Final Integrated Project

Transformation in Power Industries with

sustainability in focus by reduction of
auxiliary power consumption.

Submitted by:

Sakti Prasad Sahu

(Student ID-SS17222)

Supervised by:

Dr. Mamata Bhandar

Section :

RES100-2101-1
Table of Contents: -

1. Abstract 1

2. Introduction

a. Background/justification 1-2

b. Motivation 2
c. Research Objective 2-3
d. Research question 3
e. Significance of the study 3

3. Literature Review

a. Literatures in Tabular form 3-5

b. Gaps 6-7
c. Conceptual summary of the literature review 7-9

4. Proposed Research Design

a. Proposed choice of method 9-10

b. Data collection plan& methodology 10-20
c. Data analysis plan 21-22

5. Conclusion
a. Proposal Summary 22
b. Potential implication of the study 22
c. Potential Limitation of the study 22-23

6. References 24

7. Appendices

a. Grammarly report 25
 1. Abstract:

Business is getting tougher day by day. For a core industry, for example, Aluminum

production huge amount of power is required which can be only fulfilled by non-

renewable sources as a continuous power supply is needed without any interruption, so

to here thermal power plant is the cheapest source to produce electricity which requires

some major auxiliaries to run. The cost of generation of electricity typically varies from

3.5 to 4 Rs/mwh which can be reduced further to 3 Rs/mwh by reducing its auxiliary

power consumption, all the core industries are focusing on the reduction of the

production cost to achieve more profit.

2. Introduction:
a) Background & Justification

A thermal power station is a power station in which heat energy is converted to

electricity. Typically, fuel is used to boil water in a large pressure vessel to produce

High-pressure steam, which drives a steam turbine connected to an electrical generator.

The low-pressure exhaust from the turbine passes through a steam condenser and is

recycled to where it was heated. In thermal power plants, part of the energy generated

by the plants is being consumed by different auxiliaries i.e. various high power-

consuming equipment and machinery (Auxiliary Power Consumption). The power

consumption by these auxiliaries is very high due to poor operation or bad design of the

equipment.

All power plants should adopt the various ways of auxiliary power reduction to make

their process more effective & efficient hence saving energy along with the cost of
production will be less. 1

The prime focus in this research will be to identify the scope of auxiliary power reduction

in the power plant which leads to reducing the production cost and energy saving.

b) Motivation

I am working in the Operation department of Aditya Aluminium. I am responsible for

safe start-up, shutdown, continuous operation of the plant, raising MOCs, filling BBSO,

auditing BTG areas, issuing a permit to works, preparing and sending reports, etc. My

unit achieved more benefits /reliability from my executed digitalization projects in past.

Apart from my regular job I have assigned a focus area group of Auxiliary power

consumption and online defect monitoring system. I can see some scope of

improvement in reducing the APC further which motivates me to adopt this research

project.

The outcome of my research may help the business to run their main process efficiently

& also the Cost of production will be less.

c) Research Objective:
The objective of this research document is to reduce the Auxiliary power consumption

for saving power & cost without harming the process and system. My Research will

help Power plant industries to identify high power consumption equipment & develop

ways to reduce APC, maintain sustainability in APC reduction, and continuous

improvements in reducing APC.

d) Research question:

1. What are the best and smart practices to reduce the APC? 2
 2. How can it be sustainable?

e)Significance of the study:

Identification & Reduction of the auxiliary power consumption of the core industries

which can be applied for the reduction of the production cost & to increase the profit.

The study will also help in achieving power plant efficiency and power conservation

3. Literature Review:
a)Literature in Tabular form

I have done following literature review……

No Author Title Year Conclusion

1 Y.P .ABBI Energy Audit 2012 Book provided Energy

Thermal Power, conservation & audit
Combined Cycle, benefits of thermal
and Cogeneration power plant Benefit of
Plants modernization and
equipment
replacement. Deep
knowledge about
power plant equipment
& process, Scope of
improvements.

