler fans
BFP
ESP
TG Aux
ACC Fans
ACC CEP
Unit-4 Aux
Boiler Fans
BFP
ESP
TG Aux
ACC Fans
ACC CEP
Common Loads
CHP
AHP
AC & PNV
Compr
WTP
Lighting
Total TPP Aux.
Coal Handling plant losses
Handling loss
Wind loss
ESP
TG Aux
Boiler losses
Dry FG loss
Moisture in fuel
H2 in fuel
Moisture in Air
UBC in ash
Radiation loss
Steam turbine loss
Gland sealing loss
Stem dumping loss
Friction loss
Heaters TTD
Heaters DCA
leakages
ACC loss
Vacuum losses
Sub cooling loss
WTP Losses
Higher blow down
Higher Makeup
water
Total Plant Heat rate Tree
Boiler Fans 32%
Boiler feed
pump 28%
ACC 7%
Ash Handling
5%
Compressor 3%
WTP 0%
CHP 2%
Cooling Water
3%
Chillers 2%
AC 2%
ESP 2%
Boiler&STG MCC
5% CEP&HTP
2% Lighting
2%
Losses 3%
Wagon Loading
0%
Aux. Power Distribution section Wise
Heat rate for Power
Generation, 2918, 90%
Steam Dumping, 75,
2%
Inlet Parameters , 4,
0%
Vacuum deviation, 0, 0%
Heater effectiveness,
17, 1% Under load operation, 183,
6%
Dry fluegas losses, 45, 1%
Other, 325, 10%
Heat Rate
Ambient Temp: Avg 35.13/Max.41.00/Min28.71 22-03-2017 Previous best 145.73 MW Aux 8.85% 29-03-2017 Aux 10.09% 148.21 MWh
UOM
Bench
mark Unit-1 Unit-2 Unit-3 Unit-4 Unit-1 Unit-2 Unit-3 Unit-4 Remarks
Generation MWH 0 506 575 572 0 385 538 546
Plant heat Rate Kcal/Kwh 0 3070 3004 2992 0 3170 3023 3015
Primary Air (PA) Fan Kw/MW 10.2 0.0 25.8 15.4 15.6 0.0 30.4 16.7 16.2
Boiler Oxygen Levels % 5.9 6.1 4.7 9.74 5.46 5.33
Secondary Air (SA) Fan Kw/MW 6.07 0.0 1.5 2.4 2.4 0.0 4.5 2.3 2.3
Induced draft (ID) Fan Kw/MW 10.5 0.0 8.0 6.2 6.2 0.0 12.7 6.0 6.1
Condensate Extraction Pump (CEP) Kw/MW 1.59 0.00 2.82 2.0 2.2 0.00 3.93 2.1 2.1
ACC fans & STG Kw/MW 3.05 0.0 31.8 10.8 8.3 0.0 32.3 11.4 11.5
Boiler Feed Pump (BFP) Kw/MW 22.6 28.4 27.5 35.6 28.0
Inst Compressors Kw/MW
4.26
2.4 2.9
Service Compressors Kw/MW 4.3 3.8
Total 12 Rawmeal bowser unloaded
Water Treatment Plant (WTP ) Kw/MW 0.74 0.4 0.32 m3/kwh 0.3 0.67 m3/kwh
Coal Handling Plant (CHP) Kw/MW 0.61 1.6 1.3
CHP Performance KW/MT 2.85 --- --- 3.82 --- --- 3.84
Auxiliary Cooling Water Pump
(ACWP) Kw/MW 1.56 1.9 2.4
ESP MWH 0.832 0.558 0.547 0.865 0.702 0.552
Boiler MCC MWH 0.0 0.403 0.198 0.0 0.542 0.163
Emergency MCC MWH 0.5 0.2 0.386 0.014 0.3 0.2 0.386 0.014
Chiller &AC MW 2.632 2.636 2.720 2.767
Lighting Load & WTP Lab MWH 1.591 1.024 1.565 1.058
Wagon loading& coal Feeding MW 0.333 0.208
Transformer losses MW 5.877 5.440
Dump losses MT 44.000 19.0 14.0 35.000 13.0 15.0
Heat Rate losses Kcal/Kwh
Steam Dumping Losses Kcal/Kwh #DIV/0! 66.957 16.4 10.2 #DIV/0! 70.000 18.6 21.2
Inlet Parameters Deviation Kcal/Kwh 0.000 0.0 0.0 0.0 0.000 12.4 7.6 4.4
Heaters inefficient due to low flow Kcal/Kwh 0.000 0.0 9.9 6.4 0.000 0.0 7.0 4.0 Dry flue gas Losses due to Excess
Air Kcal/Kwh 0.000 0.0 47.8 42.3 0.000 61.5 14.3 19.6
Import from Grid MWh 7.417 12.000
Export to grid(IEX+Injection loss) MWh 18.133 13.000 IEX-0 MWH
Shutdown/Start-up power MWh 0.50
Remarks
50.8 56.9
70.2 72.4 75.8
78 83.6 86.3 86.7
0 20 40 60 80 100
Plan
t load
factor %
GCW
RDCW
KCW
SCW
RCW
RWCW
AC
VC
HCW
4th
9.08 9.25 9.37 9.57 9.69 10.12
10.6 11.37 11.47
0 5 10 15
Au
x. Co
nsu
mp
tion
%
VC
RWCW
GCW
ACW
RCW
SCW
RDCW
KCW
APCW
1st
3036 3055
3103 3103 3109
3127 3159 3172
3305
2900 3000 3100 3200 3300 3400
Heat R
ate Kcal/K
wh
RDCW
VC
APCW
ACW
RCW
RWCW
AC
SCW
KCW
7th
64 112
195 237 248
281 286
325 334
0 100 200 300 400
Gen
eration
AC
ACW
KCW
RCW
RWCW
SCW
VC
HCW
4th
7.73 7.82 8.15
10.95
7.69 6.96 6.92
0
2
4
6
8
10
12
15 18 25 25 27 30 250
A
u
x
.
