- Feasibility report Energy conservation in BFP by reducing gearbox ratio

M.G.Morshad Energy Manager / TS II Neyveli Lignite Corporation Ltd

Introduction
M/s VOITH has up with a suggestion that about 160 KW of power can be saved in BFP if input speed of HC is optimized by changing gear box ratio. The purpose of this presentation is to study the feasibility of such power saving opportunity in BFP of TS II

Background
For any centrifugal pump Flow ( Q) is proportional to (Speed)2 Head (H) is proportional to (Speed) Input power (KW) is proportional to (Speed)3

Background
Rated flow of any pump is designed based on the minimum speed which occurs during operation at lowest grid frequency
And rated motor capacity is designed based on the maximum speed which occurs during operation at highest grid frequency

Background
Considering the grid condition in India, pump and motor capacity are designed based on the frequency band (47.5 Hz - 51.5Hz)

But after implementation of ABT, grid frequency band has narrowed down to (48.6 Hz to 50.5Hz)

Background
As a result of that Pumping system has become oversized with respect to the present grid condition And therefore there is a definite possibility of power saving by optimizing the size & capacity of PUMP- MOTOR

BFP system and rated parameters

Speed 1485 RPM Electrical Input Speed 5301 RPM Hydraulic Out Put 2543 KW

Speed 5141 RPM

420 m3/Hr 2222 M

MOTOR
Capacity 4000KW Efficiency = 95 % PF = 0.85

HC Slip = 3%

PUMP
Efficiency = 81%

GB ratio 1: 3.57 Shaft Out put 4000 KW Mechanical Input 3140 KW

Parameters that influence the performance of BFP

Power supply at grid frequency

a) Grid Frequency Motor speed changes with grid frequency

Primary wheel

The speed of the primary wheel changes with motor speed.

Parameters that influence the performance of BFP

b) Gear ratio It is used to match the speed of the primary wheel with the turbine wheel The ratio is selected in such a way that during lowest grid frequency (48.6 Hz) - when motor operates at lowest speed, pump does not fail to deliver the rated flow

Parameters that influence the performance of BFP

c) HC slip The percentage speed difference between primary and turbine wheels is known as slip. The slip can be controlled linearly by draining out oil between two wheels with the help of scoop tube.
% SLIP = [(PW speed TW speed) / PW speed] X100 Primary wheel speed depends on grid frequency Turbine wheel speed depends on the position of the scoop tube

Function of Hydraulic Coupling

Primary wheel speed depends on grid frequency Turbine wheel speed depends on the position of the scoop tube

Hydraulic Coupling

Scoop tube withdrawal position

60% 70% 80% 100%

Scoop tube movement

Slip & scoop tube position

When scoop position is low (64%) - high quantity of oil drains out from HC and the slip between two wheels get increased Similarly when scoop position is high (73%) - less quantity of oil drains out from HC and the slip between two wheels get decreased
% Slip

10 5.24 3

60

70

80

90

% Scoop position

Performance calculation of BFP

Operating parameters of BFP 7B at full flow
(Data collected on 24/7/08 from 11:45 to 12:30 Hrs) Flow Head Motor current = 405 m3/Hr = 1800 M = 326 Amps

Motor voltage
System frequency Measured motor speed

= 6.59Kv
= 48.97 Hz =1458 RPM

Measured pump speed

Scoop position

= 4930 RPM
=73%

Performance calculation - MOTOR

Motor input = 1.732 X 326 X 6.59 X 0.85 = 3162 KW Assumed motor efficiency = 94% Out put at motor shaft = 3162 X 0.94= 2972 KW Measured motor speed = 1458 RPM Torque on motor shaft = (974 X 2972)/1458 = 1985 Kg-m GB ratio = 1:3.57 Speed of the primary wheel = 1458X 3.57 = 5205 RPM Torque on the primary wheel = 1985 / 3.57 = 556 Kg-m
3162 KW Speed 1458 RPM Torque 556Kgm