2 Jeffrey.A.Green Improving the 2014 This study

Energy Efficiency of
incorporates the
a Mid-size Power
Plant by Reduction potential use of
in Auxiliary Power
Variable Frequency
and Improved Heat
 Transfer Drives on various
motors as well as
areas of improved
heat transfer in an
older, mid-sized
coal-fired power
plant

3 Xingrang liu Thermal Power 2016 The study shows to

Plants: Modeling, solve highly complex
Ramesh Bansal
Control, and industry problems
Efficiency regarding identification,
improvement control, and
optimization through
integrating
conventional
technologies, such as
modern control
technology,
computational
intelligence-based
multiobjective
identification and
optimization,
distributed computing,
and cloud computing
with computational fluid
dynamics (CFD)
technology.
4

7
b)GAPS:-

I am not able to find the correlation with the following areas/processes of Core
Industries How we can enhance the efficiency of the equipment? How major equipment,
power can be optimized? (How each equipment can be run less than its rated
parameters without hampering the process?) Best operation practices to reduce APC.
(What measures and action are to be taken to operate the equipment efficiently?) .No
one mentioned the sustainability & future aspects of APC reduction in the manufacturing
organization. It’s very much important to maintain the APC for the long term and further
changes must be required to maintain its consistency. Nowhere it is mentioned that how
we have implemented many initiatives to reduce the aux power consumption during. 6
operation & maintenance time of the power plant and benchmarking of our performance
and to achieve energy optimization during operation and maintenance of the plant.
7

c) Conceptual summary of the literature review: -

After review of the literature, I can conceptualize the following things that can be

contributed through my research topic The first step must be for improvement in energy

efficiency is accurate data collection and energy calculation of losses in all equipment

and subsystems, so all instruments used in the plants are calibrated regularly. The

result will suggest improvement in the energy efficiency of operating plants possible

through regular energy audits.

Overhauling & replacement of equipment for short term as low investment and for long

term identification of investment towards replacement or modernization of old

equipment Assessments of the health of the machines and area that contribute to the
shortfall as compared to the design parameters and important to assess residual life for

critical equipment.

In power plants, fluid flow rates are may or may not controlled using dampers or valves

but the motors that power the pumps stay at full speed resulting in a significant amount

of wasted electrical power; energy is also lost due to poor heat recovery prior to gases

leaving the system. By examining pump usage as well as additional heat available for

recovery, potential energy savings will be determined.

During the project phase of the plant, various initiatives must be taken to optimize the

resource utilization and reliability of plant operations. It was important to adopt a

comprehensive approach to optimize the auxiliary equipment during the project phase.

Some of the innovative ideas that were adopted during commissioning and project

period are Effect major power-consuming fans like an Induced draft fan (Used to pull out

flue gases of the boiler by maintaining negative pressure in the furnace), Primary Air

Fan (Used to convey coal to the boiler) and Forced Draft Fan (Used to provide excess

air to the boiler for coal combustion) sizing during design & engineering stage. Also,

Sizing & design to optimum level of major pumps like Boiler feed pump( Used to pump

feed water to the boiler), Condensate extraction pump( Used to pump condensate from

the hot well to deaerator), Cooling water pump( Used for creating a vacuum inside

condenser), Closed cycle water pump( Used for equipment bearing cooling), Cooling

tower fans ( Used to cool the cooling water going to condenser) are very much

important to check APC. Use of variable frequency drives to the existing motor, areas of

improved heat transfer in an older coal-fired power plant.

Major Balance of plant area like Electrostatic precipitator (Used to handle flue gas Ash),

energy consumption can be reduced through optimum utilization of various options built-

in the ESP controller. In Ash Handling System (Used to handle ash of the boiler flue

gas) fly ash system is run for 10 hrs up to 70% of the Plant load factor of the unit and 15

hrs for 90% PLF of the unit to optimally use the inherent capacity of ash hoppers. It

helps us to stop the entire ash conveying system for a while and save auxiliary power

and a Staggered conveying cycle ensures that no more than 7 lines are in operation at

the time of conveying. Hence it could complete the entire conveying with one conveying

air compressor in service. 8

In Coal Handling System (used to supply coal to the mill bunker through conveyer belts)

increasing belt loading factor has helped us to reduce the belt running hours and reduce

the coal handling power consumption, Operating practices have been developed to

avoid the idle running of equipment and helps to reduce the power consumption. A new

improved coal blending process is identification and implementation in CHP for

reduction of aux power and also a new method of blending eliminates the requirement

of running extra equipment during blending of coal process which leads to saving of

auxiliary power in coal handling.