%
Plant Capacity MW
APC %
86.69%
13.31%
TPP Power share
Net apc
CFBC with ACC
Action plan to Reduce Auxiliary power from present 9.3% to 7.6%
S.NO Area Actions FPR Expected Per day
Saving (KWH)
Target date
1 TPP Improve PLF by Power wheeling / selling to IEX VPG 1350 Continue
2 Boiler-PA Fan
1. Reduce PA fan flow from 20 to 17.5 Kg/s. 2. Optimization of Oxygen in Boilers. 3. False air entry to be arrested in APH. 4. Reduction of Bed Height from 1010 to 950 mm
SKR 1250 30.12.17
3 Compressor
1. Avoid parallel unloading of Raw meal Bowzers. 2. Stop Ash handling operation while Unloading of Raw meal bowzers. 3. Ensure Ash handling system operation in probe mode only and optimize ash handling cyclic time. 4. Avoid Air Cleaning with compressed air. 5. Shut off Air valves of Phase-1 equipments while running only Phase-2 TPP is in operation. 6. Run only VFD operated compressors. 7. Installation of low pressure Air Compressor for raw meal unloading 8. Air audit to be conducted for CHP,AHP & boiler area
SKR 1230 20.03.18
4 Boiler- BFP
1. Single BFP operation whenever load is less than 16 MW to operate Two Boilers. 2. During normal operation, BFPs to be operate in DP from 10 to 8 Kg/Cem2 while low load operation.
SKR 960 15.12.17
5 Air-Conditioning Installation of split AC's in office area & stopping 2 Units of package AC.
VPG 950 15.12.17
Integrity - commitment- Passion -Seamlessness -Speed 16
Target-7.2% APC in Dalmia Cement CPP
,Karnataka
6 ACC Reduce ACC fan speed from 30 to 20 % in winter or alternatively reduce blade angle to reduce air flow.
HH 600 15.12.17
7 TPP Substation Optimization of Transformer losses VPG 600 30.12.17
8 Boiler-ID Fan Reduce draft progressively from -30 to -20 Kg/cm2. SKR 320 30.12.17
9 Cooling Tower 1. Reduce ACW Pump discharge pressure from 3.5 to 2.8 Kg/cem2. 2. CT fan operation interlocked with temperature
SKR/VPG 250 15.12.17
10 Boiler-SA Fan Operate SA Fan in close loop with Bed temp and its logic preperation in DCS
SKR/VPG 180 30.12.17
11 CHP 1. Minimizing Coal handling plant Idle running hours 2. Stop Bag filters operation while Petcoke feeding.
SKR 110 15.12.17
12 Lighting
1. Installation of solar day lights in WTP, TG building , Project & Mechanical Workshop. 2. Installation of LED lights
VPG 100
30.01.17
13 Boiler-Fuel Feeder Re-calibration of fuel feeder bed height from 30 TPH to 12 TPH and logic preperation in DCS
VPG/VM 60 30.11.17
14 WTP Operate WTP once in a Two days. SKR 44 15.12.17
Total Expected saving 8004
Integrity - commitment- Passion -Seamlessness -Speed 17
Title of Project
Annual Electrical Saving (kWh)
Annual Thermal Saving In Mcal
1 Installation 4 nos of VFDs in ACC-3&4 1360000
2 PH-1 boilers after Heaters feed water inert connection
1420800
3 Operation of HRPP 37 Kw compressor instead of 160Kw
225060
4 LED lights installation inPh-2 TG building& all areas 8689
5 Day lights installation in TPP 6307.2
6 Reduction of CEP discharge pressure from 9.5 to 8 kg/cm2. and operate cascade operation with Deaerator pressure
8400
7 Arresting of False air entry in ESP-4 28749
8 Optimization of oxygen levels in Boilers 1626800
Intgrity - commitment- Passion -Seamlessness -Speed 18
Title of Project
Annual Electrical Saving (kWh)