MOTOR
Efficiency = 94% PF = 0.85

Speed 5205 RPM

Out put 2972 KW Torque 1985Kg-m

Performance calculation PUMP

Pump hydraulic output= 9.81X (405/3600)X1800 = 1986 KW Rated hydraulic output = 2543 KW ( Flow 420 m3/hr , Head- 2222M) Rated efficiency = 81% Rated mechanical input = 2543 / 0.81 = 3140 KW Rated speed = 5141RPM Measured speed = 4930 RPM Actual input = 3140 X ( 4930 / 5141)3 = 2769 KW

Speed 4930 RPM

Hydraulic Out Put 1986 KW

PUMP
Efficiency = 71.7%

Mechanical Input 2769 KW

Performance of BFP at full flow

Speed 1458 RPM Electrical Input 3162 KW Speed -5205 RPM Torque 556 Kg-m Speed 4930 RPM 405 m3/Hr 1800 M Out Put 1986 KW

MOTOR
Efficiency = 94 % PF = 0.85

HC Slip = 5.28 % Loss = 203KW Effi = 93%

PUMP
Efficiency = 71%

GB ratio 1: 3.57 Out put 2972 KW Torque 1985 Kg-m Input 2769 KW

Performance calculation of BFP

Operating parameters of BFP at part flow
(Data collected on 24/7/2008 from 11:45 12:30 Hrs)

Flow Head Motor current Motor voltage System frequency Measured motor speed

= 340 m3/Hr = 1780 M = 292 Amps = 6.59Kv = 49.2 Hz =1471 RPM

Measured pump speed

Scoop position

= 4709 RPM
=64%

Performance of BFP at part flow

Speed 1471 RPM Electrical Input 2833 KW Speed -5251 RPM Torque 493 Kg-m Out Put 1649 KW

Speed 4709 RPM

HC Slip = 10.32% Loss = 250 KW Effi = 90.6%

340 m3/Hr 1780 M

MOTOR
Efficiency = 94 % PF = 0.85

PUMP
Efficiency = 68.33%

GB ratio 1: 3.57 Out put 2663 KW Torque 1763 Kg-m Input 2413 KW

Power saving in BFP due to changing of GB ratio

FULL FLOW GB Ratio Motor speed PW speed PW torque 3.57 1458 RPM 5205 RPM 556 Kg-m 3.4 1458 RPM 4957RPM 556 Kg-m PART FLOW 3.57 1471 RPM 5251 RPM 493Kg-m 3.4 1471RPM 5001RPM 493 Kg-m

Motor output
Power saving Pump speed % Slip in HC Scoop position

2972 KW
4930 RPM 5.28% 73%

2829 KW
4930RPM 0.5 % 89%

2663 KW
4709 RPM 10.32% 64%

2531 KW
4709 RPM 5.83% 75%

143 KW

132KW

How power saving is achieved

Motor delivers torque to rotate the primary wheel at a constant speed Motor shaft power = Torque X speed With reduction of GB ratio speed of the primary wheel gets reduced But the torque delivered by the motor remains constant As a result of that motor shaft power gets reduced

Performance of BFP at lowest grid frequency with reduced GB ratio

FULL FLOW Grid frequency [ f ] Motor syn speed [ Ns = (120 X f ) / P] Assumed motor slip [ %S] Motor speed [Nm = Ns(1-%S)] Gear Box ratio [ R] Primary Wheel speed [Np = Nm XR] Measured pump speed [Nt] HC slip [(Np Nt) / Np] X 100 Scoop position 48.6 Hz 1458 RPM 0.7% 1448 RPM 3.4 PART FLOW 48.6 Hz 1458 RPM 0.3% 1453 RPM 3.4

4923 RPM
4930 RPM Neg. Slip Not Possible

4940 RPM
4709 RPM 4.67% 80%

Minimum & Maximum power saving due to modification

PART FLOW Grid frequency [ f ] Motor syn speed [ Ns = (120 X f ) / P] Assumed motor slip [ %S] Motor speed [Nm = Ns(1-%S)] Gear Box ratio [ R] Primary Wheel speed [Np = Nm XR] Torque on the Primary Wheel [T] Motor output [Np X T / 974] Motor output before modification Power saving 48.6 Hz (Min) 1458 RPM 0.3% 1453 RPM 3.4 4940 RPM 493 Kg-m 2500 KW 2663 KW 163 KW 49.2 Hz (Ave) 1476 RPM 0.3% 1471 RPM 3.4 5001 RPM 493 Kg-m 2531 KW 2663 KW 132 KW

