Shree Mega Power Final

Detailed Energy Audit at
Confederation of Indian Industry

Shree Mega Power,
CII Godrej Green Business Centre, Hyderabad,
India
Beawar
At the outset
Thank you for
Opportunity
Support
Objective
SMP
Achieve Maximum Energy

Saving
Improve on a continuous
basis to achieve status of a
world class power plant
Methodolog
y
Data
Collection
Measurements
Discussion
And Now
Presentation
Past Energy Conservation

activities
Extensive use of VFD
Excellent monitoring system
Installation of lighting transformer
Individual isolation valve for

compressor cooling water
And many more

Committed Team
ROLE OF CII
Catalyst / Facilitator role
Supplement in-house activities
Identify energy saving proposals
All possible assistance
Monitoring
Vendor identification
Not fault finders !!

Operation of ACW pump

Design
Flow
- 2200 m3/hr
Pressure - 50 m
Rated power - 342 kW
Cooling tower
Equipment
cooling
Actual
Flow
- 1490 m3/hr
Pressure - 32 m
Power
- 220 kW
ACW pump installed to cater cooling

water needs of plants equipment
Three pumps installed for pumping water

to users from cooling tower
One in operation
VFD installed in one pump ( In Operation)
Water flow measurements, pressure

measurements and Temperature
measurements taken to assess efficiency
of the pumping system
Pump design:
Q : 2200 m3/hr
H : 50 m
kW : 342 kW
Actual:
Q : 1490 m3/hr
H : 32 m
kW : 220 kW
Pump being operated in lower speed
Changes happened in cooling water circuit
Pump efficiency:
63%
Pump operating in a low efficiency range
Bed ash cooler not in full operation
Operated at a lower range
Good potential to save energy by installing

a new pump for actual requirement
Recommendation:
Install a new pump for actual

requirement
Q : 1200 m3/hr, H : 35m, kW : 146 kW
VFD used in the earlier pump can be

used
About 70 kW can be saved
Annual Saving -
Rs 16.80 Lakhs
Investment
Rs 8.00
Lakhs
Payback
5 months
Install new correct size pump

for side filter water pumping
Water is constantly pumped to the side filter
About 150 m3/hr of water is being pumped
This water is tapped from the ACW pump

outlet
Pumped to sided filter at 3.2 bar
ACW flow : 1490 m3/hr
About 10% is being pumped to the side filter
Potential to save energy by installing a

correct head pump for side filter
Install new pump for side filter

water pumping
By installing a new pump, 10% of

flow of the ACW pump can be
avoided
VFD speed can be reduced
Recommendation:
Install separate pump for side filter

150
m3/hr, 15 m, 9.5 kW
Reduce 10% of flow in ACW pump

Reduce
speed of VFD
About 10 kW can be saved

Install new pump for side filter

water pumping
Annual Saving -
Rs 2.40 Lakhs
Investment
Rs 0.50
Lakhs
Payback
2 months
Operation of chillers (TG

chillers)
14.00C
8.00C
Chiller 3
Return
Water from
AHU
Chiller 2
11.80C
Supply to
AHU
Chiller 1
12.30C
130C
Chilled water pumps
Operation of chillers
3 chillers installed for catering air

conditioning load of TG building
Flow measurements taken:
All three in operation

Flow through chillers : 160 m3/hr
Return water from AHU is pumped to the

chillers
AHU return water temp0 : 150C

Chilled water temp0 from chiller 3 : 8.00C
Chilled water temp0 to AHU (after mixing) :
12.30C
Due to mixing of water temperature of

chilled water increases from 8.0 to 12.3 0C
Almost 40C is lost because of mixing of
water from
For every 10C temperature change, chiller

power consumption changes by 4%
In chiller 3, two compressors are in

operation
In chiller 1&2, only one compressor in
operation
Certain times compressors are loaded
only for 40 60%
Good potential to save energy by avoiding

this chilled water mixing
Operate only two chillers and have one in

stand by
Additional savings since pumping of water

to 3rd chiller will be avoided
Improved temperature conditions in user

space
Better user comfort

Recommendation:
Avoid temperature loss due to mixing

of chilled water
Operate only two chillers with same
set points
21 kW can be saved
Annual Saving -
Rs 5.00 Lakhs
Increase set point of the

chillers
Chiller set point set at a very low
temperature
Lower the chiller temperature, chiller

consumes more energy to achieve the
temperature
Supply & return air temperature in the AHU
also studied
70C
Supply air temperature : 13 140C

