Controlling Auxiliary Power
Consumption
Requirement of Energy
Management in Utilities
Improvement in PLF
Reduction in APC
Requirement of Energy Management in
Utilities – Ways to Improve
Energy Audit followed by implementation of
recommendations.
Energy Management System: By taking
action on shortcomings indicated and reports
generated.
Stand-Alone Meters are not enough
Generally provide only Raw Data
Readings cannot be correlated on-line,
in Real-Time
Difficult to relate Energy Consumption in
Auxiliaries to Generation
Optimisation requires On-Line Data. Difficult to
achieve with Stand-Alone Instruments.
THERMAL STATIONS
AUXILIARIES MAY CONSUME 6%TO 14%
OF TOTAL GENERATION
EACH ONE PERCENT REDUCTION CAN
RESULT IN SAVINGS OF CRORES
ANNUALLY AND RELEASE A FEW
MEGAWATTS
NO REDUCTION POSSIBLE UNLESS
CONSUMPTION IN EACH MEASURED
THERMAL AUXILIARIES
NO EXISTING SYSTEM OF
MEASUREMENT OF ENERGY
CONSUMPTION IN AUXILIARIES
AUXILIARY CONSUMPTION CALCULATED
FROM DIFFERENCE OF POWER
GENERATED AND POWER TRANSMITTED
THERMAL AUXILIARIES
AS NO DIRECT MEASUREMENT IS BEING
DONE APC CALCULATION IS
APPROXIMATE
EFFICIENCY OF EACH EQUIPMENT IS
UNAVAILABLE
LOSS OF EFFICIENCY DUE TO
TECHNICAL / MAINTENANCE REASON
CANNOT BE ASCERTAINED
THERMAL AUXILIARIES
•FOR A TYPICAL 210 MW UNIT
•HT MOTORS 6.6 KV - 43 NO’S
•LT MOTORS 415 V - 510 NO’S
TOTAL CONNECTED LOAD - 36.5 MW
= 17.5%
THERMAL AUXILIARIES
PROPOSED ENERGY MONITORING
•HT MOTORS - 43 NO’S
PLUS STATION AUXILIARIES ( CW AND ASH
SLURRY PUMPS) TOTALLING APPROX 50
MONITORING POINTS FOR EACH 210 MW
UNIT
THERMAL AUXILIARIES
FOR OTHER MOTORS
USE OF PORTABLE ANALYSER ON
AS REQD. BASIS
RELEVANCE OF ENERGY
CONSERVATION
MAXIMISE DESPATCH OF ENERGY BY
MINIMISING INTERNAL USAGE
ENERGY USAGE MINIMISED BY
OBTAINING OPTIMUM EFFICENCY
ADVANTAGES OF ON LINE
MONITORING
ENERGY CONSUMPTION OF MAJOR
AUXILIARIES WILL BE AVAILABLE
PROPER ACCOUNTING AND ENERGY
BALANCE POSSIBLE
LOSSES CAN BE DETERMINED
DETERIORATION OF EFFIENCY CAN BE
IDENTIFIED AND CORRECTED AT FIRST
OPPORTUNITY
ADVANTAGES …
PROPER COSTING OF ENERGY
GENERATION
ACCURATE ON LINE DATA ELIMINATING
HUMAN ERRORS
BENCHMARKS CAN BE SET FOR PLANT
COMPARISON WITHIN AND WITHOUT
POSSIBLE
CASE STUDY
BOILER FEED PUMP
Thermal Unit ( 210 MW )
ITEM KWH KWH / DAY
BFP-1B 2085 55938
BFP-1C 2312 62285
FD Fan-1A 380 10797
FD Fan-1B 383 10879
ID Fan-1A 770 21280
ID Fan-1B 800 22820
PA Fan-1A 780 18210
PA Fan-1B 780 18135
Case Study – Boiler Feed Pump
Boiler feed pump 1C showed higher energy
consumption.
This pump was overhauled in recent past by
manufacturer.
The pump internals ( cartridge ) was also
replaced recently.
New technology valve was also fitted in this
pump.
Case Study contd.
All factors stated should have resulted in lower energy
consumption .Obvious conclusion was that
measurements were incorrect.
Meter was rechecked and recalibrated.
Software for on line monitoring was also checked but
no fault could be located.
Pump continued to show higher consumption.
Case Study contd.
As running 210 MW unit could not be shut down,
checks were carried out on motor as well as the pump
in operation.
Results were inconclusive as no defects could be
ascertained.
Plant authorities decided to wait till next scheduled
shut down.
For over two months pump operated with excess
consumption of 6500 units per day.
Case Study - Conclusion
During shut down, the pump was dismantled.
Observed that in the recirculating valve there
was a gap resulting in higher energy for
same pumping requirement.
From the BFP itself, On line monitoring
system could payback in less than two
months.
Analogue ammeter of say 500 Amp full scale
may not show noticeable difference between
228 and 252 Amps
Another Case Study of BFP
Operation
In another NTPC unit, BFP- B was drawing
3450 KW average load whereas BFP – A
was drawing 3187 KW. There was no change
in unit output, Feed water flow or change in
main steam pressure .
Further investigation has revealed higher
clearances in BFP – B. Change of cartridge
has been planned.
BFPs – Some Relevant issues
Recirculating Valves – Problem of passing
even when indication of valve being closed.