4. Proposed Research Design

a) Proposed choice of method

I will follow the following research methods to answer my research questions…

1. What are the best and smart practices to reduce the APC?
I will follow the quantitative methods by taking the major equipment parameters which

are drawing less power with same Unit load of the power plant & hence auxiliary power

consumption will be reduced. 9

Examples –

a) I will try to find out co-relation with various parameters to identify /forecast

how same equipment drawing high and low power consumption with same

unit load( means same power generation i.e. MW of the unit, like if a unit is

running with 125 MW ,at this time how equipment is drawing different power) .

Definitely this solution will help power plant to reduce the auxiliary power

consumption, will enhance reliability, current efficiency. 10

I will try to find out the co-relation between the parameters of the pot using graphs of the
equipments showing current( I) with same load in different modification.

Here the equipments are either destagged or variable frequency drive is used to reduce
the power consumption.

Reference : Aditya Aluminum Captive power plant data from maxdna dcs

2. How can it be sustainable?

For sustainability continuous monitoring of each equipment parameters and taking

necessary action for any parameter deviation is required. Apart for from this

necessary power calculation and new advanced technology must be applied at

particular time in future.

b) Data collection plan & methodology:

In my research, I have taken all major equipments rated operating parameters such a

current, pressure, as given in the BHEL manual

I have also taken the historical data and graph of the equipment parameters running in

past years with same unit load from MAXDNA-DCS. I will be able to find out the 11

correlation of the parameters changes with different modification of equipments.

I have also compared the electrical parameters (Current I) and calculated the power

consumption for the equipments with same running unit load.

So far I have collected some data from the data base & graphs shown in the following

pictures….

EQUIPMENT NAME RATED CURRENT( I) RATED VOLTAGE (V)

BOILER FEED PUMP 497 AMPS 6.6 KV
COOLING WATER PUMP 123 AMPS 6.6 KV
DMCOOLING WATER 23 AMPS 6.6 KV

PUMP
CONDENSATE 44 AMPS 6.6 KV

EXTRACTION PUMP
PRIMARY AIR FAN 111 AMPS 6.6 KV
FROCED DRAFT FAN 44 AMPS 6.6 KV
 INDUCED DRAFT FAN 1031 AMPS 6.6 KV
COAL MILL ( TOTAL 5 IN 47 AMPS 6.6 KV

NO)
AIR COMPRESSOR 68.4 AMPS 6.6 KV

Above are the rated electrical parameters of the high power consuming equipments with

rated voltage 6.6 kilovolt and also these equipments are highly responsible for high

auxiliary power consumption in main Boiler-Turbine-Generator area.

So below I have shown some graphs and equipment pictures which shows how by

using Variable frequency drive and destagging of pump reduces the current of the

equipment with same unit load and hence reduces the APC.

Here:

1. Boiler feed pump: destagging done

2. Cooling water pump & DM cooling water pump: Impeller trimming done.

3. Condensate extraction pump: VFD installation done

12
.The above graph is dated: 10 /11/ 2019

Here

a) Unit generation is : 125 MW

b) Boiler feed pump withdrawing : 284 amps

13
Now In this trend which taken 19/11/21 clearly

At Unit generation: 125 MW

a).Cooling water pump drawing 105.6 amps after impeller trimming.

b) boiler feed pump drawing 260.5 amps after impeller destaging 14

In the above graph which is taken on 10/10/18

At unit generation 125 MW

a) Cooling water pump drawing 118.7 amps

b) Condensate extraction pump drawing 33.9 amps

c) Dm cooling water pump drawing 22.7 amps

15
Clearly in the above graph which is taken on 4/12/21

At Unit Generation: 125 MW

a) Condensate extraction pump drawing 17.6 amps after installation of

Variable frequency drive.

b) Cooling water pump drawing 105 amps after impeller trimming.

c) DM cooling water pump drawing 18.8 amps after impeller trimming.