Measured pump speed [Nt]

HC slip [(Np Nt) / Np] X 100 Scoop position (From graph)

4709 RPM
4.67% 78%

4709 RPM
5.83% 75%

Impacts on boiler filling due to change in GB ratio

Boiler filling parameters Motor current = 200 amps (max) Discharge pressure = 200 Ksc (max) Flow = 180 m3/h ( 80m3/h - Drum & 100 m3/h - recirculation)

Performance calculation during boiler filling

Motor input = 1.732 X 200 X 6.59 X 0.85 = 1940 KW Assumed motor efficiency = 94% Out put at motor shaft = 1940 X 0.94= 1823 KW Measured motor speed = 1471 RPM Torque on motor shaft = (974 X 1823)/1471 = 1207 Kg-m GB ratio = 1:3.4 Speed of the primary wheel = 1471X 3.4 = 5001 RPM Torque on the primary wheel = 1207 / 3.4 = 355 Kg-m Pump hydraulic output= 9.81X (180 / 3600) X2000 = 981 KW Assumed pump efficiency = 65% Pump mechanical input = 981 / 0.65 = 1509 KW Assumed torque on primary wheel = torque on turbine wheel = 355 Kg-m

Calculated turbine wheel speed = (1509 X 974) / 355 = 4140 RPM

Slip = (5001 4140)/ 5001= 17.21% Scoop position = (5001 4140) / 5001= 47%

Performance of BFP during boiler filling

( Reduced GB ratio and normal frequency )

Speed 1471 RPM

Electrical Input 1943 KW

Speed - 5001 RPM Torque 355 Kg-m Speed 4140 RPM HC Slip = 17.21% Loss = 317KW Scoop = 47%

Out Put 981 KW

180 m3/Hr 2000 M

MOTOR
Efficiency = 94 % PF = 0.85 Frequency = 49.2 Hz

PUMP
Efficiency = 65%

GB ratio 1: 3.4 Out put 1826 KW Torque 1207Kg-m Input 1509 KW

Performance of BFP during boiler filling

( Reduced GB ratio and 48.6Hz frequency )
Speed 1453 RPM Electrical Input 1943 KW Speed 4940 RPM Torque 360 Kg-m Speed 4082 RPM HC Slip = 17.36% Loss = 317KW Scoop = 47% 180 m3/Hr 2000 M Out Put 981 KW

MOTOR
Efficiency = 94 % PF = 0.85 Frequency = 48.6 Hz

PUMP
Efficiency = 65%

GB ratio 1: 3.4 Out put 1826 KW Torque 1224 Kg-m Input 1509 KW

Observation
During low grid frequency (48.6Hz), BFP cannot be run with full flow. It can only be run with part flow Because of this restriction, modification needs to be carried out at least in two BFP out of three Provision may be made to operate the scoop between 47 % and 85% There will not be any impact on boiler filling activity due to change in GB ratio

Average power saving / BFP = ( 163+132)/2 = 147 KW

Total power saving for 2 BFP = 147X 2 = 295 KW

Energy saving calculation

Total power saving in two BFP = 147X 2 = 295 KW
Energy saving / year = 0.7X24X365X295 = 1.808940 MU

Reduction in Aux Consumptions= (0.295/210) = 0.15%

Extra revenue / year = 1.66 X 1808940 = Rs30,02,840.00

Lignite saving / year = 1808940/1000 = 1809 Tons

Carbon mitigation / year = 1800/10 = 180 Tons

Simple Payback calculation

Cost for modification of one GB = Rs 62,40,000.00
Total modification cost for two BFP = Rs1,24,80,000.00 Extra revenue / year = Rs 30,02,840.00

Simple payback periods = (12480000/3002840) = 4.15 Yrs

Facts need to be further investigation

Q 1 Will there be any possibility of developing vibration in pump due to change in mass at primary wheel side as a result of changing GB ratio ? Q 2 Will it be possible to bring back the original set up within a shortest time if problem is notice in the modified GB ?

Thank You