AP Cement Works - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Power/4... · Step Project Initiation SH (Opern) ... Reduction of Bed Height from 1010

AP Cement Works Captive Power plant

A Unit of UltraTech Cement

Integrity - commitment- Passion -Seamlessness -Speed 1

Welcome to all

2

APCW Cluster

B

A

D

B- ARCW – G.U. 1.1 Million Ton

Cement

C

D - SBT – B.T. 1.0 Million Ton

Cement

A - APCW – I.P. Phase 1 Clinker – 2.7 Million

Ton Phase 2 Clinker – 3.4 Million

Ton Total Cement – 6.4 Million

Ton

A B

C- GICW – G.U. 1.2 Million Ton

Cement

C

D

Total Clinker : 6.1 Million

Ton Cement : 9.7 Million

Ton

4x25 MW TPP 1x4 MW WHRPP 2x11.7 MW WHRPP

First ISO:50001:2011 certified unit

Achieved 28206 ESCERTS in PAT cycle-1

Established first of its kind(in India) WHRPP

GreenCo Gold Award Unit

Day lights installation for all machinery buildings

Successfully completed Steam blowing with coal in place of HSD for Boiler#4 (first time in the history of Thyssen Krupp Boilers).

Energy Policy implemented in Dec – 2011

Energy Policy states unit’s

commitment towards continual energy performance improvement.

Energy policy is communicated at all levels.

Energy policy is regularly reviewed and last reviewed on 1st March’16.


To Reduce TPP Power Cost to the cement plant by means :

To reduce the auxiliary consumption

To reduce the Plant heat rate .

Responsibility Chart:-

FH –CPP

DH-Operation

SH Operation

DH-Mechanical

SH Mech

DH-E&I

SH-Electrical

SH-Instrument

SH-Energy

Step Project Initiation SH

(Opern)

Engineer

(E)

Engineer

(Electrical)

Project

leader

Hods/

FH

(TPP)

1 Data collection I R I A I

2 Equipment wise power consumption data

analysis R R R A / C I

3 Identifying Power saving potential area R R R A C

4 Conduct Brain storming session R R R A C

5 Project Execution -PROCESS R I I A I

6 Project Execution -E&I I R I A I

7 Project Execution -MECH I I R A I

8 Post Evaluation R R R A C

9 Sharing of Outcome R R R A I

Unit-1 Aux.

Boiler Fans

BFP

ESP

TG Aux

ACC Fans

ACC CEP

Unit-2 Aux.

Boiler Fans

BFP

ESP

TG Aux

ACC Fans

ACC CEP

Unit-3 Aux.

Boiler fans

BFP

ESP

TG Aux

ACC Fans

ACC CEP

Unit-4 Aux

Boiler Fans

BFP

ESP

TG Aux

ACC Fans

ACC CEP

Common Loads

CHP

AHP

AC & PNV

Compr

WTP

Lighting

Total TPP Aux.

Coal Handling plant losses

Handling loss

Wind loss

ESP

TG Aux

Boiler losses

Dry FG loss

Moisture in fuel

H2 in fuel

Moisture in Air

UBC in ash

Radiation loss

Steam turbine loss

Gland sealing loss

Stem dumping loss

Friction loss

Heaters TTD

Heaters DCA

leakages

ACC loss

Vacuum losses

Sub cooling loss

WTP Losses

Higher blow down

Higher Makeup

water

Total Plant Heat rate Tree


Monitoring System

Boiler Fans 32%

Boiler feed

pump 28%

ACC 7%

Ash Handling

5%

Compressor 3%

WTP 0%

CHP 2%

Cooling Water

3%

Chillers 2%

AC 2%

ESP 2%

Boiler&STG MCC

5% CEP&HTP

2% Lighting

2%

Losses 3%

Wagon Loading

0%

Aux. Power Distribution section Wise

Heat rate for Power

Generation, 2918, 90%

Steam Dumping, 75,

2%

Inlet Parameters , 4,

0%

Vacuum deviation, 0, 0%

Heater effectiveness,

17, 1% Under load operation, 183,

6%

Dry fluegas losses, 45, 1%

Other, 325, 10%

Heat Rate

Ambient Temp: Avg 35.13/Max.41.00/Min28.71 22-03-2017 Previous best 145.73 MW Aux 8.85% 29-03-2017 Aux 10.09% 148.21 MWh

