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3 L Program (BEE)
Piyushkumar Pandya DGM (Electrical)
New Technology-VFD at DTPS
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.
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
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
Consumption 520 MW 39.6 % 37.Detail of Auxiliary Power Consumption Total Plant Generation Auxiliary Power Consumption HT Motor Consumption LT Motor Consumption Lighting & Misc.50 MW 1.50 MW 6 confidential .50 MW 0.50 MW @ 7.
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 7 Running load 24750 15700 480 1216 9400 51.546 MW Actual consumption 21110 9848 426 553 5523 37.460 MW confidential 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 8 confidential .
HFO Pump-VFD 9 confidential .
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 confidential .
located near the HFO firing pumps to HFO tank. PCV maintains the HFO discharge header pressure to 21-23 Kg & remains approx. 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). 50% open during normal operation of both units 11 confidential .HFO Pump –Process detail During the normal operation of both units.
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 12 confidential .
74 KW Cost of VFD Energy saving/Annum : Rs.1 KW 9.68 Lacs : Rs.1.1.70 Lacs Simple payback : 12 months 13 confidential .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.
14 confidential .HFO Pump-VFD The first VFD of DTPS has given Very high saving and confidence.
Seal Air Fan 15 confidential .
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) 16 confidential .
A. FAN AIR I/L PG SID-1 SID-2 DPS SID-3 PS SID-1 SID-2 17 confidential .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.
9 m3/s 1950 mmWc 120 KW Fan-A Fan-B 18 confidential .Seal Air Fan-Flow Diagram 800-900 mmWc 20-25% open 3.
The energy is wasted across the damper. The damper is opened up to 20-25% only. The rated head is 1650mmwc against operating head of 8001000mmwc.Seal Air Fan-Control Philosophy The seal air fan has the damper control at its suction side The Header pressure requirement is 800-1000mmwc. 19 confidential .
Control Philosophy with VFD Decision taken to install VFD after risk assessment as tripping will lead to unit tripping & generation loss. One common VFD employed for the two seal air fan of a Mill.Seal Air Fan. Configuration and logic has been selected so that total capital cost reduced along with operational flexibility. 20 confidential . 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.
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.00 Lacs Simple payback : 9 months 21 confidential .30.5 Lacs : Rs. 43.
Seal Air fan VFD 22 confidential .
Vent Air Fan-Dry Ash Silo system 23 confidential .
Vent Air Fan – Flow Diagram 24 confidential .
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 25 confidential .13300 m3/hr Head .Vent Air Fan – Fan Specification Capacity.
53 Lacs Simple payback : 17 months 26 confidential .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. 4.5 Lacs : Rs.
Colony Drinking water Pump 27 confidential .
Flow diagram Colony overhead water tank Pump-A PG Service water tank Pump-B 28 confidential .Colony Drinking water Pump.
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 29 confidential .
1.3 Lacs Simple payback : 5 months 30 confidential .6 Lacs : Rs.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. 3.
Colony Drinking water Pump VFD 31 confidential .
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 32 confidential .
Condensate Extraction Pump 33 confidential .
Hence one fan trial with VFD was complicated. ID/PA/FD fans are continuously runs on sharing basis.Selection of CEP for VFD application CEP has solo operation. and comparatively easy to control. Hence CEP was selected for trial operation of VFD 34 confidential . BFP rating is 9 MW hence availability of this rating VFD is difficult.
CEP.Flow Diagram 35 confidential .
Operation C/O practice to be reviewed to get max. Control logic and setting to be modified. energy saving Protection system to be reviewed.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. 36 confidential .
In put Isolator 2. Out put isolator MOTOR 3~ 37 confidential . Bypass Isolator 3.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 1 2 3 VSD-CEP-A-2 1 .Operating and protection interlocks Modified SLD for VSD installation 50+51 INSTANTENEOUS OVER CURRENT A.
Protection scheme 38 confidential .
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. 39 confidential . Pune.6KV.50Hz. Ltd.VFD specification Rating :880KW with bypass arrangement Voltage:6. Beijing Supplier : M/s.Yantra Automation Pvt.
Measurement of parameter Parameter Design Parameter Operating parameter Parameter with VFD Capacity 770 M3/hr 640 tons/hr 640 tons/hr Head 20.8 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 40 confidential .5Kg/cm2 21.3 Kg/hr 14.5-15 Kg/cm2 Temperature 45.
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.1 Lacs :Rs.75 lacs :17 months 41 confidential .44.
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.VFD Protection Under voltage: 0. two cell Local emergency push button :Enable Cell cabinet temperature alarm : 40o C Cell Cabinet temperature trip :45oC 42 confidential .
HMI –MV VFD 43 confidential .
Installation of CEP VFD 44 confidential .
Installation of VFD 45 confidential .
MV Drive-Basic Configuration 46 confidential .
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 47 confidential .Supply frequency 2.MV Drive-Principal Speed of an electric motor is determined by 1.
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 48 confidential .
The Basic Variable Speed Drive INPUT TRANSFORMER MOTOR RECTIFIER DC LINK INVERTER 49 confidential .
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 50 confidential .
Power cell 51 confidential .
Power cell arrangement 52 confidential .
Thank you May 12 2008 .
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