Energy Audit Procedure

for

Coal Handling Plant

Contents

Objective.

Instrumentation used.

Audit procedure.

Report Preparation Format.

Auditor tools.

Saving potential sheets.

Observation sheets.

Objective
To evaluate the performance of coal handling plant on following lines(1) To measure the relevant electrical parameters i.e. power drawn (Kw) or current
/power factor /voltage at various load conditions.
(2) Evaluation of energy requirement in bunkering, stacking & reclaiming.
(3) To evaluate specific energy consumption (kwh/Ton).
(4) To evaluate the normal coal throughput on an average basis.
(5) Estimation of average hours of operation of the CHP towards bunkering, stacking
& reclaiming modes.
(6) Observation & Analysis of
(a) Drive Speed
(b) Belt tension
(c) Condition of rollers
(7) Identification of areas of improvement / retrofit / modification leading to better
system capacity utilization.

INSTRUMENTS REQUIRED
1)

Energy meter (0.2 Class accuracy)

2 Nos

or,
a)

Kw meter

1 Nos

b)

Volt meter

1 Nos

c)

Ampere meter

1 Nos

d)

Power factor meter

1 Nos

2)

Tachometer

1 Nos

3)

Tensiometer

1 Nos

AUDIT PROCEDURE
STEP-1 (COMPILE THE CHP EQUIPMENTS DATA)

Compile all data of main CHP equipments in respect of rated specifications as

well as performance guarantee test values.

A schematic diagram of the coal handling plant.

STEP-2 (COMPILATION OF IMPORTANT SYSTEM DATA)

Collect last 1 year data on the following on a month wise basis (day wise would
be preferable) (Refer Annexure-I)
Total coal handled (tons)
Total power consumption in CHP
CHP utilization factor
Equipment wise utilization hours

Evaluate average load of the system from the past data.

STEP -3 (MEASUREMENT OF PARAMETERS)

Measure the input electrical parameters like Kw or PF, Voltage; Current of all
motor drives both LT & HT for no load & average load conditions.

Note the average equipment wise operating hours using time totalizes.

STEP -4 (EVALUATION OF COAL THROUGHPUT RATE)

Study track hopper management / coal unloading. If necessary, do time motion

study.

Note the average coal throughput rate using coal totalizer.

STEP 5 (EVALUATION OF LOADING OF EQUIPMENTS)

Determine equipment wise % loading (i.e. actual TPH / rated TPH) as well as the
motor % loading (i.e. Actual Kw / Rated Kw)

Also make a table, listing each of the equipment and their actual & design
electrical parameters like Kw, pf, V, A.

STEP-6 (CALCULATION OF SPECIFIC ENERGY CONSUMPTION)

Calculate Kw /Ton for existing operations i.e. bunkering, stacking, reclaiming

both activity wise & equipment wise for last one year.

Refer annexure-II

STEP -7 (DEVELOPING MONTH WISE SPECIFIC ENERGY

CONSUMPTION PLOT)

Based on energy meter reading & coal receipt data calculate month wise kwh /
Ton for last one year.

Plot kwh/Ton on Y axis & months on X axis.

STEP -8 (COAL SAMPLE ANALYSIS)

Send 2-3 samples of coal taken from the belts feeding to the crushers for sieve
analysis to determine extent of coal particles below 20 mm size. (Refer annexureIII)

STEP -9 (DRIVE SPEED ANALYSIS & BELT TENSION)

Measure drive speed N1 (with the help of tachometer), Dia of drive and driven
pulley D1,D2.

Calculation theoretical value of driven rpm (N2)

N1
.

D1
=

..

N2
D2
Measure actual driven rpm(Na) by tachometer.

Calculate liner speed of belt (Sb)

Sb =

Measure actual linear speed of belt (Sa)

Calculate slip = Sb -Sa

Tolerances of slips should be < 4% for conveyor belts.

Recommendations maybe made accordingly.

!! D2Na

Step-10 (Lub oil inspection)

Collect the oil sample.

Get the sample analysed.

If the metal traces are found beyond permissible limits, recommend for
complete oil change or inspection of bearings.

REPORT PREPARATION FORMAT

The audit report may be prepared in the following format.

a)

Foreword

b)

Audit team

c)

Recommendation
-Energy conservation option
- Saving potential

d)

Observation

e)

Present Practices

f)

Technical specifications

g)

Single line Diagram.

: Explain in detail present status.

AUDITORS TOOLS
1) Installing power saver device in major LT motors.(conveyor belt etc.)
Major HT /LT motors i.e. conveyors, crushers etc. are often partially loaded & also there
is frequent starts /stops. Hence to mitigate the above problem, it is proposed to provide
power saver devices in major motors. Advantages of power saver devices are described
below.