Return air temperature : 19 240C
Chiller set point can be increased and can be

operated without affecting the user comfort
Increase set point of the

chillers
Recommendation:
Increase the set point of the chiller

9
- 100C
Temperature setting of the chiller

according to the ambient condition
A
simple automation system can be put in

place
12 kW can be saved
Annual Saving -
Rs 2.88 Lakhs
Convert 3 way valve to 2

way valve and install VFD for
3 way valves installed at the chilled
chilled
water
pumps
water lines to the VFD
Not in operation (not fully commissioned)
Installed to control the temperature of

the user space
Disadvantage of 3 way valve
Recirculates back to return line through

bypass
Recirculation is wastage of pump power

consumption

Presently there is not temperature
chilled water pumps
control as such
Supply air temperature : 13 14 0C
Return air temperature : 19 24 0C
Room temperature maintained at a lower

side
Good potential to save energy by

maintaining correct temperature at the
user space

Recommendation:
chilled
water
pumps
Replace or dummy the third port (bypass

port) of all three port valves
Recirculation
reduces, back pressure increases
Install VFD for each pump
Operate the VFD in closed loop based on

Pump
discharge pressure
Operate based on the temperature setting
Convert 3 way valve to 2 way

valve and install VFD for chilled
water pumps
Annual Saving -
Rs 1.68 Lakhs
Investment
Rs 2.50
Lakhs
Payback
18 months
Install VFD for the AHUs
Presently, no temperature control

available for the user space
Latest trend installing VFD for the air
handling units with feed back control
Feed back return air temperature
Maintain the temperature at 23 24oC
Advantages
Precise maintenance of temperature

Reduction in AHU power consumption
Reduction in chiller load
Install VFD for the AHUs
Recommendation:
Install VFD for all AHUs

Return air temperature can be given
as feed back
Annual Saving -
Rs 2.40 Lakhs
Investment
Rs 4.00
Lakhs
Payback
20 months
Install new pumps for

DMCC pumps
Four DMCC pumps installed for bed

ash coolers
Two for each unit

One
in operation in each unit
Flow & head measured to ascertain

the efficiency of the pumps
Unit 2
Unit 1
Flow
Flow
- 335
3
m
/hr
3
m /hr
Pressure
Pressure - 35 m
Power
Power
kW
63 kW
Efficiency
Efficiency - 59%
325
- 35 m
- 60
- 60%
Install new pumps for

DMCC pumps
Good potential to save energy by

installing new pumps of correct size
& efficiency for the application
Recommendation:
Install new pumps for DMCC pumps

Q : 250 m3/hr, H : 35m, kW : 38 kW
47 kW can be saved
Annual Saving -
Rs 11.28 Lakhs
Investment
Rs 3.50
Lakhs
Payback
4 months
Arrest Leakages in Flue

Combustion analysis has been carried out at
Gas Path
various location along the flue gas path
Before APH
After APH
After ESP
Parameters measured
Excess O2, CO, CO2 & Temperature
Measurements repeated on two different days
16 February 2012
20 February 2012

Gas
Path
Flue gas
analysis carried out on February
16, 2012 at various locations as shown
below:
Boiler 1
APH Inlet
APH
Outlet
ESP
Outlet
Side
Left
Righ
t
Left
Righ
t
Left
Righ
t
O2, %
4.92
5.28
4.84
6.04
5.39
5.26
CO, ppm
29
22
24
27
24
29
CO2, %
14.0
9
13.9
1
14.1
5
13.1
3
13.6
7
1440
Temp,
Deg-C
277
290
138
134
135.
6
130
Confederation
IndianIndustry
Industry
Confederation
ofofIndian