Annual Thermal Saving In Mcal
1 Auxiliary cooling water pump Corrocating to improve efficiency
87600
2 Pentane pump VFD arrangement 569000
3 Lighting power optimisation done by providing occupancy sensor, local lighting switches
53674
4 Chiller operation optimisation by providing single duct
139392
5 Gravity line provided to makeup water instead of pumping
86400
6 Boiler Blow down water heat recovery 615.543
7 Boiler fans IGV(Inlet Guide vane ) removal to Minimise suction pressure.
243936
8 L.P.Heater drain line connection to CRT (Hot well Bypass)
15260
9 VFD provided for Coal handling Dust extraction System 283532
Intgrity - commitment- Passion -Seamlessness -Speed 19
Title of Project
Annual Electrical Saving (kWh)
Annual Thermal Saving In Mcal
1 To reduce power consumption of cooling water system.( Cooling towers interconnection )
360000 -
2 Reduce power consumption of Compressors (Interconnection of Compressors)
520000
3 To save fuel( HSD) by Doing Boiler-4 commissioning with coal
- 1380000
4 AC,p&vControl room AC One Unit stopped (Current temp setting is 24 deg,Incresed to 26 deg)
131400
5 ACC fans power optimisation by locking maximum speed limit
596000
6 ACC-2 bundle shifting/modification job,ACC-2, 1st row bundles are of HDG MOC and 4th Row bundles are of Aluminium Extruded
618000
7 Energy saving by stage blinding of Boiler feed pumps 713000
Intgrity - commitment- Passion -Seamlessness -Speed 20
Sno Project Status
Savings in Kwh Savings in Thermal
1 Install Auto Star delta star convertor for identified under loaded belt conveyor motors Not feasible, It should be considered factor of safety. NA
2 Replace 150 W HPMV Lamps with 48 W LED lamps in TG hall Completed 1787
3 Install Energy efficient florescent lamps for boilers Phase manner changes with LED lights,200 no s completed approx. 800 pending 22654
4 Reduce the pressure drop across the damper in L91BF1,L51BF2,L11BF1 Completed, All dampers removed 36500
5 Optimisation of instrument air Completed ,Auto drain valve timing adjusted 73000
6 Optimisation of service air Completed, Reduces the compressor set point as equal with IFC set point ,is about 3.8 Kg/cm2 at end point 54750
7 Optimisation of cooling circuit Completed,ACW discharge pressure reduced from 4.2 Kg/cm2 to 3.2 Kg/cm2. 456250
8 Optimisation of RO pump Completed,VFD provided and Closed loop developed as per process requirement. 18250
9 Optimisation of Condensate extraction pump completed, Closed loop logic developed for avoid pressure drop across the control valve. 201600
10 Install New efficient pump for CEP in all units Not feasible, While operating steam dumping at 100% additional flow required . NA
11 Reduce the pressure drop across the FRS in PH-2 BFP's
Closed loop logic developed with Steam drum pressure. At pressure minimum DP across the BFP header to Drum maintained 8 Kg/cm2. 317550
12 Reduction in radiation losses in Boiler Completed ,Identified areas insulation completed 507480 Kcal
13 Installation of expert Optimisation system for CPP Not feasible. NA
Integrity - commitment- Passion -Seamlessness -Speed 21
Total-13 Completed-10
Not feasible -3 nos
Scope 1 emissions CO e (MT)
Total CO e MT
Reduction in emission intensity since baseline year study
Remarks
2013 - 14 401350 Base line year
2014-15 458620 4556
2015-16 611443 3541
2016-17 432895 9450
Integrity - commitment- Passion -Seamlessness -Speed 22
Sno Title
1 Installed fast bus transfer system to uninterrupted boiler operation While tripping of turbine .
2 All VFD drives running with Closed loop operation Like Boiler feed pump,CEP etc.
3 Provided 11 KV VFD with MV drive for Boiler feed pump
4 ESP Charging ratio 1:7 to 1:1 with maintained Environmental norms.
5 Interconnection of Instrument and Service air line
6 Boiler blow down heat recovery with heat Exchanger
7 Ejector Steam tapping from Extraction line in stead of Mainstream line
8 PPF usage instead of HSD for boiler start-up
Integrity - commitment- Passion -Seamlessness -Speed 23
• Installed 12 no's of light pipe for buildings and Workshops .
Integrity - commitment- Passion -Seamlessness -Speed 24
Used 15.5 Mt of carbon black powder as alternate fuel.
Integrity - commitment- Passion -Seamlessness -Speed 25
Two way transportation for Rawmeal and fly ash handling with bulker.
Two way Transportation for Petcoke receipt and Cement dispatch.
Integrity - commitment- Passion -Seamlessness -Speed 26
13.71
11.60 11.03
10.01 10.27
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
2013-14 2014-15 2015-16 2016-17 2017-18
AP
C %
Last 3 years
85.5
87 88
81 81
3003 3034 3030
3118 3167
2000
2200
2400
2600
2800
3000
3200
3400
76
78
80
82
84
86
88
90
2013-14 2014-15 2015-16 2016-17 2017-18
PH
R K
cal/
Kw
h
• Planted 200 No's Trees in CPP for Last year 16-17 in the view of Vanam –Manam.
Integrity - commitment- Passion -Seamlessness -Speed 28