16
Above is the picture of Cooling water pump with running parameter where I
showing the pump current in ampere (I).

17
Above is the picture of DM Cooling water pump with running parameter where I

showing the pump current in ampere (I).

18
Above is the picture of Condensate extraction pump with running parameter

where I showing the pump current in ampere (I).

19
Above is the picture of Boiler feed water pump with running parameter where I

showing the pump current in ampere (I).

20
C) Data analysis plan & utilities intend to use.

Here from the above graph we found that at same Unit generation: 125 MW

1. Current of boiler feed pump changed from 284 amps to 260 amps.

2. Current of condensate extraction pump changed from 33.9 amps to 17.6

amps

3. Current of Cooling water pump changed from 118.7 amps to 105 amps

4. Current of DM cooling pump changed from 22.7 amps to 18.8 amps

Power calculation:

For 3 phase motor Power P = √3 x VL x IL x Cos Ф 

Where V-voltage ,I-current,  Cos Ф –power factor

So lets calculate the power consumption:

Here, V : 6.6 kv, power factor: 0.8

1. Boiler feed pump Destagging

a) P= √3 * 6.6*260*0.8= 237.776 kw 21

Similarly Boiler feed pump normal

P=√3 * 6.6*284*0.8= 259.724

So clearly we have 259.724-237.776 kw= 21.948kw can be saved

Which indicates we can save 21.948*24 = 526.752 kw per day ,

Now the average Generation cost is Rs 3.5 per kilowatthour which means we are

saving 526.752*3.5 = Rs 1843.632 saving per day

Similarly for

2. Cooling water pump ( 118.7/105 amps) we are saving : 7.234*24*3.5= Rs

607.65 per day

 3. DM Cooling water pump ( 22.7/18.8 amps) we are saving: 2.06*3.5*24=

Rs 173.04 per day

4. Condensate extraction pump (33.9/17.6) we are saving: 8.597*3.5*24=

Rs 722.14 per day

4. Conclusion

a)Proposal Summary
Anticipated Outcomes: -

 Result will suggest the applicability of the Variable frequency drive and

impeller/pump destaging leads to a good amount of power saving.

 So if we take the equipments like BFP,CW pump, DMCW pump and CEP which

are considered as high power consuming equipments we can save total Rs

3346.462 per day and 3346.462*365= Rs 1221458.63 per year

b) Potential implication of the study 22

My research will help power industry to reform a new structure which leads to good

amount of APC saving. As a result, the process will run continuously as per desired way

and more energy efficient. We can go for for rest of the equipment which need to be

study its feasibility in its implementation so that Power consumption will be more less

and also saving good amount of money. Business will be able to meet the annual KPI.

c) Potential Limitations of the study

The study will be conducted only in one Captive Power plant. Hence the result will

be based on of one unit. For better results this study can be broadened and can be
conducted in multiple power plants around the world. This result will give unbiased

information about the applicability of the transformation in equipments for the

reduction of the power consumption & hence profit will be more. Also research will

suggest about some good points like if the equipment is drawing more power ,we

can check for the deviation ( For example may be equipment impeller damaged or

problem in the process side like some drain valve opened etc.).

Here Two things must be considered while modification of the equipment.

1. We must calculate the cost of installation of any modification of equipment

so that it’s benefited for the plant running for years.

2. We must look for the process must be go on smoothly without affecting the

process parameters (like pressure, flow) and equipment healthiness.

5. References:
1. https://ieiwbsc.in/wp-content/uploads/2015/10/apc-lecture.pdf
2.https://www.sciencedirect.com/topics/engineering/auxiliary-power-
consumption.
3.https://www.iitk.ac.in/npsc/Papers/NPSC2004/818-ART-293.pdf.
4.https://www.powerplantandcalculations.com/2020/07/best-practices-to-
reduce-auxiliary-power-consumption-powerplant.html.
5.https://www.researchgate.net/publication/271564085_Optimization_of_Au
xiliary_Power_Consumption_of_Combined_Cycle_Power_Plant
23