Gas
Path
Flue gas
analysis carried out on February
20, 2012 at various locations as shown
below:
Boiler 1
APH Inlet
APH
Outlet
ESP
Outlet
Side
Left
Righ
t
Left
Righ
t
Left
Righ
t
O2, %
3.84
2.47
4.77
4.68
4.82
5.04
CO, ppm
34
21
26
23
27
27
CO2, %
15.0
1
16.2
3
14.2
14.3
1
14.1
8
13.9
8
Temp,
Deg-C
286.
8
261
150
131.
8
142.
4
129.
8
Confederation
IndianIndustry
Industry
Confederation
ofofIndian

Gas
Path
Flue gas
analysis carried out on June 27,
2012 at various locations as shown below:
Boiler 2
APH Inlet
APH
Outlet
ESP
Outlet
Side
Fron
t
Rear
Left
Righ
t
Left
Righ
t
O2, %
4.5
4.2
3.8
3.1
4.2
3.8
CO, ppm
48
29
29
37
41
37
CO2, %
14.3
14.8
15.1
15.7
14.7
15
Temp,
Deg-C
266
270
158
143
143
137
Confederation
IndianIndustry
Industry
Confederation
ofofIndian

Gas
Path
Air leakages
estimated in Unit 1
There is an increase in O2 level on right hand side of

the APH
Significant decrease in flue gas temperature
Clear indication of air leakage into the system
Effect of air leakage
Reduction in heat recovery and hence reduction in

opening efficiency of boiler
Increase in ID fan power consumption

Gas Path
By arresting the air leakages
Reduction in power consumption of

each of the ID fan by 5.5 kW
Equivalent reduction in petcoke

consumption
210 Tonne/annum

Gas Path
Annual Savings
Lakhs
Investment
Lakhs
Payback period
Rs. 19.00
Rs. 12.00
8 months

Boiler feed pump

154 kg/cm2
5.69 kg/cm2
ECO
263.1 Tph
3(2 )
523 TPH
170.3 kg/cm2
HP 2
HP 1
259.1 Tph
7.52 MW for four pumps
Control Station
Pr diff 7 kg/cm2
Multistage stage pressure

reduction drag valve

Boiler Feed Pump

Further reduce the pressure drop across the control
station
Limitation stable operation of the plant
Best pressure drop maintained 4 kg/cm2
% Reduction in pressure drop 1.5 %
Corresponding reduction in Power Consumption in the pump
During the study tried to measure the leakage

through the recirculation valve
Unable to measure
Temperature measurement clear indication of

recirculation
Boiler Feed Pump
Approximate estimation about 3-5% of flow

Install multi stage pressure reduction drag
valve
Pressure reduction happens in multiple stages
More than 8-12 stages
Highly reliable
Minimize the leakage as low as possible
Typical
reduction
3%
Annual
Savingsin power consumption
Rs. 54.00
Lakhs
Investment
Lakhs
Rs. 60.00
Fan Performance
PA fan
Description
PA fan
-2A
PA fan
-2B
PA fan
-1A
PA fan
-1B
Flow (m3/sec)
34.90
34.76
35.49
32.98
Head mmWC
1157
586.7
1121
1206
Power
Consumption in
kW
565.5
586.7
586
597.5
Efficiency %
82.35
74.67
70.06
68.7
Fan Performance
SA fan
Description
SA fan
-1A
SA fan
-1B
SA fan
-2A
SA fan
-2B
Flow (m3/sec)
34.58
44.70
37.16
36.85
Head mmWC
639
660
583
575
Power
Consumption in
kW
303
448.5
363.9
356.8
75.27
67.88
64.85
64.86
Efficiency %
Performance SA fan
Observations
Suction side pressure
SA fan -1 A
- 60 mmWC
SA fan -1 B
- 95 mmWC
Sa fan -2 A
-68 mmWC
SA fan -2B
-66 mmWC
Suction side pressure drop is higher
It will result in corresponding increase in fan

power consumption
Performance SA fan
Recommendations
Install correct size of duct for SA fan

