BHEL CCDP audit

1

Energy Auditing the Electrical Utilities BHEL CCDP

ByRenga Ramanujan CReg No. 01110548014

Guided by,Internal Guide : External Guide : Mrs. Gomathi E Mr.

Ramakrishnan D (Asst Prof Petrochemical Dept.)(AGM CCDP BHEL)

Anna University R&D BHEL

Trichy Trichy

2

Introduction A complete and comprehensive energy audit study

was conducted on the electrical utilities, BHEL CCDP in Thiruchirapalli, in the months of Jan-Apr 2012

Study was performed aiming the following objectives.

Conservation of energy, as a social responsibility, as a commercial benefit to user

Participate in the proposed, perform and achieve in trade (PAT Scheme) under, National mission on enhanced energy efficiency program

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ObjectiveMain objective of the project is to audit the

electrical equipment's and propose suitable savings with paybacks

The following equipment's considered in Auditing :MotorPumpsCooling TowerLightingCompressorTransformer

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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

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IGCC (Integrated Gasification Combined Cycle)

Fig IGCC Plant Process

6

Gasification ReactionsExothermic

C + O2 CO2

C + ½ O2 CO

C + 2H2 CH4

CO + H2O CO2 + H2

Endothermic C + CO2 2CO

C + H2O CO + H2

Incomplete Combustion of coal forms an gas called as syn-gas (CO+H2 ).

Coal gas has the Calorific value(in CCDP) is ( 1030 Kcal/Nm3 ) . These gasification reaction is taken place in a gasifier which kept in an

high pressurized conditions.

7

PLANT

PROCESS

DIAGRAM

8

TNEB Bill for R&D Side as on ( 06-01-2012 ) :Statement of electrical energy consumption During the Month of DEC-2011 in respect of HT SC.No.58 CCDP

SI NO Description Electrical

Consumption

In Units

01 CCDP 1,20,060

02 FCB 22,200

03 Welding research institute 38,300

04 Misc.Buildings,Street Lights 3,500

Total 1,84,060

Sanctioned demand in KVA 2000Maximum demand touched in KVA during 1885.80the month of DEC 2011Power Factor 0.96 lagEnergy Supplied by TNEB 1,84,060 UnitsPer Unit rate 6.76 `Amount Paid to TNEB 12,44,245 `

Auditing Electrical Utilities

Equipment Audited

MotorsCompressorsCooling Towers LightingPumps Transformers

Motor Auditing ReportImportant Data In Motor Auditing :

% Loading – Working Power *100 Rated Power

Were, Loading of an Motor Determines;

75 % Loading- All motors designed efficiency is under this loading % only. PF factor is in the range of 0.8 -0.9 at this % loading. So its necessary step in auditing the motor to measure the

loading percentage.

Efficiency- Efficiency is measured by the losses method ,this efficiency

plays the main role in energy consumption of the device.

Efficiency vs Loading graph

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

10

20

30

40

50

60

70

80

90

100

Efficiency vs Loading

75-100 HP30-60 HP15-25 HP0-10 HP

loading

Eff

icie

ncy

Power factor vs Loading

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

0.2

0.4

0.6

0.8

1

1.2

PF Vs Working Load

75-100 HP30-60 HP15-25 HP0-10 HP

Full load-Amperage

Pow

er F

acto

r

Motor Details BHEL CCDPThere are about 139 Motors

running in the Plant including motor and compressor drives

The loading % is calculated in all the motors its found that 25 motors are running in under loading conditions among which 6 motors are high rated Motors which has been taken and efficiency has been calculated for that Motors

Under-Loading Motors

Vibrator-4( Rated Power-7.5 kW)

% Loading - 38.667 %

Working Efficiency - 78.69 %

PF - 0.92

Belt Conveyor( Rated Power- 5.5 kW)

% Loading - 41.81 %


PF - 0.88

Bucket Elevator (Rated Power-5.5 kW)

% Loading - 47.27 %


PF - 0.85

Under loading Motors

Crusher (Rated Power-30 kW)

% Loading - 46.67 %


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

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Make: NGEF(vibrator 4)Rated Power : 7.5 KWRated Current : 13.7 AmpsRated speed : 1440 RPMInsulation class : FDuty cycle : S1Designed efficiency ɳ : 88%Number of Poles : 4Connection : DeltaStarter : DOL

No Load (15% load setting)Voltage : 415 VCurrent : 5AFrequency : 50 HzStator resistance : 1.75ΩPower : 1200 W

