Beruflich Dokumente
Kultur Dokumente
3 L Program (BEE)
15/05/2008
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Introduction
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Introduction
Various Energy saving projects implemented like Implementation of Elan system Optimisation of lighting system Installation of solar and LED based lighting system
All operational and financial issues like reliability, risk assessment and cost-benefit analysis carried out for each projects
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Total Plant Generation Auxiliary Power Consumption HT Motor Consumption LT Motor Consumption Lighting & Misc. Consumption
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Pump Fan
VFD at DTPS
LV VFD (415V)
HFO Pump-37KW Seal Air Fan-120KW Vent Air Fan-90KW Colony Drinking water Pump-45KW
MV VFD (6.6KV)
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HFO Pump-VFD
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Flow Diagram
PCV
HO28 HO12 RETURN TO HFO TANK HO28 HO12 HO12 HO12
TO HOPCV
HEATING STEAM
PP PS PC PSAL
PI T C V
PCV
HO11 HO12 HO12
PT
PI
PI
TI PI PI PS PI
TC TO HOTCV
PI
HTR-3
PI
PI
PDI
PUMP-3
DPI
TI CONDENSATE PP
PUMP-2
HTR-2
PUMP-1
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zero
The HFO gets re-circulated through short and long re-circulation line of both boilers to maintain the HFO temperature
Flow through short & long re-circulation is very less & maximum quantity of HFO re-circulated through Pressure Control Valve (PCV), located near the HFO firing pumps to HFO tank.
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Recirculation is identified as source of energy wastage Decision taken to install VFD and open the recirculation fully Risk assessment carried out Introduction of first VFD for DTPS and hence trial run of VFD planned Vendor identified for trial run Operational reliability ensured and energy saving achieved Permanent installation done
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Valve position
Recirculation mode
100% open
Speed
1480 rpm
1243 rpm
Power
37 KW
18.1 KW
9.74 KW
Simple payback
: 12 months
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HFO Pump-VFD
The first VFD of DTPS has given Very high saving and confidence.
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Flow Diagram
TO CAD SLD-6 COAL FEEDER SLD-6
SID-13
SID-13
AIR I/L
AIR I/L
PG SID-1 SID-2
DPS
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Fan-A Fan-B
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The rated head is 1650mmwc against operating head of 8001000mmwc. The energy is wasted across the damper.
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Configuration and logic has been selected so that total capital cost reduced along with operational flexibility.
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25% open
100% open
Speed
1480 rpm
977 rpm
Power
120KW
110-120 KW
55 Kw
Simple payback
: 9 months
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The rated head of the vent air fan is very high compared to the process requirement
The damper is throttled heavy (20% open only) leading to significant pressure loss
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25% open
100% open
Speed
1480 rpm
1243 rpm
Power
69KW
69KW
48 KW
Simple payback
: 17 months
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PG
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Motor rating-45KW Actual power consumption-40KW The rated head of the pump is very high compared to the process requirement (8Kg/cm2) The valve is throttled (60% open only) leading to significant pressure loss
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60% open
100% open
Speed Power
2955 rpm 45 KW
2955 rpm 40 KW
2233 rpm 25 KW
Simple payback
: 5 months
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35
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50+51 INSTANTENEOUS OVER CURRENT A.C TIME OVER CURRENT RELAY 86 LOCKING OUT RELAY
99
50+51
94
86
VSD-CEP-A-2
MOTOR 3~
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Protection scheme
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VFD specification
Rating :880KW with bypass arrangement Voltage:6.6KV,50Hz,3 phase Overload cpacity:120% Insulation class H 36 pulse control with constant V/f
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Measurement of parameter
Parameter Design Parameter Operating parameter Parameter with VFD Capacity 770 M3/hr 640 tons/hr 640 tons/hr
Head
20.5Kg/cm2
21.3 Kg/hr
14.5-15 Kg/cm2
Temperature
45.8 0C
45 0C
45 0C
Speed
1480 rpm
1480 rpm
1300 rpm
Power
650 KW
590 KW
440 KW
Control system
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Cost-Benefit Analysis
Power consumed without VFD : 590KW
Power consumed with VFD : 440KW
:150KW
:Rs.44.1 Lacs :Rs.75 lacs :17 months
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VFD Protection
Under voltage: 0.65 Un
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HMI MV VFD
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Installation of VFD
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MV Drive-Basic Configuration
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MV Drive-Principal
Speed of an electric motor is determined by
1.Supply frequency 2.Number of pole pairs Speed = Frequency x 60 Number of pole pairs Speed of a 2 pole motor on 50Hz is 3000RPM (3600RPM on 60Hz) We must change the frequency to change the speed
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Fault tolerant enabling operation with one or more failures Easy repair High Efficiency
No harmonic heating
No insulation stress No additional bearing current
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RECTIFIER
DC LINK
INVERTER
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Power cell
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Thank you
May 12 2008