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Company & Plant Profile Background Principle Of Hydraulic Coupling Hydraulic Coupling Losses Loss Calculation by Heat Loss method Validation by Slip Loss method Efficiency Aspect Recommendation Benefit
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Company Profile
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Plant Profile
DTP S
lowest heat-rate. highest capacity utilisation. least secondary fuel consumption. highest plant availability.
Certified for Integrated Management System (ISO9001, 14000, 18000), SA 8000, ISMS 27000. Energy efficiency at core.
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Thermal power plant has several fans such as Induced draft (ID) fans, Forced draft (FD) Fans, Primary air fans (PA fans). These fans contribute to significant auxiliary power consumption. ID fans alone contribute to about 12% of total auxiliary power consumption The function of Induced Draft fan is to suck the gases out of furnaces and push them into the stack. Boiler is provided with two nos. of Induced Draft Fans. Each ID fan is provided with regulating damper control and scoop control for controlling the loading on fans, Inlet/Outlet gates for isolation to facilitate startup/maintenance of fan.
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ID FANA
GD-19
TE PT
APH-A
GD-3 O2 ANA. GD-6
EP-A
GD-13 GD-10 HYD. COUP GD-18 PT TE GD-15 CO ANA.
S T A C K
ID FANB
GD-20
TE PT
TE 3nos
APH-B
GD-2 GD-4 PT TE 3no s GD-8
EP-B
GD-14 GD-12
GD-16
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Flow Speed
Q1 N 1 = Q2 N 2
SP1 N 1 = SP 2 N 2
2
kW 1 N 1 = kW 2 N 2
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The ID fans are controlled with VFC control. The variable fluid coupling works on the principle of hydrodynamics. It consists of an impeller and rotor(runner) enclosed in a Casing. The impeller is connected to the prime mover, while the rotor is connected to the driven machine. The coupling is filled with fluid, usually mineral oil. The speed of the driven equipment is varied by varying the quantity of fluid Supplied between the impeller and the runner.
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Hydraulic Coupling Losses:There are two Types of Losses of power in VFC: Hydraulic Losses Mechanical Losses
Speed (RPM)
Slip (%)
Losses (KW)
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A difference between input & output speed is essential in a fluid coupling in order to enable it to transmit torque. Difference between input & output speed is normally expressed as percentage of the input speed & refereed to as slip.
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Hydraulic loss:-
SR. NO.
PARAMETER
UNIT
UNIT-2 ID FAN-2A
89
AVERAGE
ID FAN-2B
105 94
M3/Hr
104
78
Deg. Celsius
2.2
2.6
2.8
2.65
55
54
53
54
54
D = (A*B*1000) 860
KW
266.04
235.81
310.46
341.861
288.54
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Validation
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SR. No.
PARAMETER
UNIT
UNIT-2 ID FAN2A
1257.00 96.00
AVERAGE
ID FAN2B
1289.00 96.00 1253.25 96.00
A B
Motor I/P Power ID fan Motor Efficiency Scoop Position Motor Speed Fan Speed Slip VFC, I/L Power
KW %
1224.00 96.00
% RPM RPM % KW
KW
920.15
936.58
936.95
966.67
940.09
I=G-H
VFC Loss
KW
254.89
256.70
269.77
270.77
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Efficiency Aspect
Efficiency of variable fluid coupling is= 1- slip. Fan driving system efficiency can be improved by regulating fan speed by digital Variable Frequency Drive(VFD) instead of VFC. Fan driving system efficiency driving= motor* VFC = motor*(1-slip)
MOTOR
VFC
I/P Power = P
motor= 96%
VFC= 1-slip
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SR. NO.
A B C=(1-B/100)100 D=A*C/100
PARAMETER
motor Slip vfc driving
UNIT
% % % %
old
96 21.86 78.14 75.0144
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Recommendation
Installing a Variable Frequency Drive for this variation in flow requirements will result in substantial energy savings. The speed of the fan can be varied to attain the desired flow. There are two options: 1. To install variable frequency drives for the ID fans with VFC in place. In this case, fan speed is varied by VFD keeping VFC scoop 100% open.Design VFC slip at scoop 100%: - 3.4%
SR. NO.
A B C=(1-B/100)100 D=A*C/100
PARAMETER
motor Slip vfc driving
UNIT
% % % %
new
96 3.4 96.6 92.736
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2. To install variable frequency drives for the ID fans & remove VFC . In this case VFC slip loss is nil since slip =0
SR. NO.
A D=A*C/100
PARAMETER
motor driving
UNIT
% %
old
96 96
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Cost-Benefits:
(New Efficiency-Old efficiency) % Energy Saving = ------------------------------------------ * 100 New efficiency
SR. NO.
A B C D=100*((C-B)/C) E=A*C/100
PARAMETER
AVERAGE MOTOR I/P POWER old
UNIT
A %
Value
1253.25 75.01 VFD WITH VFC OPERATING AT FULL SPEED (SCOOP=100%) VFD WITHOUT VFC
% % KW
96 21.86 274.02
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In DTPS, there are 4no. ID fans. Above energy saving calculation is for one fan. If cost of unit- 3.50 Rs/KWH & annual Operating Hrs. =8200 Hr, benefit & simple payback period is shown in the following table:
SR. NO.
PARAMETER
UNIT
Value
VFD WITH VFC \OPERATING AT FULL SPEED(SCOOP=100%) VFD WITHOUT VFC
KW No
274.01
TOTAL ENERGY SAVING KW COST/UNIT TOTALINVESTMENT ANNUAL OPERATING HRS ANNUAL SAVING SIMPLE PAYBACK PERIOD Rs. Rs.CR. Hrs. Rs CR Month
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