Load (75% load setting)Voltage : 415 VCurrent : 12.5 APower : 2900 W

Motor Calculations :

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SolutionIron Loss with friction Windage loss

Pi + fw=Pnl-Pst.cu (Stator Cu loss)

Pst.cu= 3*(No load current/√3) 2*Stator Resistance =3*(5/√3)2*1.75Pst.cu = 43.75 WPi + fw=1200-43.75

= 1156.25 WStator resistance at working condition with respect to insulation classStator resistance = (1.75)*(110+235/ 30+235)

=2.28 ΩStator Copper losses at Full load

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

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Full load slip

Ns =120*50/4 = 1500 RPM

S= (1500-1440)/1500

S=0.04

Rotor Power Pr= 7500/(1-0.04)

=7812.5W

Power Input Pi=Pr+pst.Cu(FL)+(Pi+fW)+Pstray

= 7500+427.67+1156.25+0.018

= 9.531 KW

Ns= 120f/p S= Ns-N/

Ns

Pr= Rated power/(1-S) Watts

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Motor Efficiency:% ɳ=Rated output/Power Input *100

= 7.5/9.531 *100=78.69%

Power FactorPF=Pi/√3* Rated Voltage*Rated currentPF= 9.531*1000/√3*415*13.5 =0.968 lag

Payback and ProposalsProposals

Installation of ʎ-∆ convertor

Installation of VSD Drive

Installation of reduced rating Motors

Installation of DE Controllers

Installation of Capacitors

Motor Energy saved/Year

Costs Saved/Year

Payback Period

kWh ` Months

Vibrator 4 16386 1,06,509 10.7

Belt conveyor 20184 1,31,196 4.1

Bucket Elevator

18600 1,20,900 4.8

Crusher 104682 6,80,433 2.6

Belt Conveyor 3

60240 3,91,560 6

Total 220092 kWh 14,30,598 `

Payback for Installing VSD Drive :

21

Compressor Auditing Report

The Compressor is an Least efficient device the compressor is major electrical consumption device on the plant.

The compressor air is used in an plant for the Instrumentation air , service air ,an heatless dryer compressor ,and LPC for Gas turbine, Plant AC.

The compressor audited to find out the leakage, Actual FAD

and the volumetric efficiency is calculated and the efficient enviornment is proposed in this auditing

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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

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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)

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Compressor AuditingInstrument AirRated power : 37 kW

Design CFM : 162.5087

Actual CFM : 103.596

Specific Energy Consumption : 0.24 kW/CFM

% Volumetric ɳ : 63.75 %

% Leakage : 34.49%

Service AirRated power : 90 kW

Design CFM : 528.1536 CFM

Actual CFM : 319.22 CFM


% Volumetric ɳ : 60.47%

% Leakage : 31.70%

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Compressor AuditingLPCRated power : 1.07 MW

Design CFM : 36034.56 CFM

Actual CFM : 29337 CFM


% Volumetric ɳ : 67.54 %

% Leakage : 35.06%

Plant AC Compressor 2 No’sRated power : 20 kW ; 20kW

Design CFM : 70 CFM ; 60 CFM

Actual CFM : 54 CFM ; 42 CFM

Specific Energy Consumption : 0.21 kW/CFM ; 0.21 kW/CFM

% Volumetric ɳ : 64% ; 64.7%

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Proposals and PaybackObservation : Instrument ,service air compressors are installed in the air 1985 and LPC

installed in 1990 and Plant AC compressors installed in 1994.Its been found that the Volumetric efficiency is around 60% in all compressors represents the age doesn’t the performance of compressors.

Problem exists in the leakage between the compressor and the receiver tank.

Found out Leakage areas : Damaged Valve seperating the drier unit and service air

compressor. Leakage in pipe joints of pipes at the room corner ends

leaving the compressor room to the outside storage tank. Bypass Valve present near the tank were the pipe

connceted to the storage tank

For precision leak detection ultrasonic leak detectors are recommended

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Savings Analysis (With Leakage arresting of 20%)

Compressor Leakage Energy Waste

Energy Savings

Cost saved

Instrumentation

34.39 % 84840 60000 3,90,000

Service Air 31.70 % 294600 247465 16,08,526

Total 3.07,465Units/year

19,98,522.5`

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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.

