40 MW CPP Chanda -...

2017 Chanda Cement Works

Energy Leadership

Welcome to CII

17th National Award for Excellence in Energy Management 2017

30, 31 August & 01 September 2017

Presenter : Sandeep Kumar Garg

40 MW CPP Chanda


Contents…

1. Company Profile

2. Process flow diagram & configuration

3. Plant Performance over the year

4. Innovative Projects with No investments

5. Innovative Projects with investments

6. Best practices

7. Energy Saving Projects – Way forward


CPP - 1X15MW + 1X25MW - Commissioned in 2002 (15MW) & 2010 (25MW).

Chanda is the first cement plant set up in the state of Maharashtra.

Located at Ghugus Taluka-27 KM from Chandrapur and 165 KM from Nagpur.

Company Profile - Chanda Cement Works

Maharastra

Chanda


Process Flow Diagram…


Plant Performance Over the Years

13.21 12.79 12.55

10.41 10

Year 2014 Year 2015 Year 2016 Till July

2017

Aspiration

2017

APC %

3287 3265

3212

3110 3100

Year 2014 Year 2015 Year 2016 Till July 2017 Aspiration2017

SHR (Kcal/Kwh)


Auxiliary Power Consumption Vs PLF - 2017

11.07

10.12 10.04 10.05

10.39

10.98

10.43

9.50

10.00

10.50

11.00

11.50

Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 Jul-17

60

.12

77

.74

73

.07

77

.17

72

.57

61

.65

71

.61


SN Energy Saving Projects

Saving Achieved

Electrical Energy (MWH)

Thermal Energy

(Ton/Year)

Rs. Lac

01 Implementation of DP logic in BPF of Unit#1 201 - 8.10

02 Implementation of DP logic in BPF of Unit#2 252 - 10.10

03 Optimisation of CEP discharge pressure form 10 to 6.0 Kg/cm2 for Unit#1

101 - 4.04

04 Optimisation of CEP discharge pressure form 10 to 6.0 Kg/cm2 for Unit#2

98 - 3.92

Total savings 652 26.16

Energy Saving Projects with zero investment…2017


SN Energy Saving Projects

Saving Achieved

Electrical Energy (MWH)

Thermal Energy

(Ton/Year)

Rs. Lac

01 Improved TG vacuum by arresting leakages in exhaust path through Helium leak detect test

- 80.75 2.66

02 CBD vent line connected to deareator. - 210 6.93

03

CHP power optimization by increasing through crusher out put & reducing idle running hours through keen observation at coal feeding grizzly hopper.

300 - 12.0

04 Impeller trimming of Raw Water Pump for reduction of APC.

25 - 1.0

05 Recycle & reuse of BAC cyclone trapped material. - - 2.40

Total savings 325 290.75 24.99

Energy Savings Projects with zero investment…2015 - 16


SN Energy Saving project

Saving Achieved/Year Investments

(Rs. Lac)

Pay Back

Months Year Electrical

Energy (MWH)

Thermal Energy (Ton)

Rs. Lac

01

P&V pump replaced with low capacity pump, by modification of water spray system existing louvers replaced with cellulose pad.

43.50 - 1.74 0.50 3 2017

02

Unit=1 condenser tube assembly replacement to improve vacuum from -0.80 to .91 Kg/cm2.

- 700 23.45 61 2.60 2016

03 HT VVFD installed in BFP of unit#1

294 - 11.76 30 2.5 2016

04 HT VVFD installed in BFP of units#2

798 - 31.92 75 2.3 2016

05 VVFD installed in IAC of both units.

100 - 4.03 3 8 2016

Energy Savings Projects with investment…2015-17

Continued..


Energy Savings Projects with investment…2015-17

SN Energy Saving project

Saving Achieved Investment (Rs. Lac)

Pay Back

Months Year Electrical

Energy Thermal Energy

Rs. Lac

06 Replacement of Cooling tower fan blades with hollow blades of Unit#1

156 - 6.24 7.68 14 2016

07 VVFD installed in condensate extraction pump no.1 of unit#1

67 - 2.68 2.5 10 2016

08 VVFD installed in condensate extraction pump no.1 of unit#2

93 - 3.70 3 8 2015

09 Boiler No. 01 & 02 APH tube replacement

84 - 6.72 40 7 2015

10 Replacement of Cooling tower fan blades with hollow blades of Unit#2

597 - 23.90 7.32 4 2015

11

Improve MDC air slider reliability to replacement of slider sintered sheet to ceramic cloth. Reduce maintenance cost.

- 24 7.90 0.95 2 2017

Total savings 2232.5 724 124.04 230.95


Concept # 1 DP Logic implementation in BFP…

Concept..

• DP LOGIC for Boiler Feed Pump to reduction of auxiliary power consumption.

Background..

• HT VFDs ware installed for Boiler Feed Pumps (BFP) -1 in both units which was operating at reduced fixed RPM as per requirement. However most of the time even on reduced pump loading, discharge pressure of BFP is more than the requirement on varying loads.

Approach..

• After studying the system it was observed that even if discharge pressure is maintained 5 to 6 kg/cm2 above the drum pressure, system behaves stable.

• Logic was developed in-house & incorporated in DCS so that PID will automatically take set point of 5 kg/cm2 higher than drum pressure. (Differential pressure of 5 kg/cm2 is maintained between drum pressure & BFP Discharge Pressure).