UOM

Bench

mark Unit-1 Unit-2 Unit-3 Unit-4 Unit-1 Unit-2 Unit-3 Unit-4 Remarks

Generation MWH 0 506 575 572 0 385 538 546

Plant heat Rate Kcal/Kwh 0 3070 3004 2992 0 3170 3023 3015

Primary Air (PA) Fan Kw/MW 10.2 0.0 25.8 15.4 15.6 0.0 30.4 16.7 16.2

Boiler Oxygen Levels % 5.9 6.1 4.7 9.74 5.46 5.33

Secondary Air (SA) Fan Kw/MW 6.07 0.0 1.5 2.4 2.4 0.0 4.5 2.3 2.3

Induced draft (ID) Fan Kw/MW 10.5 0.0 8.0 6.2 6.2 0.0 12.7 6.0 6.1

Condensate Extraction Pump (CEP) Kw/MW 1.59 0.00 2.82 2.0 2.2 0.00 3.93 2.1 2.1

ACC fans & STG Kw/MW 3.05 0.0 31.8 10.8 8.3 0.0 32.3 11.4 11.5

Boiler Feed Pump (BFP) Kw/MW 22.6 28.4 27.5 35.6 28.0

Inst Compressors Kw/MW

4.26

2.4 2.9

Service Compressors Kw/MW 4.3 3.8

Total 12 Rawmeal bowser unloaded

Water Treatment Plant (WTP ) Kw/MW 0.74 0.4 0.32 m3/kwh 0.3 0.67 m3/kwh

Coal Handling Plant (CHP) Kw/MW 0.61 1.6 1.3

CHP Performance KW/MT 2.85 --- --- 3.82 --- --- 3.84

Auxiliary Cooling Water Pump

(ACWP) Kw/MW 1.56 1.9 2.4

ESP MWH 0.832 0.558 0.547 0.865 0.702 0.552

Boiler MCC MWH 0.0 0.403 0.198 0.0 0.542 0.163

Emergency MCC MWH 0.5 0.2 0.386 0.014 0.3 0.2 0.386 0.014

Chiller &AC MW 2.632 2.636 2.720 2.767

Lighting Load & WTP Lab MWH 1.591 1.024 1.565 1.058

Wagon loading& coal Feeding MW 0.333 0.208

Transformer losses MW 5.877 5.440

Dump losses MT 44.000 19.0 14.0 35.000 13.0 15.0

Heat Rate losses Kcal/Kwh

Steam Dumping Losses Kcal/Kwh #DIV/0! 66.957 16.4 10.2 #DIV/0! 70.000 18.6 21.2

Inlet Parameters Deviation Kcal/Kwh 0.000 0.0 0.0 0.0 0.000 12.4 7.6 4.4

Heaters inefficient due to low flow Kcal/Kwh 0.000 0.0 9.9 6.4 0.000 0.0 7.0 4.0 Dry flue gas Losses due to Excess

Air Kcal/Kwh 0.000 0.0 47.8 42.3 0.000 61.5 14.3 19.6

Import from Grid MWh 7.417 12.000

Export to grid(IEX+Injection loss) MWh 18.133 13.000 IEX-0 MWH

Shutdown/Start-up power MWh 0.50

Remarks

50.8 56.9

70.2 72.4 75.8

78 83.6 86.3 86.7

0 20 40 60 80 100

Plan

t load

factor %

GCW

RDCW

KCW

SCW

RCW

RWCW

AC

VC

HCW

4th

9.08 9.25 9.37 9.57 9.69 10.12

10.6 11.37 11.47

0 5 10 15

Au

x. Co

nsu

mp

tion

%

VC

RWCW

GCW

ACW

RCW

SCW

RDCW

KCW

APCW

1st

3036 3055

3103 3103 3109

3127 3159 3172

3305

2900 3000 3100 3200 3300 3400

Heat R

ate Kcal/K

wh

RDCW

VC

APCW

ACW

RCW

RWCW

AC

SCW

KCW

7th

64 112

195 237 248

281 286

325 334

0 100 200 300 400

Gen

eration

AC

ACW

KCW

RCW

RWCW

SCW

VC

HCW

4th

7.73 7.82 8.15

10.95

7.69 6.96 6.92

0

2

4

6

8

10

12

15 18 25 25 27 30 250

A

u

x

.

