Energy Conservation

Techniques
By
R. V. Ghate
Tata Power Company ,
Mumbai.

Energy Conservation in Power

Utility

A power plant produces electrical energy and

also consumes a substantial amount of
energy in the form of auxillary consumption
required for various plant equipments and
services
Management attitude -The top management
of the company is committed to, and has
the right attitude towards energy
conservation.This is passed on to the the
plant staff for ensuring success by Quality
Management Systems such as Tata Business
Excellence Model and ISO

Tata Power

Consistent achiever of Business Results.

Vision Statement-To be an Excellent
and Efficient organisation.
Focus on enhancing Business and
Customer Orientation.

Trombay Generating Station

Installed Capacity-1350 MW

ISO 9001:2000 Certified

Perception has changed to strike a

balance between reliability and energy
conservation

Trombay Generating Station

Key Drivers for changeTata Business Excellence Model

(TBEM )
-Leadership
-Customer and Market Focus
-Process Management
-Business Results

Energy Conservation in Power

Utility

Energy conservation in Power Utility is

achieved mainly by-

1) Operating the equipments at maximum

efficiency.
2) Reduction of Auxiliary Power Consumption

Energy Conservation Measures adopted at

Tata Power Company Limited have taken
both these factors into consideration

Factors affecting Auxiliary

Consumption

Unit Generation and Load Pattern

Operation of Plant Auxiliaries

Service auxiliary such as Illumination,

Air Conditioning etc

Unit startups / shutdowns

Criteria used for adopting new

energy saving methods

Reliability

Sustainability

Method and Quality of verification

Investment required

Energy Saving Techniques

Energy saving Techniques adopted are

classified in the following categories

Design and Conceptual Stage

Techniques developed through O&M
experience
Energy auditing by external agencies

Design and Conceptual Stage

Design and Conceptual Stage

Use of Steam Turbine driven Boiler

Feed Pumps. ( 2 X 9 MW)
Pioneered concept of using Variable
Speed Drives for Large Motors by using
LCI drives for 4 X 2 MW ID Fan Motor
of 500MW Unit
Use of Fluid Coupling for Motor Driven
Boiler Feed Pump

Techniques developed
through O&M Experience

In addition to techniques adopted at design

stage various initiatives have been taken over
the years to optimise the Auxiliary Power
Consumption. These are

Monitoring of Aux Power Consumption

continuously improving the levels and accuracy
Formation of Cross Functional Teams to analyse
and optimise process
Modification in Operation Strategy to achieve
Optimisation
Knowledge sharing and benchmarking with other
power utilities

Snapshot of Aux Power of

Unit 5 at 500 MW
11-07-02

11:00 hr

TOTAL AUXILIARY CONSUMPTION

25

20.25

20

HT cons
LT cons

15
10

3.57

5
0

MW

HT CONSUMPTION
(kW)
5500
5000

ID FANS
CWP

4500

FD FANS

4000

PA FANS

3500

CEP

3000

FGD

2500

AWP

2000

SGWCP

1500

MILLS

1000

HTR DRIP
PUMP
ACW

500
0

LT C O NS UMP T IO N
(kW)

750
700
650
600
550
500
450
400
350
300
250
200
150
100
50
0

DMPT5B
SST5A
SST5C
UST5B
CLPT5B
UST5A
VST
COMPT5B
CWPT5A
COMPT5A
ESP5A
CLPT5A
ESPT5C
CHPT5B
CWPT5B
ASHPT5A
ASHPT5B

Prioritisation

Ideas and suggestions captured from

various initiatives are then prioritised
into three categories

Without investment

With minor investment

With major investment

Without Investment
Blue Date of
Print Idea
No
1
2

3
4

5
6
7
8
9

10
11
12
13

Savings upto 31.03.03

Ideas for which detailed blueprint w ere made
Original Est Annual
Actual
(Ideas indicated in blue were implemented)
Idea by Saving Rs saving Rs
in Lakhs
in Lakhs
till 31.03.03

Status

Jul-99 Running of 3 nos SGWCP motors in Unit 5 instead of 4

motors
Jul-99 Running of 2 nos SGWCP motors in Unit 6 instead of 3
motors

Mr APW
& team
Mr APW
& team

53.00

7.57 Implemented since 19/02/2003

38.00

19.15 Implenented since 24/08/2002

Jul-02 Operation of Unit 5 ESP thyristor panel in Charge Ratio

mode
Jul-02 Operation of fewer Coal Mills at Unit 5 with higher
loading

TRAC

45.30

TRAC

42.00

TRAC

117.00

TRAC

2.62

Not found feasible in view of

increased coal firing.
Implemented since Sep 02.
Less coal mills operated w ith
higher loadings (presently
increased to 70% from 40%)
Actual savings could not be
captured.
63.88 Implemented since September
02.
Not found feasible.