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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

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Lighting Auditing Report

Lighting consumption data at different sections

Gasifier Section - 105.36 units/dayGas Cleaning System - 71.16 units/dayCoal yard - 84.42 units/dayEngineering Building - 46.72 units/dayStreet Lighting - 159 units/dayOther areas - 326.34 units/day

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Lighting calculations Turbine & Crane Hall:

Length : 70 m Width : 30 m Height : 6 m Average Lux : 92 Target Lux : 50 Number of workers : 32 Total Watts Utilized : (400*21) = 8.4 kW

Floor area : Length * Width110*45 = 4950 m2

Room index : floor area / (height-0.83)*(length + Width)4950 / (6-0.83) * (110 + 45)= 3.48

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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

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Light AuditingPlace Area TotalWatts ILER

Gasifier Section(Ground Floor)

375m2 1.155kW 0.74

Power house 2100m2 3.2kW 1.05

Turbine Hall 4950m2 8.4 kW 1.08

Control Room 600m2 2.24 kW 0.51

Pump House 1000m2 1.32 kW 1.004

Compressor House

875m2 1.28kW 0.892

Stores and Instrumentation room

2800m2 3.295 kW 0.93

Reference room

600m2 920W 0.93

Gas CleaningGround floor

400m2 2.12 kW 0.297

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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 `

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Proposals and SavingsGasifier section and gas cleaning section mostly

uses an Mercury vapour lamp in most of the places

this light can be replaced with induction lamps

Street lamp is mainly an 125 W Mercury vapour

lamp which and 250 w sodium vapour lamps these

lamps can be replace with the CFL Lamps

40W FTL lamps equals 18 W CFL so FTL lamps are

replaced with CFL Lamps

Motivating green energy with Solar Street

lighting

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SavingsPlace Energy

Wasteunits

Energy saved with new settings units

Costs saved`

Gasifier Section

8079 5885 38,255

Street lighting 58035 37120 2,41,312

Power House 14016 13889 90,279

Turbine Hall 36792 16556.4 1,31,534

Control Room 3205 2809.3 18,260

Gas Cleaning 35838 31130 2,02,345

Reference room

282 257 1671

Total 111331.69 723656 `

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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

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Formula usedRange (°C) = [CW inlet temp (°C) – CW outlet temp (°C)]

Approach (°C) = [CW outlet temp (°C) – Wet bulb temp (°C)]

Effectiveness= Range / (Range + Approach)

• Blow down = Evaporation loss / (C.O.C. – 1) m3/hr

• Make up water requirement= Evaporation loss + Blow down loss m3/hr

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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%

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CCDP Cooling Tower(1)

Fan Motor: 15 KW

Rate of Flow 1880 m3/hr

44oC

33o

C

Wet Bulb Temp: 28oC

Dry Bulb Temp: 30.5oC

125 ϕ m

103.7 ϕ m

8.39 ϕ m

Fan Blades

3.6 ϕ m

Tower Frame: Treated timber

No of Fans: 4

No of blades: 3

4.88 ϕ m 4.88 ϕ m 4.88 ϕ m

Calculated Values:

Range : 11oCApproach : 5oCEffectiveness : 68.75%Evaporation : 31.64m3.hrLossBlow down :10.54 m3/hrLossConnected :Pumps ACW1,2(45kW),

CW 1,2 (150 kW) HP Aux pump(30 kW)

Fan : CT fans 3*15kW

Air Flow Rate : 138700 m3/hr

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CCDP Cooling Tower (2)

Fan Motor: 20 KW

Rate of Flow2440 m3/hr

45oC

36oC

Wet Bulb Temp: 28oC

Dry Bulb Temp: 30.5oC

160 ϕ m

130 ϕ m

8.50 ϕ m

Fan Blades

3.8 ϕ m

Tower Frame: Treated timber

No of Fans: 4

No of blades: 3

4.88 ϕ m 4.88 ϕ m 4.88 ϕ m Calculated Values:

Range : 9oCApproach : 8oCEffectiveness : 52.95%Evaporation : 33.6m3.hrLossBlow down :11.196 m3/hrLossConnected :Pumps PFBG 1&2 (75kW)

MHD 1,2 (40 kW) HP Aux pump(30 kW)

Fan : CT fans 3*15kW

Air Flow Rate : 138700 m3/hr

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Cooling tower pump analysis

Cooling Tower -1ACW Pump 1 & II

These pumps are working under interval basis if one pump operated other been at stand by.

Flow 220 m3/hr

Measured flow 208 m3/hr

Head 40 m

Power consumed 55.47 kW

Hydraulic power 22.67 kW

Shaft Power 45 KW

ɳPump 50.38%

Power consumption /year 22180 units/year

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Cooling Tower -1

CW Pump 1 & IIThese pumps are working under interval basis if one

pump operated other been at stand by.

