1 / 19

CPP Kymore Cement Works

CPP Kymore Cement Works. COST SAVING INITIATIVES. CPP Kymore Cement Works. Identify & Implement Energy Saving measures at CPP Minimize Old CPP Running Maximizing CPP power to mines. Optimisation of operating cost. Action Plan. CPP Kymore Cement Works.

calder
Download Presentation

CPP Kymore Cement Works

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. CPP Kymore Cement Works COST SAVING INITIATIVES

  2. CPP Kymore Cement Works • Identify & Implement Energy Saving measures at CPP • Minimize Old CPP Running • Maximizing CPP power to mines Optimisation of operating cost Action Plan

  3. CPP Kymore Cement Works -Operating both TG sets at a frequency of 49.85 Hz. - Switching off one SST. - Optimizing indoor lights burning - Stop one BFP , when system load is less than 37 MW - Auto start/stop of one CT fan with respect to CW temp. - Operating Both TG sets at a voltage of 10.9KV. - Auto start/stop of bed ash belt conveyors & scrapper conveyors as per the opening/closing of bed ash auto drain valves. Energy Saving Measures

  4. CPP Kymore Cement Works Power Consumption  (speed)3 Speed  Frequency Power consumption  (Frequency)3 Optimization of Operating Frequency at New CPP This shows that high operating frequency results in high power consumption Step by Step, the operating frequency was brought down to 49.85 Hz Reduction in frequency = X 100 = 0.3% On a conservative estimate, 0.5% reduction in frequency can save 1% of total power generation. Annual saving – (38,000 X 0.003)kw X 8600 Hrs/yr =980400 KWH 50-49.85 50

  5. CPP Kymore Cement Works After commissioning of TG-5, two SSTs were kept in service. One SST was taken out of service on 20/01/2008, as load on the transformer was very less. Load on the transformer before taking out of service 0.4MW Transformer & cable Loss @ 2% = 8 KW Average saving for this year = 8 KWX346 daysX24Hrs = 66432 KWh Taking One Service Stn. Transformer Out of Service

  6. CPP Kymore Cement Works Substation room indoor lightings are automatically switched on/off by opening/closing of entrance door. Limit switch is introduced in the lighting circuit of the individual room which is operated by the door latch. Following rooms are provided with limit switch. 1. TG5 11KV switchgear room, 2.TG4 11KV switchgear room,3. Cubical room at 9.00M El. 4, 415MCC room at 9.00M El. 5, AHU room, UPS Control Panel room, Battery charger & battery room at 14.5M El. 6. ESP control rooms 7. Misc.pump house & MCC room 8. Ash Handling compressor & MCC room 9, DM plant & ETP MCC room 10, CWP MCC room (TG4+TG5), 11. DG set room (TG4+TG5) 12. Air washer rooms 13, Store rooms in TG building 3 Nos. Total nos. of Fluorescent lights – 840 Nos. Fluorescent Light wattage = 40 W Lights are switched off for a minimum period of – 22 hrs /day Annual savings – 840kW X 0.04kw X 22 Hrs/Day X 365 days =269808 kWH Auto Switching of Indoor Lighting

  7. CPP Kymore Cement Works Stopping of BFP whenever system load is less than 37 MW (After resolving water balancing problem) Avg. Stoppage hrs in the month – 192 Hrs Actual Power consumption of one BFP – 225 kw (√3 x 22x 660Vx0.9 / 1000 = 225 KW) Saving per annum 192 hrs x 9 Months x 225 KW = 3,88,880 KWH

  8. CPP Kymore Cement Works Maintaining system voltage at 10.9 KV Loading of all HT motors was observed to be less than the rated. Hence System voltage was gradually reduced to - 10.9 KV Voltage available at all HT Motors – 6.55 KV % Reduction ( 6.6-6.55)/6.6 x100 = 0.757 On a conservative estimate, every 4% reduction in voltage, results in power saving of at least 0.5% % Saving of power = 0.75 x0.5 /4 = 0.094 Total HT Load connected = 20 MW Annual savings 20000 x 0.00094 x 8600 = 1,61,680 KWH

