5

ENERGY SAVING PROJECT

REDUCTION IN CEP POWER CONSUMPTION

Background
The POG groups for FY 19-20 were created and Equipment efficiency was allotted to my team
on 21/04/2019,as a part of POG we started to calculate the efficiency of different equipment
with well-designed format in MS excel, in this process we struck the idea of VFD installation for
CEP with in-house available equipment’s and cable, the same was suggested in NOV-19 month
POG report of CEP, later discussed with HOD for feasibility and cross checked with equipment’s,
found viable and project executed.

Details of Innovated Idea

• CEP-1 was running with direct drive from 6.6KV source which had an average power
consumption of 345kwh at an 80% of unit full load capacity
• Post stoppage of HRBs, with only boiler-9 and boiler-10 running at full capacity, unit
load is limited to max 80% of full load capacity. But CEP will always be running at full RPM
which is causing higher DP across deaerator control station leading to energy loss in terms of
pressure and eventually in terms of power.

 Since boiler-10 was procured with two

boiler feed pumps with single VFD drive
for different reason, but due change in
the scenario, feed water for boiler-10 is
being pumped from-2 existing BFPs, so
procured boiler-10 BFPs were kept Idle.

 Finding this as an opportunity of IDLE

VFD utilization to save power, checked
for CEP motor suitability with VFD drive,
found matching and taken the supply for
CEP-1 motor from boiler-10 VFD. After
installing VFD CEP-1 RPM reduced from
1460RPM to 1344 RPM and discharge
pressure reduced from 19.5 KSC to
16.2KSC.

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ENERGY SAVING PROJECT

Benefits
• After installation Power consumption of CEP-1 reduced from an average of 345kwh
reduced to an average of 285Kwh for an 80% of unit full load capacity. The discharge pressure
dropped from 19.5 ksc & 16.5 ksc and RPM reduced from 1460 to 1344 RPM (power
consumption data from generation report)
• The Benefit of saving 5760 rupees per day calculated after installation of VFD to CEP-1

Highlights
 Utilization of already existing Boiler-10 Idle VFD
 Utilization of IDFAN-5 cable to connect CEP motor to VFD panel.
 Reduction in RPM, pressure and subsequent power saving with in-house modification.
 Since it is implemented with all in-house available sources, it is not applicable for ROI

Key dates
POG group formation and allotment – 21/04/2019
Suggestion given through POG report – 19/11/2019
Cable disconnection from IDFAN-5 for CEP VFD connection started on – 18/12/2019
Implementation and Commissioning of Project – 29/02/2020

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ENERGY SAVING PROJECT

Month Avg Kwh

Dec-19 349.97
Jan-20 349.45
Feb-20 347.32
Mar-20 280.8
Apr-20 272.73
May-20 289.83
Jun-20 284.68
Jul-20 289.44
Aug-20 286.41
Sep-20 289.55
Oct-20 295.33
Nov-20 296.65
Dec-20 293.26
Jan-21 290.18
Feb-21 291.43
Mar-21 292.72

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ENERGY SAVING PROJECT

   
 

Kaizen Department:
Project Date:17-
Project 2- Quality Circle Name:
No: 03-2020
Format OPERATIONS

Title of Project: Reducing power consumption of Condensate Extraction pump

by installing VFD

Category: ( * ) Productivity, ( ) Quality, ( * ) Cost, ( ) Delivery, ( )

Safety, ( ) Morale, ( ) Environment
Before Root Cause
Improvement Measures After (Situation)
(Situation) Analysis
CEP-1 was Why power Power consumption
running with consumption of CEP-1 reduced
direct drive CEP-1 is from an average of
from 6.6KV more. 345kwh reduced to
source Post stoppage an average of
which had of HRBs,with 285Kwh for an 80%
an average only boiler-9 of unit full load
power and boiler-10 capacity.The
consumption running at full discharge pressure
of 345kwh capacity,unit dropped from 19.5
at an 80% load is limited ksc & 16.5 ksc. And
of unit full to max 80% RPM reduced from
load of full load 1460 to 1344
capacity capacity.but RPM(power
CEP will consumption data
always be from generation
running at full report)
RPM which is
causing higher
DP across
deareator
control station
leading to
energy loss in
terms of
pressure and CEP-1 Power Consumption
Reduction in RPM
eventually in 400 345
terms of 1500
1460 102%
285
power. 1450 100%
1400 98%
200
1344 96%
1350
94%
1300 92%
0
1250
BEFORE AFTER 90%
1200 88%

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Photo

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