Flow requirement is same for SA and PA fan
35 m3/hr
Duct size at suction - different for SA and PA
fan
For PA fan (3.34 0.832) = 2.78 m2

For SA fan (2.53 0.7)
= 1.77 m 2
Reduce the suction side pressure drop for

all the fans
Maintain pressure drop up to -20 mmWC at
suction side
Annual
Savings
Rs. 30.00
Total saving of 125 kW
Lakhs
Investment
???
Fan Performance
ID fan
Description
ID fan
-1A
ID fan
-1B
ID fan 2A
ID fan
-2B
116.67
118.81
109.44
105.12
298
311
259
260
Power Consumption in
kW
536.8
528.2
401.3
342.3
Efficiency %
66.81
72.19
76.94
86.98
Flow (m3/sec)
Pressure mmWC
ID Fan performance
-220 mmWC
35mmWC
40 mmWC
ID 2A
401. 3 kW
= 76.94%
40 mmWC
Optimize the performance of

Secondary Dust Extraction
fan
-420 mmWC June 30, 2012
-92 mmWC June 30, 2012
Bag Filter
-510 mmWC +5 mmWC
-370 mmWC
119.49 kW
= 89%
P = 328 mmWC

Secondary Dust Extraction fan
Pressure loss across the damper is

140 mmWC
P across the bag filter: 328 mmWC
Purging cycle is timer based.
Recommendation
Open the damper 100%

Install the VFD for the fan
Control the flow with VFD
Feedback
signal from P across bag filter

Secondary Dust Extraction fan
Recommendations
Operate the purging cycle based

on P across bag filter
Maintain the P across bag filter
90-120 mmWC
Power savings of 75 kW
Annual Savings
Lakhs
Investment
Lakhs
Payback period
-
Rs. 6.75
Rs. 10.00
18
Avoid the Damper loss in Lime

Mill Blower
Pressure loss
across the damper
is 140 mmWC
Recommendation
-319 mmWC
-470 mmWC 254 mmWC
121.22 kW
= 94%
Open the damper

100%
Install the VFD for
the fan
Control the flow
with VFD
Avoid the Damper loss in Lime

Mill Blower
Power savings of 24 kW
Annual Savings
Lakhs
Investment
Lakhs
Payback period
months
Rs. 2.16
Rs. 8.00
45
Avoid leakage in Service

Air System
Total 2 Compressors Screw

Compressor
Users
1 in service and other in standby

Flyash loading into the bunker
Lime loading into the bunker
Methodology
Kept one compressor running and

stopped all the users

Air System
Observation
51.16 % - Loading
48.84 % - Unloading
Operating Hours 6000

Kept a margin of 5 % leakage
Clear indication of huge leakage

Air System
Recommendation
Arrest all the leakages

Install drain valve which operates on
condensate level and not on timer
based.
Currently
drain is kept crack open
Annual Saving -
Rs 17.00 Lakhs
Avoid leakage in Conveying

Air System
Total 4 Compressors Screw

Compressor
Users
2 in service and others in standby

Flyash conveying from ESP, APH to
silo
Methodology

Avoid leakage in Conveying

Air System
Observation
11.11 % - Loading
88.89 % - Unloading
Operating Hours 8000

Annual Saving -
Rs 1.44 Lakhs
Avoid leakage in Lime Conveying

Air System
Total 4 Compressors - Reciprocating
Users
2 in service and others in standby

Flyash conveying from ESP, APH to
silo
Methodology

Avoid leakage in Lime Conveying

Air System
Observation
12.50 % - Loading
87.50 % - Unloading
Operating Hours - 4000