Existing Problem:
a) At no load & partial load motor draws the same power.
b) Higher starting current leads to over heating which in turn produces thermal
stresses resulting in reduction of life of the motor.
c) Due to higher starting current, life of motor and power contactor will be reduced.

Advantages of power saver:

a) Power consumption will vary according to lead.
b) Starting current gets reduced to almost half.
c) Increase in supply voltage starts the motor smoothly & starting currents are also
limited.

1) Power factor correction

Induction motors are characterized by power factors less than unity, leading to lower
overall efficiency (and higher overall operating cost) associated with a plants electrical
system. Capacitors connected in parallel with the motor are typically used to improve the
power factor . The impacts of pf correction include kVA demand (and hence reduced
utility demand charges), reduced I2R losses in cable upstream of capacitor (and hence
reduced energy charges), reduced voltage drop in cables (leading to improved voltage
regulation), and an increase in the overall efficiency of the plant electrical system.
The size of capacitor required for a particular motor depends upon the no-load reactive
power (KVARs) drawn by the motor, which can be determined only from no-load testing
of the motor. In general, the capacitor is than selected in such a way that capacitor rating
does not exceed 90% of the no load KVARs of the motor. (Higher capacities could result
in over voltages and motor burn-outs.) Alternatively, typical power factors of standard
motors can provide the basis for conservative estimates of capacitor ratings to use for
different size motors (Table 1).
Since a reduction in line current, and associated energy efficiency gains, is reflected
backwards from the point of application of the capacitor, the maximum improvement in
overall system efficiency is achieved when the capacitor is connected across the motor
terminals, as compared to somewhere further upstream in the plants electrical system.
However, economies of scale associated with the cost of capacitors and the labor required
to install them will place an economic limit on the lowest desirable capacitor size.
Savings are also a function of cable lengths and resistance (Table 2) and the electricity
tariff.

3)Lighter Synthetic Belting

Use of higher synthetic (Nylon / Polyester / Polyamide etc.) belting in place of heavier
cotton belting has resulted in reduction of power consumption by coal conveyors.

4) Use of chemicals for reduced water spray

Mixing of chemical compounds in water for suppression of dust provides much better
atomization of water spray, by way of reduction in surface tension of water. Thus for the
given application of dust suppression, lesser quantity of water us sprayed which also
result in lesser wastage of latent heat in the steam generator.

5) Maximum Mechanical Handling: Minimum Bulldozing

Sequence of coal handling operations like receipt unloading stacking and reclaiming and
the selection of machinery is made in such a way that all the handling operations are
accomplished without the use of semimechanised means like bulldozers which are more
energy intensive equipments.

6) Reduced Number of Fillings.

Live storage capacity of raw coal bunkers and the filling pattern of bunkers is so planned
that 24 hours coal requirement of the generating units is met by not more than two fillings
per day. This does not require the CHP to be started and stopped again and again.

TABLE-1
Capacitor ratings for power factor correction by direct connection to induction
motors capacitor rating (KVARs) for motor speed
Motor
3000(rpm) 1500(rpm) 1000(rpm) 750(rpm) 600(rpm) 500(rpm)
Rating(hp)
5
2
2
2
3
3
3
7.5
2
2
3
3
4
4
10
3
3
4
5
5
6
15
3
4
5
7
7
7
20
5
6
7
8
9
10
25
6
7
8
9
9
12
30
7
8
9
10
10
15
40
9
10
12
15
16
20
50
10
12
15
18
20
22
60
12
14
15
20
22
25
75
15
16
20
22
25
30
100
20
22
25
26
32
25
125
25
25
30
32
35
40
150
30
30
35
40
45
50
200
40
40
45
50
55
60
250
45
45
50
60
65
70
Note:- The values here are based on average conditions and efficiency to maintain a
power factor of 0.95 to 0.97 between 33.3% and 125% of rated load, and are applicable to
50-Hz motors of 220,400/440, and 3300 volts.
Table-II
Annual savings in energy charges from power factor correction by shunt capacitor across
motor terminals as a function of motor load and length of cable between control panel
and motor .a
Annual savings in energy charges (Rs.) b
for cable length (meters)c of :
25m
50m
100m
150m
165

330

661

991

150

299

599

898

120

241

481

722

127

254

508

761

Note;-(a) For a 15-kw motor operating 86.4% efficiency and 0.84 power factor at 100
%load. A 6 kVAR capacitor would be installed to correct the power factor.
(b) Assuming an electricity tariff of 1.4 Rs /kWH and 7920 operating hours per year.
(c) Assuming a cable cross-sectional area of 35 mm2 and resistance pf 0.00104
ohm/meter.