%

Plant Capacity MW

APC %

86.69%

13.31%

TPP Power share

Net apc

CFBC with ACC

Action plan to Reduce Auxiliary power from present 9.3% to 7.6%

S.NO Area Actions FPR Expected Per day

Saving (KWH)

Target date

1 TPP Improve PLF by Power wheeling / selling to IEX VPG 1350 Continue

2 Boiler-PA Fan

1. Reduce PA fan flow from 20 to 17.5 Kg/s. 2. Optimization of Oxygen in Boilers. 3. False air entry to be arrested in APH. 4. Reduction of Bed Height from 1010 to 950 mm

SKR 1250 30.12.17

3 Compressor

1. Avoid parallel unloading of Raw meal Bowzers. 2. Stop Ash handling operation while Unloading of Raw meal bowzers. 3. Ensure Ash handling system operation in probe mode only and optimize ash handling cyclic time. 4. Avoid Air Cleaning with compressed air. 5. Shut off Air valves of Phase-1 equipments while running only Phase-2 TPP is in operation. 6. Run only VFD operated compressors. 7. Installation of low pressure Air Compressor for raw meal unloading 8. Air audit to be conducted for CHP,AHP & boiler area

SKR 1230 20.03.18

4 Boiler- BFP

1. Single BFP operation whenever load is less than 16 MW to operate Two Boilers. 2. During normal operation, BFPs to be operate in DP from 10 to 8 Kg/Cem2 while low load operation.

SKR 960 15.12.17

5 Air-Conditioning Installation of split AC's in office area & stopping 2 Units of package AC.

VPG 950 15.12.17


Target-7.2% APC in Dalmia Cement CPP

,Karnataka

6 ACC Reduce ACC fan speed from 30 to 20 % in winter or alternatively reduce blade angle to reduce air flow.

HH 600 15.12.17

7 TPP Substation Optimization of Transformer losses VPG 600 30.12.17

8 Boiler-ID Fan Reduce draft progressively from -30 to -20 Kg/cm2. SKR 320 30.12.17

9 Cooling Tower 1. Reduce ACW Pump discharge pressure from 3.5 to 2.8 Kg/cem2. 2. CT fan operation interlocked with temperature

SKR/VPG 250 15.12.17

10 Boiler-SA Fan Operate SA Fan in close loop with Bed temp and its logic preperation in DCS

SKR/VPG 180 30.12.17

11 CHP 1. Minimizing Coal handling plant Idle running hours 2. Stop Bag filters operation while Petcoke feeding.

SKR 110 15.12.17

12 Lighting

1. Installation of solar day lights in WTP, TG building , Project & Mechanical Workshop. 2. Installation of LED lights

VPG 100

30.01.17

13 Boiler-Fuel Feeder Re-calibration of fuel feeder bed height from 30 TPH to 12 TPH and logic preperation in DCS

VPG/VM 60 30.11.17

14 WTP Operate WTP once in a Two days. SKR 44 15.12.17

Total Expected saving 8004


Title of Project

Annual Electrical Saving (kWh)

