40 MW CPP Chanda. Energy Leadership. Presenter : Sandeep Kumar Garg

Transcription

1 Energy Leadership 40 MW CPP Chanda Presenter : Sandeep Kumar Garg Welcome to CII 17th National Award for Excellence in Energy Management 30, 31 August & 01 September

2 Contents 1. Company Profile 2. Process flow diagram & configuration 3. Plant Performance over the year 4. Innovative Projects with No investments 5. Innovative Projects with investments 6. Best practices 7. Energy Saving Projects Way forward

3 Company Profile - Maharastra Chanda CPP - 1X15MW + 1X25MW - Commissioned in 2002 (15MW) & 2010 (25MW). Chanda is the first cement plant set up in the state of Maharashtra. Located at Ghugus Taluka-27 KM from Chandrapur and 165 KM from Nagpur.

4 Process Flow Diagram

5 Plant Performance Over the Years APC % SHR (Kcal/Kwh) Year 2014 Year 2015 Year 2016 Till July Aspiration Year 2014 Year 2015 Year 2016 Till July Aspiration

6 Auxiliary Power Consumption Vs PLF Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 Jul-17

7 Energy Saving Projects with zero investment Saving Achieved SN Energy Saving Projects Electrical Energy (MWH) Thermal Energy (Ton/Year) Rs. Lac 01 Implementation of DP logic in BPF of Unit# Implementation of DP logic in BPF of Unit# Optimisation of CEP discharge pressure form 10 to 6.0 Kg/cm 2 for Unit#1 Optimisation of CEP discharge pressure form 10 to 6.0 Kg/cm 2 for Unit# Total savings

8 Energy Savings Projects with zero investment Saving Achieved SN Energy Saving Projects Electrical Energy (MWH) Thermal Energy (Ton/Year) Rs. Lac 01 Improved TG vacuum by arresting leakages in exhaust path through Helium leak detect test CBD vent line connected to deareator CHP power optimization by increasing through crusher out put & reducing idle running hours through keen observation at coal feeding grizzly hopper. Impeller trimming of Raw Water Pump for reduction of APC Recycle & reuse of BAC cyclone trapped material Total savings

9 Energy Savings Projects with investment SN Energy Saving project P&V pump replaced with low capacity pump, by modification of water spray system existing louvers replaced with cellulose pad. Unit=1 condenser tube assembly replacement to improve vacuum from to.91 Kg/cm2. HT VVFD installed in BFP of unit#1 HT VVFD installed in BFP of units#2 VVFD installed in IAC of both units. Saving Achieved/Year Electrical Energy (MWH) Thermal Energy (Ton) Rs. Lac Investment s (Rs. Lac) Pay Back Months Year Continued..

10 Energy Savings Projects with investment SN Energy Saving project Replacement of Cooling tower fan blades with hollow blades of Unit#1 VVFD installed in condensate extraction pump no.1 of unit#1 VVFD installed in condensate extraction pump no.1 of unit#2 Boiler No. 01 & 02 APH tube replacement Replacement of Cooling tower fan blades with hollow blades of Unit#2 Improve MDC air slider reliability to replacement of slider sintered sheet to ceramic cloth. Reduce maintenance cost. Electrical Energy Saving Achieved Thermal Energy Rs. Lac Investment (Rs. Lac) Pay Back Months Year Total savings

11 Concept # 1 DP Logic implementation in BFP Concept.. DP LOGIC for Boiler Feed Pump to reduction of auxiliary power consumption. Background.. HT VFDs ware installed for Boiler Feed Pumps (BFP) -1 in both units which was operating at reduced fixed RPM as per requirement. However most of the time even on reduced pump loading, discharge pressure of BFP is more than the requirement on varying loads. Approach.. After studying the system it was observed that even if discharge pressure is maintained 5 to 6 kg/cm2 above the drum pressure, system behaves stable. Logic was developed in-house & incorporated in DCS so that PID will automatically take set point of 5 kg/cm2 higher than drum pressure. (Differential pressure of 5 kg/cm2 is maintained between drum pressure & BFP Discharge Pressure). Continued..

