Energy Audit & Energy

Conservation
Opportunities in
Electrical Equipments /
Auxiliaries
Manohar Tatwawadi
Principal Director, SYNERGEM
Power Plant Electrical Equipments /
Auxiliaries

PUMP, FAN,
TRANSFORMERS
MILL MOTORS

HT
HT MOTORS
TRANSFORMERS

LT
LT MOTORS
TRANSFORMERS
 HT MOTORS
• Induced Draft Fan Motors
• Forced Draft Motors
• Primary Fan Motors
• Coal Mill Motors
• BFP Motors
• Condensate Extraction Pump Motor
• Circulating water Pump Motors….. etc.
• The Total HT Aux. consume about 6 to 7% of
Generation.
 LT Motors

• Air preheater Motors

• Ash handling plant Motors
• Coal Handling Plant (HT & LT) Motors
• Air compressors
• Cooling water pump Motors
• WT Plant Motors
• The total LT Aux equipment may consume 1%
to 1.5% of the total load.
 Electrical Energy Consumption HT Aux.
Particulars 500 MW Plant 210 MW Plant 110 MW Plant 60 MW Plant 30 MW Plant

Rating Nos Rating Nos Rating Nos Rating Nos Rating Nos

Boiler Feed Pumps 10000 2 4000 2 3500 1 1340 1 570 1

Condensate 1180 2 225 2 175 2 175 1 68 LT 2

Extraction Pumps Mot

Circulating water 2885 2 1100 1 750 1 735 1 370 1

Pumps
Induced Draft Fans 3418 2 1300 2 800 2 360 3 120 4

Forced Draft fans 1535 2 750 2 400 2 200 2 100 4

Primary Air Fans 3309 2 1250 2 400 2 350 2 46 6

Coal mills Type 480 8 335 5 630 3 630 2 170 1

Bowl Mill Bowl Mill Tube Tube Tube
Mill Mill Mill
 Particulars Energy % of % of Total Aux % of Total
Consumptio Measure Power Energy
n MWh/day d Aux including UAT, Generatio
Power ST & GT n
Losses
Ash Handling 45.41 2.75 2.57 0.22
Plant
Coal Handling 24.53 1.49 1.39 0.12
Plant
Air Compressors 24.95 1.51 1.41 0.12
ACW & DMCW 40.86 2.48 2.32 0.20
Water Treatment 76.28 4.62 4.33 0.38
Plant
Total Outlaying 212.03 12.85 12.02 1.04
HT & LT
Boiler Feed 558.58 33.85 31.66 2.75
Pump
Cond. Extra. 95.83 5.81 5.43 0.47
Pump
Induced Draft 155.5 9.42 8.81 0.76
Fan
Forced Draft fan 40.22 2.44 2.28 0.20
Primary Air Fan 153.36 9.29 8.69 0.75
Circulating Water 177.36 10.75 10.05 0.87
Pump
Coal Mills 181.85 11.02 10.31 0.89
Total of In-House 1362.7 82.59 77.24 6.70
HT
Aux Transformer 25.98 1.57 1.47 0.13
Losses
Generator 98.47 5.58 0.48
transformer
Losses
UAT and Station 15.737 0.89 0.08
Transformer
Losses
Network Losses 20.82 1.26 1.18 0.10
Other LT Load 20.46 1.72 1.61 0.14
(Including
Lighting)
Total Aux. Power 1764.20 ---- 100.00 8.67
Including UAT,
ST & GT losses
Total Measured 1649.99 100.00 ----- 8.67
Aux Power
Total Energy 20340.96 ------ ------ 100.00
Generation
Design capacity and Operating Range
for HT Pumps/Motors/Fans
S.N. Equipment Parameter Design Operating
1 Boiler Feed Pump Flow 79.7 % 71 – 91%
Pressure 83.23 % 74 – 88%
2 Condenser Extraction Pressure 87.8% 85 – 105%
Pump Flow 93.2% 70 – 98%
3 Induced draft fan Pressure 52.1% 45 – 95%
Flow 65.4% 70 – 79%
4 Forced Draft fan Pressure 55.6% 33 – 51%
Flow 77% 60 – 68%
5 Primary Air Fan Pressure 69.2% 69 – 79%
Flow 74.3% 40 – 61%
Reasons for high Aux Consumption
• Plant Specific Factors: design deficiencies,
technology, lack of inst. & control, forced
outages, operational practices / constraints
• External Factors:- Fuel shortages, quality,
higher loading of ESP, Ash handling system
• Grid Specific Factors: Backing down of units,
Reactive power generation
 Loading of ID, FD, PA fans
• Illegal Furnace Air Ingress
• APH air leakage
• Debris in flue gas duct
• ID fan /Motor maintenance
• Oversized Motors etc.
• Increased Pressure drop across APH.
 Energy Conservation Measures… Fans
• New Technology Adoption such as
• Use of VFD for Fans for ID Fans as the load is
continuously varying between 65 – 75%.
• The installation of VFDs for ID Fans will reduce the
energy consumption around 5.3 MU per year for
one 210 MW unit with a payback period of less
than 3 Years.
• When motor cooling is provided as in the case of
BFP the coolers must be serviced and maintained.
 Variable Frequency Drive
• AC 50 Htz power converted to DC in the rectifier
unit.
• DC power is then converted to Controlled variable
frequency AC Power by an inverter using Thyristors.
• Output voltage is varied by changing the width and
polarity of switched pulses, whereas the output
frequency is adjusted by changing the switching
cycle time.
• This AC drives the variable speed motor.
 Variable Frequency Drives

