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The steps involved in conducting energy audit of coal handling plant are: Data collection Observations and Analysis of - Drives Speed - Belt tension - Condition of rollers - Condition of belts - Loading of belts with respect to design value. - Loss of energy in the coal lying in stockyard due to auto ignition. - System capacity utilization. (To be pushed back) Exploration for energy conservation measures Report preparation 1
The key specification parameters shall be complied as shown below (Refer: Table 2-1)
Table 2-1 : Key Specification parameters Equipment reference Paddle Feeders Belt conveyors Vibro feeders Grizzly feeders Belt feeders Dust extraction fans Dust suppression system pumps Crusher Stacker reclaimer Other equipment Motor input Capacity power, kW TPH TPH TPH TPH TPH NM /h M /h TPH
3 3
Speed of driven Length Specific Hours of equipment energy (in case operation (rpm or linear) of belts) consumption
Total power consumption by the CHP plant % of power consumption of CHP with respect to total auxiliary power consumption Specific energy consumption, Equipment wise operating hours 1. 2. 3. 4. 5. 6. 7. 8.
% MU KWh/MT
Collect the parameters for coal as given in the Table 2-3. Table 2-3 : Coal Parameters Unit Fixed carbon Volatile matter Moisture Ash Grindability Coal calorific value -HHV Size of the coal to mill Total contract fuel fired % % % % HGI Kcal/kg mm tph Design Actual Remarks
Stroboscope: To measure the speed of the driven equipment and motor Tensiometer On line instruments (calibrated) for coal transfer rates, production, etc
2.6 Observations And Analysis 2.6.1 System Familiarisation And Operational Details
Detailed interactions with the plant personnel have to be carried out to get familiarisation for system detail and operational details. Pre visit can be made to get familiarisation with CHP configuration, particularly different routes such as bunkering mode, stacking mode and reclaiming mode.
2.6.2 Measurements & Evaluation a. Power parameters: Measure the power input i.e. electrical parameters such as kW, kVA, Current, Voltage, power factor, for all drives for no load and load conditions
Berbagi dan Menyebarkan Ilmu Pengetahuan Serta Nilai-Nilai Perusahaan
b. Coal throughput rate: Study track hopper management/coal unloading. It is also desired to study time-motion study. Note the coal throughput using coal totalisers or other alternative methods.
c. Evaluation of equipment loading and specific energy consumption 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 (as shown in Table 2-4), for each of the euipment and their actual & design electrical parameters like KW, PF, V, A. Also provide remarks and calculations. Obtain operating hours Operational constrains to achieve the optimum loading
Table 2-4 : Power Consumption & Throughput Direct Bunkering (Rated capacity .tph, Average capacity tph, hour operation .) Equipment Rated kW
A
No load
kW A
Average load
kW
Average
kW /MT
Rated
kW /MT
Remarks on throughput, condition, power consumption, operating hours, operational controls for energy efficiency, specific energy consumption, operational constrains etc.
Reclaiming (Rated capacity .tph, Average capacity tph, operating hours .) Equipment Rated kW
A
No load
kW A
Average load
kW
Average
kW /MT
Rated
kW /MT
Remarks on throughput, condition, power consumption, operating hours, operational controls for energy efficiency, specific energy consumption, operational constrains etc.
Stacking (Rated capacity .tph, Average capacity tph, hour operation .) Equipment Rated kW
A
No load
kW A
Average load
kW
Average
kW /MT
Rated
kW /MT
Remarks on throughput, condition, power consumption, operating hours, operational controls for energy efficiency, specific energy consumption, operational constrains etc.
d. Calculation of Specific Energy Consumption Calculate kW /MT for existing operations i.e. bunkering, stacking, and reclaiming both activity wise & equipment wise for last one year for each CHP. Based on energy meter reading & coal receipt data, calculate month wise kWh / MT for last one year. Plot kWh/MT on Y-axis & months on X-axis.
e. 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. f. Drive Speed Analysis & Belt Tension driven rpm (N2) : N1D1 = N2D2 Measure actual driven rpm (Na) by tachometer. Calculate liner speed of the belt (Sb) Sb = p D2N2 Measure actual linear speed of belt (Sa) Calculate slip = Sb -Sa Tolerances of slips should be < 4% for conveyor belts. Recommendations may be made accordingly. Measure drive speed N1 (with the help of tachometer), Diameter of drive and driven pulley (D1 and D2. Calculation theoretical value of
g. Lub Oil Inspection Collect the lube oil sample. Get the sample analysed. If the metal traces are found beyond permissible limits, recommend for complete oil change or inspection of bearings / Gear internals. h. Performance of Crushers Observe and compare the operation of crushers and its throughput, hours of operation, power consumption, etc Carryout the sieve analysis and compare with the design or optimum values
-20 mm
-25 mm
+ 25 mm
Explore the possibility of using 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 is sprayed which also results into lesser wastage of latent heat in the steam generator. Maximum Mechanical Handling: Minimum Bulldozing: Sequence of coal handling operations like receipt, unloading, stacking and reclaiming and the selection of machinery is to be made in such a way that all the handling operations are accomplished without the use of semi mechanized means like bulldozers which are more energy intensive equipments. However Principal of FIRST IN FIRST OUT is to be adopted for coal receipt & consumption and at any time coal need not to be stocked in yard for more than incubation period (duration between coal mined and getting self ignited) 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 will eliminate frequent starting and stopping of the CHP
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