Annual Saving -
Rs 1.48 Lakhs
Optimize Instrument Air Operating

Pressure
Total 3 Screw Compressor
Operating Range
1 in Service & 2 in standby

VFD installed manual mode
5.8 6.5 kg/ cm2
Average 6.15 kg/ cm2
Users
All pneumatic instruments

Maximum pressure required by the
user is 4.5 kg/cm2
Dome valve operation 5 kg/ cm2

Pressure
Recommendation
Take VFD into auto mode and set the

pressure to 5.2 kg/cm2.
Presently Compressor is
Loading
- 96 %
Unloading - 4 %
New average operating pressure will

be 5.2 kg/ cm2
Unloading can be avoided

Pressure
Savings
By avoiding unloading
By reducing pressure
kW
Annual Saving -
- 1.74 kW
- 31.89
Rs 8.00 Lakhs
Optimize Service Air Operating

Pressure
Total 3 Screw Compressor
Operating Range
1 in Service & 1 in standby

VFD installed manual mode
6.5 - 7.5 kg/ cm2
Average 7 kg/ cm2
Operating hours
Users
- 4000 hrs
Lime feeding into bunker

Flyash feeding into bunker
These user need only 2 kg/ cm 2
Optimize Service Air

Operating Pressure
Recommendation
Take VFD into auto mode and set the

pressure to 4.5 kg/cm2.
Install a new receiver tank of higher
capacity
This
will avoid frequent loading and

unloading
Can cater to sudden requirement also
Savings
Power
-65 kW
Annual Saving
-
Rs 7.80 Lakhs
Install VFD for Loop Seal Blower in

boiler-1
Total 2 Blowers
Operation
Runs on full load

Discharge valve full open
Power consumption 68 kW
Boiler -2 Runs with similar blower but with

VFD (manual mode)
1 in service and other in standby
Power consumption 28 kW
Measurement could not be done because of

non-availability of points
Here comparative study is done with
blower of Boiler-2
Install VFD for Loop Seal Blower in

boiler-1
Recommendation
Install VFD
Run
in auto mode based on the pressure

requirement
Run on manual mode similar to Boiler-2
Savings 40 kW
Annual Saving -
Rs 9.60 Lakhs
ELECTRICAL
Optimize the Loading of Ash

Handling Plant Distribution
Transformers
6.6kV
Existing system
DT-1 2.5 MVA

339.61 KVA
13.5% Load
DT-2 2.5 MVA

439.25 KVA
17.57% Load
0.433kV

Transformers
Transformer losses:
DT 1: 3.36 kW
DT 2: 3.61 kW
Since loading is less, load can be

transferred to a single transformer
Loss in one transformer operation
4.922 kW
Net saving : 2.05 kW

Transformers
6.6kV
Proposed
system
DT-1 2.5 MVA

778.86 KVA
31.07% Load
DT-2 2.5 MVA
0.433kV

Transformers
Recommendation:
Operate only one transformer

Switch
load from the other transformer
Total Savings 2.05 kW

Annual Saving -
Rs 0.49 Lakhs
Investment
Nil
Optimize the Operation of dry

type Distribution Transformers
6
Dry
type
distribution
transformers cater to the loads
in 3 meter. Observations in:
DT-5 (2 MVA)
DT-6 (2 MVA)
2 MVA transformer used to

cater the load for CEP and other
LT motors.

6.6kV
DT-6 2 MVA
277.2 KVA
13.8% Load
DT-5 2 MVA
431.8 KVA
21.59% Load
0.433kV
Optimize the Operation of dry type

Distribution Transformers
Transformer losses:
DT 5: 3.88 kW
DT 6: 3.33 kW

5.45 kW

Recommendation
Shift
the
entire
load
transformer to the DT-5.
Isolate the primary

transformer and
DT-6
the
DT-6
Energise the transformer once in 30 days

for 8 hours to avoid the moisture problem
of
of
(Or)
Change over from DT-5 to DT-6 and vice

versa on a monthly basis and perform
maintenance in the isolated transformer.