ANNEXURE -I
DATA SHEET COAL HANDLING PLANT
MONTHLY DATA REQUIRED
PARAMETER
1. Total coal receipt

UNIT
Lakh tons

2. Total electrical connected load

MW

3. Over all operating load

MW

4. Plant equipment operating hours

Hrs

5. Operating hours of wagon trippler

Hrs

6. Plant utilization factor

7. Total gross generation of station

MU

8. Total auxiliary power consumption

of the station

MU

9. % Auxiliary power consumption

10. Total power consumption by the

CHP plant

MU

11. % of power consumption of CHP

wrt APC

ANNEXURE-I
EQUIPMENT DATA
Equipment

Rated
PF

1. Paddle feeder
2. Belt conveyor
3. Crushers
4. Vibro feeders
5. Vibro greezly feeder
6. Belt feeder
7. Dust extraction fans
8. Dust suppression
pumps

Kw

Actual
A

PF

%
Loading
Kw

CHP KEY EQUIPMENT SPECIFICATION DATA

EQUIPMENT
REFERENCE

Paddle Feeders
Belt conveyors
Vibro feeders
Grezzly
feeders
Belt feeders
Dust extraction
fans
Dust
suppression
pumps

CAPACITY
TPH

MOTOR
INPUT
POWER

SPEED OF
DRIVEN
EQUIPMENT(R
PM OR
LINEAR
SPEED)

LENGTH HOURS OF
(IN
OPERATION
CASE
PRODUCTION
OF
BELTS)

ANNEXURE-I

RUNNING HOUR DETAILS

Month

Stage--Track Hopper
Hr

Apr
May
Jun
July
Aug
Sep
Oct
Nov
Dec
Jan
Feb
Mar
Monthly
Average

Bunkering
Hr

Stacking
Hr

Reclaiming
Hr

ANNEXURE I

UTILIZATION FACTOR OF CHP

Month

Stage
Track hoper
Apr
May
Jun
July
Aug
Sept
Oct
Nov
Dec
Jan
Feb
Mar
Apr
May

Bunker end

ANNEXURE-1

MGR Details
1. No of rakes with NTPC

----

2. Circuit Rate Length

---km

3. Time required for a rake to

complete circuit
a. Placement at mine
b. Sampling (manual)
c. Loading
d. Mine to track hopper
e. Rake Unloading
f. Track hopper to mine

---hrs

4. Rakes detail

---Wagons per rake (First wagon

remains empty due to placement
problem)
---MT coal / Wagon.

5. No. of rakes received per day

---(In General)

6. Coal per rake

---MT

---minutes
---minutes
---minutes
---minutes
---minutes
---minutes

ANNEXURE-II

BUNKERING
STAGE--RATED CAPACITY
AVERG CAPACITY
S.NO Equipment Rated Voltage
kw

T/H
T/H
No load

Avg load

Specific Energy
Consumption
No load

Average Rated

Amp Kw Amp Kw Kw/Ton Kw/Ton

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

PF-12
PF-3/4
C1A/1B(P)
C1A/1B(S)
C2A/2B(P)
C2A/2B(S)
VS-1/2
VS-3/4
CR-1/2
CR-3/4
BF-1/2
BF-3/4
C-CA/3B
C-4A/4B
C-5A/5B
C-6A/6B
C-7A/7B
C-8A/8B
TOTAL

Kw/Ton

ANNEXURE-II

RECLAIMING
STAGERATED CAPACITY
AVERAGE CAPACITY
S Equipment Rated Rated No load
no
KW
Volt

Average
Load

T/H
T/H
Specific Energy
Consumption
No load

Average Rated

Amp Kw Amp Kw Kw/Ton Kw/Ton

1

Bucket
wheel
2 Boom
cony
3 C9A/9B(P)
4 C9A/9B(S)
5 C10A/10B
6 C11A/11B
7 C-5A/5B
8 C-6A/6B
9 C-7A/7B
10 C-8A/8B
TOTAL

Kw/Ton

ANNEXURE-II

STACKING
STAGERATED CAPACITY
AVERAGE CAPACITY
S Equipment rated Rated No load
no
Kw Volt

T/H
T/H

Specific Energy
Consumption
No
Average Rated
Load
Ampear Kw Ampear Kw Kw/Ton Kw/Ton Kw/Ton

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

PF-1/2
PF-3/4
C1A/1B(P)
C1A/1B(S)
C2A/2B(P)
C2A/2B(S)
VS/-1/2
VS-3/4
CR-1/2
CR-3/4
BF-1/2
BF-3/4
C-3A/3B
C-4A/4B
C-9B(P)
C-9B(S)
Boom con
TOTAL

Average load

ANNEXURE III

COAL SAMPLE SIEVE ANALYSIS

Crusher inlet (%)i.e. from belt feeder to

crusher
+ 40 mm
-40 +20 mm -20 mm

Crusher outlet (%)

+40 mm

-40 +20 mm

-20 mm