Input Power

Variable
Frequency Variable
controller Frequency
Operators Power
Interface A.C. Motor

•During starting of VFD normally low freq and volt is

applied to the motor. So the High starting current is
reduced. This is known as soft start.
 Various applications for VFD
• ID Fans .. To control draft
• FD Fans … to control air supply
• Coal Feeders…. To control Coal supply
• Cooling water Pumps …. To control CW supply to
condenser
• Cooling Tower Fans…. To control CW inlet Temp.
• Cond Extr Pumps… to control Condenser level
• Boiler Feed Pump … to control Boiler Drum Level.
 Advantages of VFD
• Smooth Control of Flue gas.
• Absence of Limitation of number of starts.
• No Voltage dips in the system
• Increased efficiency over wide operating
speed range.
• Increased life of motors due to soft starts.
• Simple arrangements for cooling of Hydraulic
Coupling
• Reduction in size of unit/station Transformer.
 VFD For Boiler Feed Pumps

• The load on BFP is also continuously varying

and is about 2 to 2.5% of the Generation
• The installation of VFD will reduce the energy
consumption by around 13.8 MU per year per
210 MW Plant and the payback period upto 3
to 3.5 years.
 Steam driven BFPs
• The efficiency of conversion of the plant can
be increased from 33 to 35%.
• Equivalent power of about 7 MW in case of a
210 MW unit can be released to the grid.
• Better controllability as compared to Electric
Motor.
• Savings can be achieved at part load also.
 Mill Motors
• Variation in speed not required
• Motor currents vary due to variations in Coal,
Air.
• Restrict the input coal size.
• Increased DP across Mill will increase Mill
power.
• Coal fineness also affects the loading of the
mill.
 LT Auxiliaries - Motors
• Magnetic Losses: Dependent on the thickness
of the core stampings, applied voltage and
frequency.
• Copper Losses: Sensitive to the current flow in
the motor winding, quality of power supply
i.e. unbalanced voltage, voltage variations,
harmonics, winding temp etc.
 Voltage unbalance
• The design of the 3 Phase motor calls for a 3
phase balanced supply. The unbalance leads
to flow of additional negative sequence
currents in motors resulting in rise in the temp
of the windings.
• This will reduce the motor capacity.
• The operation of motor above 5% un balance
is not recomended
Variation of motor current and losses