Transformers
Recommendation:
Operate only one transformer

Switch
load from the other transformer

Annual Saving -
Rs 0.42 Lakhs
Investment
Nil
Switching off the idle running

Transformer
In Dry type distribution

transformers DT-3 and DT-4,
DT-3 is taking the entire load with the

bus coupler ON and DT-4 is off load.
However, the DT-4 is Idle charged

and hence the magnetizing loses or
the no load losses are prevalent.

Transformer
Idle running transformer
No load loss
Typically for a 2 MVA transformer, the noload losses are 2.5 to 3 kW
It is observed that the Transformer DT-4 (2

MVA) in 3-meter is idle running and can be
turned off
A saving of at least 2.5 kW can be achieved

by turning off the idle running transformer

Transformer
Annual Saving
Investment
Nil
Rs 0.60 Lakhs
Optimize the Loading of Coal

Transformers
There are 4 Distribution Transformers in
Coal Handling Plant.
DT-1 and DT-2 are operating with bus

coupler off.
While for DT-3 and DT-4, DT-3 is taking the

entire load while the DT-4 is de-energized.
Excellent initiative and has to be applied to

DT-1 and DT-2 as well since the majority of
load is conveyers which are lightly loaded.

Transformers
6.6kV
Existing system
DT-1 2 MVA
397.33 KVA
19.8% Load
DT-2 2 MVA
110.6 KVA
5.5% Load
0.433kV

Transformers
Transformer losses:
DT 1: 3.72 kW
DT 2: 4.00 kW

4.25 kW

Transformers
6.6kV
Proposed
system
DT-1 2 MVA
507.93 KVA
25.3% Load
DT-2 2 MVA
0.433kV

Transformers
Annual Saving -
Rs 0.83 Lakhs
Investment
Nil
Install auto star delta star

converters in identified motors
Loading of motors studied
Majority of motors 50 to 85%

loaded
Some motors under loaded
Poor power factor
High voltage dependent losses
Low efficiency
Following are lightly loaded motors

Rating
Actual
%
Motor in identified
KW
KW
Load
converters
Chain conveyer 2
motors
18.5
5.83
31.5
for unit-1
Chain conveyer 1
for unit-2
18.5
4.28
23.1
Belt Conveyer 1A
45
9.14
20.3
Belt Conveyer 2A
22
2.86
13
Belt Conveyer 4A
37
6.53
17.6
Belt Conveyer 5A
22
5.45
24.7
Belt Conveyers 1B,2B,3B,4B and 5B are OFF during the

measurements.
Recommendation
converters
in identified motors
Install auto star delta star converter
for motors loaded <40%
Advantages
%age loading improves
Power factor improves
Efficiency improves
Delta & Star Motor Connection

L1
IL = 3 Ip
VL
VP =
3
L1
VL
VL = V P
L2
L2
L3
L3
Delta connection
Star connection

Operating efficiency
increases
converters
in identified
motors
At least 10% can be saved

3.4 kW can be saved
Annual Saving -
Rs 0.51 Lakhs
Investment
Rs 2.25
Lakhs
Simple Payback -
53 Months
Optimize Lighting Voltage
Detailed lighting load measurement carried

out in 3 meter lighting and Unit 2 ACC of the
plant
Dedicated Lighting transformers are installed

in Various locations
Excellent initiative by Plant team
Lighting Voltage observed in the range of

240V
It was observed that in all the lighting feeders,

2 lighting transformers are installed and are
running in parallel with less loading on both.
One lighting transformer can be

isolated to improve the loading
and also maintain a minimum tap.
Optimum Voltage for lamps is 210215V
Higher Voltage results
Higher Power consumption
Increased failure rate of lamps


S.N
o
Area
Voltage
(V)
Load
(kW)
Unit-1 Main LDB TF1
239
15.15
Unit-1 Main LDB TF2
241
23.23
Unit-2 Main LDB TF1
241
13.3
Unit-2 Main LDB TF4 above