Flow 800 m3/hr


Head 235 m

Power consumed 100 kW


Shaft Power 76.65 KW

ɳPump 65%

Power consumption/year 400000 units/year

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Cooling Tower -2

PFBG pump I & IIBoth pumps are running.

Flow 450 m3/hr


Head 40.7 m



Shaft Power 74.9 KW

ɳPump 62.11%

pump consumption/year- 367600 units

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Cooling Tower -2

MHD I & IIThese pumps are working under interval basis if

one pump operated other been at stand by.

Flow 75 m3/hr


Head 100 m



Shaft Power 40 KW

ɳPump 44%


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Cooling Tower -2

HP Aux PumpThese pumps are working under interval

basis if one pump operated other been at stand by.

Flow 25 m3/hr


Head 250 m



Shaft Power 29.91 KW

ɳPump 57.5%


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ProposalsWater used is found to be contaminated ,will cause

slates on the surface condenser. maintainance of water solid levels is necessary

Tower frame in cooling tower 1 is damaged its recommended to works on damage or install an new cooling tower frame

Cooling tower pumps all pumps except ACW and PFBG pumps are operated just above 50 % its recommended to install high efficient pumps around 60-70%

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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

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Installing an efficient pump By installing efficient pumps 2% of current energy consumption is

reduced. Old consumption 362644 units

New consumption 362644*0.8 =290115.2

Cost saved=(362644-290115.2)*6.5 = 4,71,438 `

Investment = 7,50,800

Payback = 19.11 Months

Energy and cost saved

By Repairing Tower Frame : 13,03,848

Installation of efficient pumps : 7,50,800

Cost Saved /year in 2054648 `

Cooling tower

50

Transformer Auditing report:Transformer :

BHEL CCDP Uses 2 transformer which has been installed as per the norms of TNEB,as CCDP is sanctioned with 2000KVA demand

Transformer 1 - 500 KVA Transformer 2 – 1500 KVA

Transformer is an static device hence the losses are low.While performing performance analysis of an transformer these data to be find out,Losses(Both No load , Load Losses)Best LoadingPower factor management

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Transformer Audit 1500 kVA Transformer

No load loss - 1.32 KW

Full Load Loss - 8.5 kW

Total loss - (NL Loss +FL Loss*(Act KVA/Rated KVA)

3.21 KVA

Operating hours - 9hrs

Currently loaded -42.13%

Calculating Annual Loss during Working Days:

Loss-(3.21*9)*300*1.85 =10833 kWh/Annum

Calculating annual loss during Non-Working days

Loss-(3.21*12)*365*1.32=10128.75 kWh/Annum

Total 12 month Transformer loss-10833 + 10128=20961 KVA/Annum

Present Energy utilization from TNEB – 964,952 kVA/Annum29% lossed in transformer

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1500 kVA Best loadingBest loading-√(no load loss/FL loss)*Rated kVA

= √ (1.32/1.85)*1500 = 766.94 kVA = 51 %

500 kVA TransformerNo load loss-1.05FL Loss - 6.5Total loss - 15.507 kWh/dayCurrently Loaded – 39%Annual Loss during working days – 5815 kVAAnnual loss during Non Workin – 4704 kVATotal loss in years - 9653 kVABest Loading % - 40.91%

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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.

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Power Factor Management Apr-11-0.85May-11-0.67Jun-11-0.78Jul-11-0.77Aug-11-0.8Sep-11-0.9Oct-11-0.88Nov-11-0.76Dec-11-0.92Jan-12-0.96Feb-12-0.78Mar-12-0.7Apr-12-0.8

NEED For PF Correction

AVG PF : 0.8 lag

Converting KVA to KW 640*0.8 = 512 KWh With 0.9 PF640 *0.9 = 576 KWh

64 units saved per hour

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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

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Transformer SummaryCosts Saved PF Correction - 39,260 `/yearIncrease Loading % - Increasing loading from 42 % to 51%

57

Pump AuditingThe Main data to be found out during

pump auditing isHydraulic PowerShaft PowerPump Efficiency

For calculating these data'sFlow RateHeadPower ConsumptionIs measured

58

Pump Audit

Formula Used : Hydraulic (kW) = Q x Total Head, (hd – hs) x x g

1000

• Pump shaft power= Hydraulic power X ɳ Motor

Pump efficiency, ɳ Pump = Hydraulic power

Pump shaft power

Were

Q-Flow Rate m3/sec

H-Head m

- Density kg/m3

g- Acceleration due to gravity m2/ s

59

Auditing CalculationsMotor name plate details: (Liquor Pump –Quench Column)

