WELCOME TO

3 L Program (BEE)
15/05/2008

Piyushkumar Pandya DGM (Electrical)

New Technology-VFD at DTPS

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Introduction

The Energy efficiency and conservation is the prime objective of DTPS

Intensive study done for various Energy system like thermal, Electrical, water The performance of all Electrical system and loads analysed for optimum resource utilisation Internal and external audit has signify the vast potential available to be saved in Electrical systems.

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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

The motors being the major consumer of Electrical energy

Variable frequency drive has been identified as prime tool

All operational and financial issues like reliability, risk assessment and cost-benefit analysis carried out for each projects

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Variable Frequency Drive-Tool for Energy saving

Energy waste is identified through internal and external audit System requirement and equipment design mismatch Variable frequency drive has been identified as tool Initially LV VFD commissioned MV VFD trial and then successful commissioning done

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Detail of Auxiliary Power Consumption

Total Plant Generation Auxiliary Power Consumption HT Motor Consumption LT Motor Consumption Lighting & Misc. Consumption

520 MW 39.50 MW @ 7.6 % 37.50 MW 1.50 MW 0.50 MW

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Application wise Load detail

Application Total Motors motor in service 27 12 13 12 02 06 04 37 Service duty Continuous Continuous Continuous Partial Continuous Connect ed load (KW) 47600 15700 1200 1216 15410 81.126 MW
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Running load 24750 15700 480 1216 9400 51.546 MW

Actual consumption 21110 9848 426 553 5523 37.460 MW

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Pump Fan

Compressor 05 Conveyor Mill Total 06 08 58

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)

Condensate Extraction Pump -650 KW

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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

FROM HFO TANK

PUMP-1
10

TO U#1 & U#2

HTR-1

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HFO Pump Process detail

During the normal operation of both units, the HFO consumption is

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.

PCV maintains the HFO discharge header pressure to 21-23 Kg &

remains approx. 50% open during normal operation of both units

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HFO Pump VFD as Solution

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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HFO Pump VFD-Measurement of parameter

Parameter Design Parameter Operating parameter Parameter with VFD Pressure 23 Kg/cm2 20-23 Kg/cm2 23 Kg/cm2

Valve position

Recirculation mode

50% open with recirculation mode

1480 rpm

100% open

Speed

1480 rpm

1243 rpm

Power

37 KW

18.1 KW

9.74 KW

Cost of VFD Energy saving/Annum

: Rs.1.68 Lacs : Rs.1.70 Lacs

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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Seal Air Fan

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Seal Air Fan

Seal air fan is used for providing sealing to coal Mills, classifier gates and feeders There are six Mills and each has two seal air fans Largest LT auxiliary in DTPS consuming 120KW power Total power consumption is 480 KW(120KW*4)

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Flow Diagram
TO CAD SLD-6 COAL FEEDER SLD-6

TO CAD MIXING BOX

COAL FEEDER MIXING BOX MILL SHELL

BALL FEED MECH.

SID-13

SID-13

AIR I/L

AUTO VISCOUS FILTER

GIRTH GEAR S.A. FAN

AIR I/L

PG SID-1 SID-2

DPS

SID-3 PS SID-1 SID-2

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Seal Air Fan-Flow Diagram

800-900 mmWc

20-25% open 3.9 m3/s 1950 mmWc 120 KW

Fan-A Fan-B

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Seal Air Fan-Control Philosophy

The seal air fan has the damper control at its suction side The Header pressure requirement is 800-1000mmwc. The damper is opened up to 20-25% only.

The rated head is 1650mmwc against operating head of 8001000mmwc. The energy is wasted across the damper.

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Seal Air Fan- Control Philosophy with VFD

Decision taken to install VFD after risk assessment as tripping will lead to unit tripping & generation loss. First trial run taken The seal air fan damper to be open 100% The speed to be adjusted manually as per the requirement of header pressure. One common VFD employed for the two seal air fan of a Mill.