2 transformers are operating 240
8.86bus coup
The
in parallel with
10% reduction in Voltage
10%
reduction
consumption
in
Power
Insignificant drop in illumination
level
A total of approximately 6.54 kW can
be saved
by optimizing
the voltage of
Annual Saving Rs 0.78 Lakhs
the lighting transformers in those
Investment
NIL
areas.
Simple Payback -
Months
Lighting Optimisation
Light Pipe
Good potential to install in ware house and in office areas
Lighting movement sensors
Good potential to install in areas of low movement

MCCs
Wash
rooms
Lighting Optimization
LUX Sensors
Lights continue to glow even during day time
Potential to install LUX sensors to street lights and focus lights
Operated based on LUX levels
Timers for Street lights
Lights continue to glow even during day time
Potential to install timers for street lights and operate street lights based on timings
Observations
Harmonics Measurements
Harmonics are produced

linear equipment
due
to
non
Variable frequency drives
DC drives
UPS, Computers, etc
Switching Devices Diode, Thyristor, rectifier
Welding units
IEEE recommendations
THD-V < 5% up to 33 kV
THD-I < 15%
Harmonics
are
measured
distribution transformers
at
all
Current harmonics observed above

the recommended values at the
transformers with vfd motors.
Effects of harmonics
Failure of capacitor banks
Mal functioning of relays & false

tripping of breakers
Over heating of motors & transformers
Tag #
THD-V%
THD-I%
AHP DT-1
0.3
1.2
AHP DT-2
0.3
1.1
ESP UNIT 1 DT
3.6
45.2
ESP UNIT 2 DT
2.0
50.8
ACC UNIT 1 DT 1
8.1
30.9
ACC UNIT 1 DT 2
7.6
31.3
ACC UNIT 2 DT 1
6.7
32.8
ACC UNIT 2 DT 2
9.0
29.8
Tag #
THD-V%
THD-I%
DRY TF-1
4.2
29.9
DRY TF-3
0.7
2.7
DRY TF-5
4.6
29.8
DRY TF-6
3.9
41.7
CHP DT-1
0.3
0.6
CHP DT-2
0.3
5.1
CHP DT-4
0.3
0.2
*Dry TF-4 is not in line and TF-2 incomer to panel is

locked.
*CHP DT-3 is not in line.
Latest technologies are there with
reduced harmonics
Drives come with in built filter
Recommend to install filters if any

of
these problems occur after
carrying
out detailed study
Avoid damper loss in Lime

conveying blower
Total 3 Blowers
Operation
1 in service and 2 in standby

Runs on VFD (manual mode) based on
the requirement
Pressure was measured across the

discharge damper
Pressure difference of 100 mmWC was

observed
Avoid damper loss in Lime

conveying blower
Recommendation
Damper losses should be max of

20mmWC
Savings 80mmWC to be reduced
Condenser Vacuum
System
CII and Plant team conducted a detailed ACC
vacuum audit for Both the Units

Vacuum Drop
Major concern in the Plant

Day time Vacuum : (0.7 0.75 kg/cm2)
Even observed 0.65 kg/cm2 during peak summer
temperatures
Specific Steam Consumption
Depends on the vacuum conditions

Under favorable conditions( Vacuum 0.80 kg/cm2)
470 TPH 480 TPH steam is needed for 148 MW
Under unfavorable conditions
510 TPH to 515 TPH
Condenser Vacuum
System
Audit Findings
Condenser Vacuum
Day Time Vacuum : 0.7- 0.75 kg/cm2

Starts decreasing after 5:00 7:00 PM
Sole reason is that air temperature
starts favoring
Function of Load and cooling
opportunity provided by condenser
Load characteristics
Governed by external demand