Make :KriloskarPower : 75 kWCurrent : 128 ASpeed : 2970 RPMInsulation Class : FDuty : S1Voltage : 415 V% ɳ : 85 %

Pump name plate details :Make : VK Pump industriesType : Triplex PlungerCapacity Q : 61 m3/hr (or) 0.016944 m3/secHead : 238 mSpeed : 2970 RPM% ɳ : 57.5 %

60

Datas

Motor consumption details : Power input Pi : 86.34 kW

Motor working ɳ: 80%

Pump :Capacity : 59.8 m3/hr (or)

0.016611 m3/secDensity of liquid : 1000 Kg/m3

Gravity : 9.81 m/sec2

61

CalculationsPump calculations (with measured values) :Hydraulic power = Q*H*ρ*g / 1000

= 59.8 * 238 *1000*9.81/1000 = 38.78 kW

Pump Shaft power = Motor input * motor ɳ = 86.34* 0.80 = 69.08 kW

% Pump ɳ = Hydraulic power*100 / Shaft power

= 38.78*100 / 69.08 = 56 %

62

Pump Report Auxiliary Boiler Feed Pump:

Hydraulic Power = 3.374 kW

Shaft Power = 9.3 kW

Pump ɳ = 36%

Auxiliary Boiler Hot water Feed Pump:

Hydraulic Power = 310.92 W

Shaft Power = 712.5 W

Pump ɳ = 43%

Auxiliary Boiler FO Injection Pump :


Shaft Power = 172.5W

Pump ɳ = 49%

63

Pump Report DM Plant back Wash Pump:



Pump ɳ = 49%

DM Plant Drinking Water Pump :



Pump ɳ = 50.08 %

DM Plant Make Water Pump:



Pump ɳ = 45%

64

Condensate PumpCapacity Q : 30 m3/hr (or) 0.00833 m3/secHead : 100 mHydraulic Power =7.685kW

Shaft Power =15.309 kW

Pump ɳ = 50.02 %

Proposals:

These pump working at the 50% efficiency so increase the efficiency to 65-70% Will reduce the power consumption

65

Savings and Payback Liquor pump: Rated flow : 61 m3/hr Flow Measured : 59.8 m3/hr Power consumption : 86.34 kW Pump current Efficiency : 56 % Motor current efficiency : 80 % Annual working hours : 6000

Proposals:

The pump is working under the 56 % Efficiency, Replacing the pump with the 70% Efficiency will decrease power required hydraulic power, hence reducing the power consumptionProposed Power consumption : 76 kWOne time motor Implementation cost : 68000 `

66

Payback: Annual Energy Savings : (Present power – Expected power) * Annual working hours (86.34-76)*6000 62040 kWh Annual power cost savings: Annual energy savings * cost of 1 unit 62040 * 6.5 403260 ` Payback period : One time implementation cost*12 /Annual power cost savings 68000*12 / 403260 2.4 Months

67

Savings in PumpsPump Energy

Savings/yearCost savings/year

Return of investment

Auxillary Boiler Feed Pump

10318 kWh 67067 ` 9.3 Months

Back wash Pump

4200 kWh 27300 ` 17 months

Condensate Pump

11340 kWh 73710 ` 7.5 months

Liquor Pump 62040 kWh 403260 ` 2.4

Total 87898 kWh 5,71,337 `

68

ConclusionOn auditing the electrical utilities of

the plant I am concluding the project with savings summary

Motors - 220092 kWhCompressor – 307465 kWhLighting – 111331.69 kWhCooling Tower – 316099 kWhTransformer – 10000 kWhPumping – 87898 kWhTotal 736786.69 kWh saved /year

69

Bibiliography Bibliography Handbook on Energy Audit and Environment

Managementby Abbi The Codes Guidebook for Interiorsby Sharon Koomen

Harmon, Katherine E. Kennon Technical Guide of BHEL CCDP Plantby Mithoshi Ken Shu

Wang,Yaspal singh and Karthikeyan. Hispanic Engineer & IT- Winter-Energy Auditing magazine. Keeping the Lights on: Nuclear, Renewables and Climate

Change-Great Britain: Parliament: House of Commons: Environmental

Audit Committee Investment Grade Energy Audit: Making Smart Energy

Choices-Shirley J. Hansen, James W. Brown Energy Audit of Building Systems-An Engineering Approach-

Moncef Krarti Commercial Energy Auditing Reference Handbook-Steve

Doty

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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

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THANK YOU

Education

BHEL CCDP audit