Configuration and logic has been selected so that total capital cost reduced along with operational flexibility.
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Seal Air fan VFD-Measurement of parameter

Parameter Design Parameter Operating parameter Parameter with VFD Discharge Pressure Damper position 1650 mmWc 1000 mmWc 800-1000 mmWc

25% open

Depending upon requirement 1480 rpm

100% open

Speed

1480 rpm

977 rpm

Power

120KW

110-120 KW

55 Kw

Cost of VFD Energy saving/Annum

: Rs.30.5 Lacs : Rs. 43.00 Lacs

Simple payback

: 9 months

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Seal Air fan VFD

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Vent Air Fan-Dry Ash Silo system

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Vent Air Fan Flow Diagram

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Vent Air Fan Fan Specification

Capacity- 13300 m3/hr Head - 510 mmWc

Motor rating-90KW Actual power consumption-69KW

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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Vent fan VFD-Measurement of parameter

Parameter Design Parameter Operating parameter Parameter with VFD Discharge Pressure Damper position 510 mmWc 380 mmWc 350-380 mmWc

25% open

Depending upon requirement 1480 rpm

100% open

Speed

1480 rpm

1243 rpm

Power

69KW

69KW

48 KW

Cost of VFD Energy saving/Annum

: Rs.6.5 Lacs : Rs. 4.53 Lacs

Simple payback

: 17 months

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Colony Drinking water Pump

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Colony Drinking water Pump- Flow diagram

Colony overhead water tank Pump-A

PG

Service water tank Pump-B

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Colony Drinking water Pump Specification

Head - 14 Kg/cm2

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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Vent fan VFD-Measurement of parameter

Parameter Design Parameter Operating parameter Parameter with VFD Discharge Pressure Valve position 14 Kg/cm2 14 Kg/cm2 8 Kg/cm2

60% open

100% open

Speed Power

2955 rpm 45 KW

2955 rpm 40 KW

2233 rpm 25 KW

Cost of VFD Energy saving/Annum

: Rs.1.6 Lacs : Rs. 3.3 Lacs

Simple payback

: 5 months

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Colony Drinking water Pump VFD

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MV VFD-Advantage & Barriers

Advantages: High Energy saving potential To achieve objective of aux. Power Better Process control Proved Technology Reduce O&M expense Barriers : Penetration is less in power plants Cost is high Reliability

Competency of Drive manufacturer

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Condensate Extraction Pump

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Selection of CEP for VFD application

CEP has solo operation, and comparatively easy to control.
ID/PA/FD fans are continuously runs on sharing basis. Hence one fan trial with VFD was complicated. BFP rating is 9 MW hence availability of this rating VFD is difficult. Hence CEP was selected for trial operation of VFD

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CEP- Flow Diagram

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CEP- Energy saving with MV VFD

Operating Issues: Existing system to be retrofitted with Drive. Control valve feedback signal to VFD can be given Only one VFD module is considered for each unit. Operation C/O practice to be reviewed to get max. energy saving

Protection system to be reviewed.

Control logic and setting to be modified.

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Operating and protection interlocks

Modified SLD for VSD installation

50+51 INSTANTENEOUS OVER CURRENT A.C TIME OVER CURRENT RELAY 86 LOCKING OUT RELAY

99

50+51

94

74 94 TRIPPING OR TRIP FREE RELAY 74 ALARM RELAY 99 MOTOR PROTECTION RELAY

86

VSD-CEP-A-2

1 .In put Isolator 2. Bypass Isolator 3. Out put isolator

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

Remote/Local and Analogue/Computer mode selection

Make : Beijing & leader, Beijing Supplier : M/s.Yantra Automation Pvt. Ltd, Pune.

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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

Dearator level control through Valve control

Dearator level control through Valve control

Dearator level control through Speed control

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Cost-Benefit Analysis
Power consumed without VFD : 590KW
Power consumed with VFD : 440KW

Net power saving

Annual energy saving Cost of VFD Payback period

:150KW
:Rs.44.1 Lacs :Rs.75 lacs :17 months

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VFD Protection
Under voltage: 0.65 Un

Overload :120% for 60 seconds

Short circuit current :150% instantaneously Power cell Temperature :85o C Transformer temperature alarm : 120 oC Transformer temperature :130o C Cell Bypass : Max. two cell Local emergency push button :Enable Cell cabinet temperature alarm : 40o C Cell Cabinet temperature trip :45oC

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HMI MV VFD

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Installation of CEP 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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The Ideal Variable Speed Drive

Supply Network Converter Motor Driven Load

No harmonic voltage or current distortion Near unity power factor

Fault tolerant enabling operation with one or more failures Easy repair High Efficiency

No harmonic heating
No insulation stress No additional bearing current

No rotational torque oscillations

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The Basic Variable Speed Drive

INPUT TRANSFORMER MOTOR

RECTIFIER

DC LINK

INVERTER

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The Power Cell schematic

Dedicated winding on power transformer

Power Output of Cell

Logic Control Power

Logic Control Circuits

Fiber Optic Signals to and from master control

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Power cell

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Power cell arrangement

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Thank you
May 12 2008