Annual Thermal Saving In Mcal

1 Installation 4 nos of VFDs in ACC-3&4 1360000

2 PH-1 boilers after Heaters feed water inert connection

1420800

3 Operation of HRPP 37 Kw compressor instead of 160Kw

225060

4 LED lights installation inPh-2 TG building& all areas 8689

5 Day lights installation in TPP 6307.2

6 Reduction of CEP discharge pressure from 9.5 to 8 kg/cm2. and operate cascade operation with Deaerator pressure

8400

7 Arresting of False air entry in ESP-4 28749

8 Optimization of oxygen levels in Boilers 1626800

Intgrity - commitment- Passion -Seamlessness -Speed 18

Title of Project



1 Auxiliary cooling water pump Corrocating to improve efficiency

87600

2 Pentane pump VFD arrangement 569000

3 Lighting power optimisation done by providing occupancy sensor, local lighting switches

53674

4 Chiller operation optimisation by providing single duct

139392

5 Gravity line provided to makeup water instead of pumping

86400

6 Boiler Blow down water heat recovery 615.543

7 Boiler fans IGV(Inlet Guide vane ) removal to Minimise suction pressure.

243936

8 L.P.Heater drain line connection to CRT (Hot well Bypass)

15260

9 VFD provided for Coal handling Dust extraction System 283532


Title of Project



1 To reduce power consumption of cooling water system.( Cooling towers interconnection )

360000 -

2 Reduce power consumption of Compressors (Interconnection of Compressors)

520000

3 To save fuel( HSD) by Doing Boiler-4 commissioning with coal

- 1380000

4 AC,p&vControl room AC One Unit stopped (Current temp setting is 24 deg,Incresed to 26 deg)

131400

5 ACC fans power optimisation by locking maximum speed limit

596000

6 ACC-2 bundle shifting/modification job,ACC-2, 1st row bundles are of HDG MOC and 4th Row bundles are of Aluminium Extruded

618000

7 Energy saving by stage blinding of Boiler feed pumps 713000


Sno Project Status

Savings in Kwh Savings in Thermal

1 Install Auto Star delta star convertor for identified under loaded belt conveyor motors Not feasible, It should be considered factor of safety. NA

2 Replace 150 W HPMV Lamps with 48 W LED lamps in TG hall Completed 1787

3 Install Energy efficient florescent lamps for boilers Phase manner changes with LED lights,200 no s completed approx. 800 pending 22654

4 Reduce the pressure drop across the damper in L91BF1,L51BF2,L11BF1 Completed, All dampers removed 36500

5 Optimisation of instrument air Completed ,Auto drain valve timing adjusted 73000

6 Optimisation of service air Completed, Reduces the compressor set point as equal with IFC set point ,is about 3.8 Kg/cm2 at end point 54750

7 Optimisation of cooling circuit Completed,ACW discharge pressure reduced from 4.2 Kg/cm2 to 3.2 Kg/cm2. 456250

8 Optimisation of RO pump Completed,VFD provided and Closed loop developed as per process requirement. 18250

9 Optimisation of Condensate extraction pump completed, Closed loop logic developed for avoid pressure drop across the control valve. 201600

10 Install New efficient pump for CEP in all units Not feasible, While operating steam dumping at 100% additional flow required . NA

11 Reduce the pressure drop across the FRS in PH-2 BFP's

Closed loop logic developed with Steam drum pressure. At pressure minimum DP across the BFP header to Drum maintained 8 Kg/cm2. 317550

12 Reduction in radiation losses in Boiler Completed ,Identified areas insulation completed 507480 Kcal

13 Installation of expert Optimisation system for CPP Not feasible. NA


Total-13 Completed-10

Not feasible -3 nos

Scope 1 emissions CO e (MT)

Total CO e MT

Reduction in emission intensity since baseline year study

Remarks

2013 - 14 401350 Base line year

2014-15 458620 4556

2015-16 611443 3541

2016-17 432895 9450


Sno Title

1 Installed fast bus transfer system to uninterrupted boiler operation While tripping of turbine .

2 All VFD drives running with Closed loop operation Like Boiler feed pump,CEP etc.

3 Provided 11 KV VFD with MV drive for Boiler feed pump

4 ESP Charging ratio 1:7 to 1:1 with maintained Environmental norms.

5 Interconnection of Instrument and Service air line

6 Boiler blow down heat recovery with heat Exchanger

7 Ejector Steam tapping from Extraction line in stead of Mainstream line

8 PPF usage instead of HSD for boiler start-up


• Installed 12 no's of light pipe for buildings and Workshops .


Used 15.5 Mt of carbon black powder as alternate fuel.


Two way transportation for Rawmeal and fly ash handling with bulker.

Two way Transportation for Petcoke receipt and Cement dispatch.


13.71

11.60 11.03

10.01 10.27

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

2013-14 2014-15 2015-16 2016-17 2017-18

AP

C %

Last 3 years

85.5

87 88

81 81

3003 3034 3030

3118 3167

2000

2200

2400

2600

2800

3000

3200

3400

76

78

80

82

84

86

88

90

2013-14 2014-15 2015-16 2016-17 2017-18

PH

R K

cal/

Kw

h

• Planted 200 No's Trees in CPP for Last year 16-17 in the view of Vanam –Manam.



Documents

AP Cement Works - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Power/4... · Step Project Initiation SH (Opern) ... Reduction of Bed Height from 1010