Continued..


Concept # 1 DP Logic implementation in BFP…

Investment ..

• Financial investment is ZERO.

• Technical skill & Experience - To prepare & implement DP logic on DCS through own team with keen & vigilant observation during operation.

Benefits & Economic impact..

• Improvement in APC (Auxiliary Power Consumption).

For Unit-1

KW consumed before DP Logic = 211 KW

KW consumed after DP Logic = 187 KW

Total saving in KW = 24 KW

Saving per day in 15 MW = 24 KW X 24 Hrs= 576

Units

Saving per year @ Rs 4 /unit = 576*350*4

= 8.1 Lac / Year

For Unit No.2

KW consumed before DP Logic = 285 KW

KW consumed after DP Logic = 255 KW

Total saving in KW = 30 KW

Saving per day in 25 MW = 30 KW X 24 Hrs= 720

Units

Saving per year @ Rs 4 /unit = 720*350*4

= 10.1 Lac/ Year

Total Saving per year = 18.2 Lac / year


Concept..

• Replacement of CT fan GRP solid blades assembly with FRP type to reduce in Auxiliary Power Consumption.

Background..

• In both units, Cooling tower fans were installed with VFDs which ware operated at reduced fixed RPM as per requirement.

• Originally, Fans were supplied with GRP type solid blades fan assembly, resulting in high Auxiliary power consumption due heavy weight of blades.

Approach..

• Idea is suggested by O&M team to replace GRP type blade assembly to FRP

Continued..

Concept # 2 Replacement of Cooling Tower Blades…

** Glass Reinforced Polypropylene

** Fiber Reinforced Plastic


Investment ..

• Financial investment was 16 Lac.

Benefits & Economics impact..

• Improvements in APC (Auxiliary Power Consumption)

• Improved Cooling effect due to air velocity increase by 27.72% & 31.64% respectively of both units

• Electrical Energy Saving on each fan of Unit#1 – 8.85+9.73 KWH (38.62%)

Saving per year @ 4Rs/Unit = (8.85+9.73)*24*350*4=6.24 Lac per year

• Electrical Energy Saving on each fan of Unit#2 – 37.44+33.67 KWH (42.15%)

Saving per year @4Rs/Unit = (37.44+33.67)*24*350*4=23.90 Lac per year

Concept # 2 Replacement of Cooling Tower Blades…


Concept # 3 Reduction of secondary air in CFBC Boiler…

Concept..

• Reduction in secondary air & focus on primary combustion for reduction of Station Heat Rate & Auxiliary Power Consumption

Background..

• Earlier CFBC boiler was operated with 1350 mmwc wind box pressure as per OEM recommendations, resulting in higher loading operation of PA fan, even at partial loading of boiler.

Approach..

• Idea is generated by our O&M team.

• In CFBC Boiler, PA fan header pressure reduced from 1350 to 1150 mmwc through improving the Mechanical Dust Collector efficiency by reducing slider jamming tendency.

• Secondary air reduced and more focus was given to primary combustion. This improved the recycle inventory.

Continued..


Investment ..

• Financial investment was negligible.

Benefits & Economics impact..

• Improvement in SHR by avoiding frequent leakages through air sliders(Station Heat Rate)

• Reduction in LOI by recycling.

• Reduction in boiler excess air O2% by reduction in secondary air.

• Improved boiler efficiency.

• Improvement in APC (Auxiliary Power Consumption) -

One SA fan (250KW) always maintained as hot standby.



Concept # 4 Recycling of Cyclone material…

Concept..

• Recycling of drained Bed ash pneumatically to bed as bunker and optimize the use of fresh bed material.

• Reduction in manual interference for charging of bed material at bed bunker

Background..

• Earlier in CFBC boiler, the bed material bunkers which are located at almost 25 mtrs above ground, had to be filled manually for meeting light up or any other emergency requirements. This activity required manpower involvement & safety hazards. The bed ash used, was either sieved or fresh one. Now, after the system implementation, use of fresh bed material is drastically reduced.

Approach..

• Idea was suggested by our O&M team.

• In CFBC Boiler, Bed material drained & cooled in BAC. During cooling process fine material is trapped in cyclone & collected in a vessel. These fine bed material is pneumatically conveyed to bed material bunker

Continued..


Investment ..

• Financial investment is ZERO.

Benefits & Economic impact..

• Elimination of manual interference & associated safety hazards.

• Reduced fresh bed material consumption.

• All employee satisfaction

Concept # 4 Recycling of Cyclone material…


Best practices on safety front…

Display of SOPs/SMPs & JSAs Group Isolation & Lock out provision

PPE adherence while electrical energy isolation


Energy Saving Projects – way forward…

Major Overhauling of TG # 1 & 2 to improve STG cycle efficiency & Heat Rate

CFBC boiler, APH tube assembly replacement for reduction of Auxiliary power consumption & improvement of boiler efficiency.

Elimination of raw water pump use by providing interconnecting line between Mines & River water pump.

Modification of existing coal handling circuit for reduction of Auxiliary Power Consumption as well as increasing throughput rate.

Installation of energy efficient Cooling water pumps in both units.

Existing inefficient reciprocating compressors replacement with screw compressors for reduction of APC.


Achieve ZERO Harm consistently with Lowest Power

Generation Cost by using the Innovative practices and

Corporate ethics.

40 MW CPP Chanda -...

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