35
Increased Unbalance Currents

30
nt
nt
25 e
rr
rre
u
dC
Cu

20
oa
and Losses in %

L
oa

15 ull
L

F
No

Losses
10
05

0.0 1.0 2.0 3.0 4.0 5.0

Voltage Unbalabce
 Voltage Variation
• At reduced input voltage, the motor output will
reduce and the losses will increase.
• The copper losses will increase by square of ∆
V.
• The torque is proportional to the square of
Voltage and is proportional to the slip.
• When voltage decreases, the torque decreases
and for maintaining the torque the slip
increases and speed falls.
 Harmonics
• Harmonic currents depending on their frequency
will cause additional rotating magnetic fields in
the motor.
• These magnetic fields rotate in the same direction
or in opposite direction based on the frequencies.
• The magnetic field created by 5th, 11th , 17th, 23rd ..
Is negative phase sequence and will cause reverse
torque. Other even harmonics also cause more
losses in the motor.
 Harmonics
• Voltage harmonics cause increase in iron
losses.
• Current harmonics cause increase in winding
losses.
• Harmonics can be suppresses by use of
necessary filters along with voltage stabilizers.
 Starting Characteristics
• For Direct starters the starting current is about 5
to 6 times the full load current.
• For star-delta starter the starting current is
approx 2 – 3 times the full load current.
• Star Delta starters are preferred when large no of
motors are to be started within a short period of
time.
• Delstar starters work as star delta starter during
startup and will convert to delta.
 Load Factor
• All the motors are designed for maximum
efficiency at full load.
• As the load factor decreases, motor efficiency
decreases.
• Idle running of motors consume power and
reduce power factor.
• Cost benefit analysis can be done for such cases
and appropriate motor sizing can be done.
 Speed and Duty Cycle
• For the same input power motors with higher
speed have a higher efficiency and high power
factor at rated load than lower speed motors.
• When the load varies with large nos of starts
and stops. To minimise the energy loss, the
duty cycle must be matched with the intended
duty
 Motor Rewindings
• While rewinding, sometimes the motor
assembly is heated for easy removal of
windings. This may damage the varnish
between the stampings of the stator core and
may increase the eddy currents.
• This may also cause the reduction in thickness
of the core and reduction in resistance of
magnetic path causing more eddy current loss.
 Energy Conservation Measures
• Voltage variation:- at 10% voltage drop the
torque reduces by 19% , current increases by
11% of Full load Current and efficiency reduces
by 1.1%.
• Unbalanced voltage:- Evenly distribute the load
in three phases.
• Due to single phasing the capacity will reduce
to half, in star two phases overloaded, in delta
one winding is overheated.
 Energy conservation measures
• Check up for bearing cooling systems.
• Set up filters and stabilizers for harmonics if
necessary.
• Use of starters for soft starts.
• Use higher speed motors wherever possible.
• Use proper duty cycle motors.
• Checkup the failures of the rewound motors
and conductor sizes in original motors. Etc.
TRANSFORMER LOSSES
 Transformers Iron losses
• Eddy current and
• Hysteresis loss
• Above losses due to idle charging, oversizing,
use of inferior core material, harmonics in the
distribution system etc.
• Metal glass (Amorphus) cores reduce the core
loss by 75%
• Cost about 2 times, payback period 2years.
 Suggested Measures
• Standby Transformers may be de-energized on
primary side.
• Increase the load factor to max if possible.
• Use methods for suppressions of harmonics by
using filters.
• Effective cooling of transformer: Sludge
formation in the oil, more acidity content of
oil, presence of dissolved gasses in oil.
 Tips for Energy Conservation for Industries
Motors
• Properly size to the load for optimum efficiency.
(High efficiency motors offer of 4 - 5% higher efficiency than standard motors)
• Use energy-efficient motors where economical.
• Use synchronous motors to improve power factor.
• Check alignment.
• Provide proper ventilation (For every 10 oC increase in motor operating
temperature over recommended peak, the motor life is estimated to be halved)
• Check for under-voltage and over-voltage conditions.
• Balance the three-phase power supply. (An imbalanced voltage can reduce 3 -
5% in motor input power)
• Demand efficiency restoration after motor rewinding. (If rewinding is not done
properly, the efficiency can be reduced by 5 - 8%)
Tips for Energy Conservation for Industries

Drives
• Use variable-speed drives for large variable loads.
• Use high-efficiency gear sets.
• Use precision alignment.
• Check belt tension regularly.
• Eliminate variable-pitch pulleys.
• Use flat belts as alternatives to v-belts.
• Use synthetic lubricants for large gearboxes.
• Eliminate eddy current couplings.
• Shut them off when not needed.
Tips for Energy Conservation for Industries
Fans
• Use smooth, well-rounded air inlet cones for fan air intakes.
• Avoid poor flow distribution at the fan inlet.
• Minimize fan inlet and outlet obstructions.
• Clean screens, filters, and fan blades regularly.
• Use aerofoil-shaped fan blades.
• Minimize fan speed.
• Use low-slip or flat belts.
• Check belt tension regularly.
• Eliminate variable pitch pulleys.
• Use variable speed drives for large variable fan loads.
• Use energy-efficient motors for continuous or near-continuous operation
• Eliminate leaks in ductwork.
• Minimise bends in ductwork
• Turn fans off when not needed.
 S E
EA
S PL
I O N
E ST
Q U

THANKS
MANOHAR TATWAWADI
E-mail;- mtatwawadi@gmail.com
Mob;- 9372167165