12 Concept # 1 DP Logic implementation in BFP Investment.. Financial investment is ZERO. Technical skill & Experience - To prepare & implement DP logic on DCS through own team with keen & vigilant observation during operation. Benefits & Economic impact.. Improvement in APC (Auxiliary Power Consumption). For Unit-1 KW consumed before DP Logic = 211 KW KW consumed after Total saving in KW = 24 KW DP Logic = 187 KW Saving per day in 15 MW = 24 KW X 24 Hrs= 576 Units Saving per Rs 4 /unit = 576*350*4 = 8.1 Lac / Year For Unit No.2 KW consumed before DP Logic = 285 KW KW consumed after Total saving in KW = 30 KW DP Logic = 255 KW Saving per day in 25 MW = 30 KW X 24 Hrs= 720 Units Saving per Rs 4 /unit = 720*350*4 = 10.1 Lac/ Year Total Saving per year = 18.2 Lac / year

13 Concept # 2 Replacement of Cooling Tower Blades Concept.. Replacement of CT fan GRP solid blades assembly with FRP type to reduce in Auxiliary Power Consumption. Background.. In both units, Cooling tower fans were installed with VFDs which ware operated at reduced fixed RPM as per requirement. Originally, Fans were supplied with GRP type solid blades fan assembly, resulting in high Auxiliary power consumption due heavy weight of blades. Approach.. Idea is suggested by O&M team to replace GRP type blade assembly to FRP ** Glass Reinforced Polypropylene ** Fiber Reinforced Plastic Continued..

14 Concept # 2 Replacement of Cooling Tower Blades Investment.. Financial investment was 16 Lac. Benefits & Economics impact.. Improvements in APC (Auxiliary Power Consumption) Improved Cooling effect due to air velocity increase by 27.72% & 31.64% respectively of both units Electrical Energy Saving on each fan of Unit# KWH (38.62%) Saving per 4Rs/Unit = ( )*24*350*4=6.24 Lac per year Electrical Energy Saving on each fan of Unit# KWH (42.15%) Saving per = ( )*24*350*4=23.90 Lac per year

15 Concept # 3 Reduction of secondary air in CFBC Boiler Concept.. Reduction in secondary air & focus on primary combustion for reduction of Station Heat Rate & Auxiliary Power Consumption Background.. Earlier CFBC boiler was operated with 1350 mmwc wind box pressure as per OEM recommendations, resulting in higher loading operation of PA fan, even at partial loading of boiler. Approach.. Idea is generated by our O&M team. In CFBC Boiler, PA fan header pressure reduced from 1350 to 1150 mmwc through improving the Mechanical Dust Collector efficiency by reducing slider jamming tendency. Secondary air reduced and more focus was given to primary combustion. This improved the recycle inventory. Continued..

16 Concept # 3 Reduction of secondary air in CFBC Boiler Investment.. Financial investment was negligible. Benefits & Economics impact.. Improvement in SHR by avoiding frequent leakages through air sliders(station Heat Rate) Reduction in LOI by recycling. Reduction in boiler excess air O 2 % by reduction in secondary air. Improved boiler efficiency. Improvement in APC (Auxiliary Power Consumption) - One SA fan (250KW) always maintained as hot standby.

17 Concept # 3 Reduction of secondary air in CFBC Boiler

18 Concept # 4 Recycling of Cyclone material Concept.. Recycling of drained Bed ash pneumatically to bed as bunker and optimize the use of fresh bed material. Reduction in manual interference for charging of bed material at bed bunker Background.. Earlier in CFBC boiler, the bed material bunkers which are located at almost 25 mtrs above ground, had to be filled manually for meeting light up or any other emergency requirements. This activity required manpower involvement & safety hazards. The bed ash used, was either sieved or fresh one. Now, after the system implementation, use of fresh bed material is drastically reduced. Approach.. Idea was suggested by our O&M team. In CFBC Boiler, Bed material drained & cooled in BAC. During cooling process fine material is trapped in cyclone & collected in a vessel. These fine bed material is pneumatically conveyed to bed material bunker Continued..

19 Concept # 4 Recycling of Cyclone material Investment.. Financial investment is ZERO. Benefits & Economic impact.. Elimination of manual interference & associated safety hazards. Reduced fresh bed material consumption. All employee satisfaction

20 Best practices on safety front PPE adherence while electrical energy isolation Display of SOPs/SMPs & JSAs Group Isolation & Lock out provision

21 Energy Saving Projects way forward Major Overhauling of TG # 1 & 2 to improve STG cycle efficiency & Heat Rate CFBC boiler, APH tube assembly replacement for reduction of Auxiliary power consumption & improvement of boiler efficiency. Elimination of raw water pump use by providing interconnecting line between Mines & River water pump. Modification of existing coal handling circuit for reduction of Auxiliary Power Consumption as well as increasing throughput rate. Installation of energy efficient Cooling water pumps in both units. Existing inefficient reciprocating compressors replacement with screw compressors for reduction of APC.

22 Achieve ZERO Harm consistently with Lowest Power Generation Cost by using the Innovative practices and Corporate ethics.