Condenser Vacuum
System
Cooling Opportunity in Air Cooled

Condenser at a particular load
Depends upon ambient air

temperature
Heat transfer area provided
Steam Ejectors at both the units
Handling higher infiltrated air and

condensate flow
Helium test also conducted for the
plant
Air Cool Condenser

arrangement
Exhaust Line
Steam Distribution Line
55 deg C
48 deg C
55 deg C
55 deg C
55 deg C
48 deg C
59 deg C
56 deg C
59 deg C
60 deg C
60 deg C
60 deg C
Air Cool Condenser

arrangement
Temperature in the second row
During unfavorable conditions
Always lower and shows subcooling during

favorable conditions
Indicates lesser flow going through second
stage
Last stage also behaves abnormally sometimes
Heat exchanger area does not remains
sufficient
Situation of low vacuum occurs
Its highly recommended to check the steam

distribution in second and last stages
Performance of steam
ejector
Measured flow through ejector condenser 415 m3/hr
Temperature difference
Inlet 45.75 deg C

outlet 47.4 deg C
steam flow through ejector based on heat balance 996 kg/hr
Very high compared to design
Some times two ejectors operated
Vacuum maintained during favourable condition outside temp -19-20

deg C
Operating 0.17 kg/cm2 (a)
Design 0.15 kg/cm2 (a)
Observation
-1
ejector
Cold reheat tapping temperature -
335 Deg C
Auxiliary steam header temp
220 Deg C
Significant drop in temperature of steam
Need to ensure there is no attemperation
Quantity of steam consumption in ejector will increase with

reduction in super heat / saturation steam supply
Size of pipe line may contribute only to some extent
If temp drop is due to heat loss there would be reduction in

pressure as well at the inlet of ejector
Observation
-2
ejector
Install a vacuum pump parallel to steam jet ejector

Power generation potential from cold reheat to
condensing
210 units
Avoiding 1 ton/hr of cold reheat will result in overall

reduction in steam consumption of about 0.75 ton/hr
Estimated power consumption of vacuum pump approx

90 kW
Steam requirement for 90 kW 0.3 ton/hr
Observation
-2
ejector
Net benefit
approx 0.5 ton/hr
Majority of major power plants in installed with

Vacuum pumps
Install the vacuum pump in parallel to existing

ejector
Summary of Findings
No. of
Projects
Parameter
Total Annual Saving
Rs. in Lakhs
24
187
Annual Saving without

investment
14
86
Annual saving with

investment
10
101
10
110
Investment required
Simple payback period
13 Months
To Sum-up
Shree Mega Power, Already several
efforts taken towards energy efficiency
Several projects on anvil
Thank you

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Detailed Energy Audit at

Confederation of Indian Industry

Confederation of Indian Industry

Achieve Maximum Energy

Confederation of Indian Industry

Past Energy Conservation

Extensive use of VFD

Excellent monitoring system

Installation of lighting transformer

Individual isolation valve for

And many more

Catalyst / Facilitator role

Supplement in-house activities

Identify energy saving proposals

All possible assistance

Not fault finders !!

Operation of ACW pump

Operation of ACW pump

ACW pump installed to cater cooling

Three pumps installed for pumping water

VFD installed in one pump ( In Operation)

Water flow measurements, pressure

Operation of ACW pump

Confederation of Indian Industry

Operation of ACW pump

Pump being operated in lower speed

Changes happened in cooling water circuit

Pump operating in a low efficiency range

Bed ash cooler not in full operation

Operated at a lower range

Good potential to save energy by installing

Operation of ACW pump

Install a new pump for actual

VFD used in the earlier pump can be

Confederation of Indian Industry

Install new correct size pump

Water is constantly pumped to the side filter

About 150 m3/hr of water is being pumped

This water is tapped from the ACW pump

Pumped to sided filter at 3.2 bar

ACW flow : 1490 m3/hr

About 10% is being pumped to the side filter

Potential to save energy by installing a

Confederation of Indian Industry

Install new pump for side filter

By installing a new pump, 10% of

VFD speed can be reduced

Install separate pump for side filter

Reduce 10% of flow in ACW pump

About 10 kW can be saved

Install new pump for side filter

Confederation of Indian Industry

Operation of chillers (TG

Chilled water pumps

Confederation of Indian Industry

3 chillers installed for catering air

Flow measurements taken:

All three in operation

Return water from AHU is pumped to the