  9. CPP KYMORE Present Mode of Working : The cooling tower of 25MW CPP is designed for 43 deg C inlet and 33 deg C outlet temperatures. The average outlet temperature is measured as 28.5 deg C. When ever the vacuum is maintained above -0.9 kg/Sq.cm we used to stop the fan manually. Auto Starting of one CT fan with respect to CW Temp. Modified system : Installed an AUTO select button in DCS with a built in LOGIC to STOP One Fan when ever the outlet temperature falls to 28 deg C and STARTthe fan if the temp is more than 32 deg C.

  10. CPP KYMORE Existing system FAN #1 FAN#2 FAN #3 INLET DESIGN INLET TEMP : 43 * C DESIGN OUTLET TEMP : 33 * C OUTLET

  11. CPP KYMORE AUTO FAN #1 FAN#2 FAN #3 INLET STOP 28 *C START 32*C MODIFIEDSYSTEM OUTLET

  12. CPP KYMORE Savings: Running hours for which Power savings is applicable :1299 hrs Running load of CT fan : 56 A Annual Savings : 1.732 x 415 x 0.9 x 56 x 5 months x30 days x 24 hrs /1000 (Applicable – Jan & Feb 08 and from Oct’08 to Dec’ 08) = Rs. 1, 53, 218

  13. CPP KYMORE Stop / Start of Bed ash conveyors & scrapper conveyors w.r.t. close/open of bed ash auto drain valve • Total running load of bed ash conveying system=47 KW • Running Hours saved due to subject interlocking = 16 Hrs/Day • Annual savings = 47KWX16Hrs/DayX 366 days=275232KWH • Jan 08-47KWHX16Hrs/DayX31 DaysXRs 2.36/KWH=Rs 55016.32 • Feb 08- 47KWHX16Hrs/DayX29 DaysXRs 3.21/KWH=Rs 70003.68 • Mar 08- 47KWHX16Hrs/DayX31 DaysXRs 2.94/KWH=Rs 68537.28

  14. CPP Kymore Cement Works Minimize Old CPP Running: Renovation and Upgradation of Boilers for New CPP during 2007 & operating at Optimum level resulted in shifting more load from Old CPP to New CPP. During balance 9 months of 2008, Old CPP is planned to be used only during shutdown maintenance of New CPP Boiler

  15. CPP Kymore Cement Works Cost Benefits Differential Power Generation Cost (Old CPP / New CPP) Rs. 5.58 – Rs.2.52 as= Re 3.06/kWh Avg. Generation from Old CPP for period Aug to Dec 2007 32.08 lakh KWH Avg. Generation from Old CPP for period Jan to Mar 2008 25.42 lakh KWH Reduction in generation of Old CPP : 6.66 lakh KWH (On account of increased generation from New CPP) Savings during first quarter : 6.66 x 3 Months x Rs 3.06/KWH = Rs. 61 Lakhs during the first quarter Savings expected during the remaining three quarters – Rs.663 Lakhs Minimize Old CPP Running:

  16. CPP Kymore Cement Works Maximize CPP Powersupply to BMG/ MHG Mines 2006- Grid MD –MHG 2.5MVA & BMG 1.4MVA 2007 –Grid MD-MHG 2.0 MVA & BMG 1.0MVA (M.D. was reduced)

  17. CPP Kymore Cement Works • Basis year 2007 – Avg. CPP power supply to mines = 227000 KWH/Month • CPP power supplied (Jan-Mar 08)=1452530KWH • CPP avg.power supplied per month =484176KWH • Additional power supplied to Mines by CPP = 257176 KWH • Grid Avg.Cost – Jan to Mar. 08 – Rs 5.85/KWH • CPP Avg.cost – Rs 2.86/KWH • Differential cost – Rs 2.99/KWH • Total Savings = 257176 X 3 MonthsX Rs 2.99KWH = Rs 23,06,869/- (as compared to 2007)

More Related