TRAC

3.00

Jul-02 Stopping of steam supply to Station B Tank Farm during

daytime
Jul-02 Ship Receipt line one of the heat tracing circuit to be
switched Off during non-receipt
Jul-02 Optimisation of Lighting of O&S Bldg and provision to
switch off during nightime to be made
Sep-02 Changing and cleaning of LC Oil gun in Unit 6 to be
reviewed and optimised
Sep-02 Plant area lighting in Unit 5 and 6 inside the building to
be switched off (except emergency lights)

R B More Opn B
VM
Dinkar Opn B
Sep-02 Optimisation of operation of screen wash pumps at jetty M H Takle

Sep-02 Saving service water used for air compressors

Sep-02 Providing solenoid valve in cooling lines of blend oil
pumps
Oct-02 Scavenging of oil guns to be optimised

Actual Saving upto 31.03.03 (Items 1,2,5,7)

Savings of Item no 4,8,9,13 are not included.

2.39
10.00

2.34

1.41 Implemented by SGA-28 since

Dec 02.
Implemented since April 03.
Savings to be computed.
Implemented since April 03.
Savings to be computed.
Not found feasible

BR Agaj
M H Takle

11.00

Not found feasible

No found cost effective.

TRAC

39.00

Implemented since April 03.

Savings to be computed.

Rs

92.01 Lakhs

With minor investment

Installation of Vacuum Pumps in Fly Ash

Removal system in place of Hydro ejector
based Ash Water Pumps
Replacement of conventional Central Air
Conditioning System by Vapour Absorption
system to utilise waste steam
Improving efficiency of Electrochlorination
Plant by regular acid cleaning
Replacement of ESP controllers by improved
version having option of energy efficient
mode
Use of energy efficient lighting system

With major investment

Replacement of HP Turbine Module of

500 MW Unit

Proposal of Retrofitting of Constant

speed ID Fan motor with Variable speed
drives.

Energy Audit by External

Agency

External Audit

Detailed energy audit of Trombay

Thermal Power Station was conducted
by CII in Nov-Dec 2002
CII studied various main and sub
processes
Good energy conservation practices at
TPCL as per CIIs viewpoint are

Encon at Tata Power

Installation of Load commutator invertors
(LCI) for ID fans
Optimisation of auxiliary consumption
during non-peak hours
Good excess air control in boilers
Optimum loading of motors
Efficient lighting systems
Optimum T in condensing water system
Excellent control systems

Annual
Saving

Investment
required

Simple
Payback
period

Rs.
Lakhs

Rs. Lakhs

Months

Install next lower size impeller for

the FGD spray pumps

10.48

2.50

Install Variable Frequency Drive

for Hot-well make-up water pump
in Unit # 7

0.65

1.00

19

Avoid daytime lighting and install

transmission roofing sheets in LC
oil pressure filter area

0.34

0.20

Replace conventional chokes

with electronic chokes in
fluorescent lamps

4.95

8.75

21

Some of the CII Proposals under

consideration for
implementation

Conclusion

Savings due to Energy Conservation Measures for FY 02 -03

No
1
2
3
4
5
6
7

Optimisation of Aux Power in

ESP
FGD
FAA
Ash Plant
GR Fans
CW Pumps
SGWCPs
Total

Savings in MU
0.241
0.236
0.302
2.510
4.180
2.460
1.070
11.000

Total saving in FY 02 03 11 MU
Saving Rs 2.23 Crores
Reduction in Cost 0.25 Paise / KWH

TROM BAY AUXILIARY POWER CONSUM PTION TREND

12 .0

10 .0

10 .2

9 .8

9 .6
9 .0

8 .0

7.8

6 .0
5.0
4 .0

2 .0

4 .3

4 .3

3 .5

3 .5

1.9

5.7

5.4

5.2
4 .5
4 .1

4 .8
4 .2

2 .1

5.2
4 .5

5.4

3 .8

3 .7

2 .6

2 .2

7.4

4 .6

3 .0

7.4

5.0
4 .3
3 .3
2 .7

1.5

0 .0
9 6 -9 7

9 7-9 8

9 8 -9 9

9 9 -0 0

0 0 -0 1

0 1-0 2

Y EA R
UNIT-4

UNIT-5

UNIT-6

UNIT-7

STATIO N

0 2 -0 3

BENCHMARKING OF UTILITIES

Graph 7.4.18

Trombay Aux. Cons. (%

9
8

7.4
6.52

7.05

7
6
5

4.8

4.5

4.5

4.6

4.3

3.66

4
3
1998-99
IB

1999-00

Nat Avg

2000-01
2001-02SEB
2002-03
Trombay

Comptr

NB

Conclusion

Comparison of auxiliary power consumption of

Thermal Power Utilities

India benchmark 6.33%

International benchmark 3.99%
TPCL 4.33 %

TPCLs Auxiliary Power Consumption has been

acknowledged by CEA as one of the best in
India

Thank You