Detection Possibilities
> By means of temperature increase
across the valve
> By means of increase in energy
consumption
BFPs – Specific Energy
Consumption
S p e c ific E n e rg y C o n s u m p tio n
8 .4 8 8 .3 9
8 .4 0
S E C , k W /T P H
8 .3 2
8 .2 4 8 .1 4
8 .1 3 8 .1 3
8 .1 6 8 .0 7
8 .1 0
8 .0 8 8 .0 3
8 .0 0 A ve ra g e 8 .0 8 k W /T P H
7 .9 1
7 .9 2 7 .8 7
7 .8 4
7 .7 6
7 .6 8
7 .6 0
1 A 1 B 1 C 2 A 2 B 2 C 3 A 3 B 3 C
P u m p Id e n tific a tio n
Effect of Closing Manual
Recirculating Valve
LOAD VARIATION OF BFP 1A(U#1)
2750
2725
2700
2675
2650
kW
2625
2600
2575
2550
2525
2500
Time
Effect of Closing Manual
Recirculating Valve
LOAD VARIATION OF BFP 1B(U#1)
2825
2800
2775
2750
2725
2700
2675
kW
2650
2625
2600
2575
2550
2525
2500
M M M 0 0
AM AM AM AM AM AM AM 0 P 0 P 0 P AM AM AM AM AM AM AM AM AM AM AM 0: 0 4: 0
0 0 0 0 0 0 0 :0 :0 :0 0 0 0 0 0 0 0 0 0 0 0
0 2:0 2:0
:0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 00 : 20 : 40 : 00 : 20 : 40 : :00 :20 :40 00: 20: 24: 28: 32: 36: 40: 44: 48: 52: 56:
0 0
4
9: 10: 10: 10: 11: 11: 11: 12 12 12 1: 1: 1: 1: 1: 1: 1: 1: 1: 1: 1:
Time
BFP Savings - Stopping Recirculation
by Valve Replacement
Unit-
Description Units Unit-1 Unit-2 3
*Power Reduction kW 145 155 70
Annual operating hrs Hrs@ 340 days per annum 8160 8160 8160
Energy Savings MU/annum 1.18 1.26 0.57
Monetary Savings Rs. in Lakhs/annum 20.7 22.2 10
**Investment Rs. in Lakhs 30 30 15
Payback period Months 18 17 18
BFP Savings contd.
Total energy savings = 3.01 MU per
annum
Total savings = Rs. 52.9 Lakhs per
annum
Total investment = Rs. 75 Lakhs per
annum
Overall payback period = 17 Months
Condensate Extraction Pumps
In an NTPC unit, it was observed that CEP-C
was having higher power consumption
compared to CEPs – A & B even though load
and operating conditions were the same.
CEP- C has now been kept standby saving
10 to 15 KW.
Condensate Extraction – Control
valve
Usually huge loss of pressure across the
valve.
Energy saving possible through use of VFDs
Problem of VFD control – integration thru
SCADA
Condensate extraction pump –
Use of VFDs
Drop Across Control Valve MLC 100 100 100
Power Consumption KW 450 458 460
Expected Conditions with VFD
Drop Across Control Valve MLC 30 30 30
Expected power consumption KW 350 358 360
Saving Potential
Saving Potential KW 100 100 100
Operating Hours (340 days x 24 hrs) Hrs 8160 8160 8160
Potential Savings per annum MU 0.81 0.81 0.81
Monetary savings Rs. in
Lakhs 14.5 14.5 14.5
Expected investment Rs. in
Lakhs 50 50 50
Simple payback Months 42 42 42
Case Study
Coal Mill
COAL MILL
In the Coal mills power consumption
increases with wear of grind rolls.
Thus it should be possible to establish a
relation between run hours and power
consumption.
Actual spot readings taken with energy
meters in a coal mill are shown in the next
slide with attempt to establish some pattern
in the next two slides.
COAL MILL
Coal Mill
Coal Mill - Analysis
From energy meter readings it is not possible
to establish any relationship .
Noting Specific Power Consumption trend on
line from 0 to 2500 hrs can enable
extrapolation to say 3500 hrs or even 4000
hrs.
Prediction of Specific power consumption at
4000 hrs and consequently extra power
consumption vs cost can provide an
optimum replacement point in no of hours for
each mill as characterstics for each are
different.
Coal Mill - Analysis
When Bullring replacement is done it is
necessary to know whether Specific power
consumption has changed as compared to
original state.
If not, there could be other causes also which
contribute to higher consumption.
Actual power consumption of a coal mill is
shown in next slide. Mill E is showing
unusually high consumption.
Case : 1
DAILY POWER CONSUMPTION & [Link]
UNIT-1 UNIT-2 UNIT-3 UNIT-4
EQUIPMENT NAME AVG. KW AVG. KW AVG. KW AVG. KW
MILL-A 139 160 161 153
MILL-B 135 147 166 148
MILL-C 148 141 163 151
MILL-D 131 144 158 157
MILL-E 173 0 159 142
MILL-F 148 139 138 145
[Link] 146 146 158 149
Coal Mill
Looking at high consumption mill E is
attended to for necessary repair and
maintenance.
Results of correct operation can be seen in
the next slide – a reduction of over 50 KW in
one mill.
DAILY POWER CONSUMPTION & [Link]
UNIT-1 UNIT-2 UNIT-3 UNIT-4
EQUIPMENT NAME AVG. KW AVG. KW AVG. KW AVG. KW
MILL-A 134 139 142 149
MILL-B 119 124 133 131
MILL-C 138 117 159 149
MILL-D 0 130 153 138
MILL-E 121 119 0 120
MILL-F 124 0 102 0
[Link] 127 126 138 137
CASE STUDY
COAL HANDLING PLANT
Case Study – Coal Handling Plant
NTPC had taken over Thermal Station from Electricity
Board against dues.
Station had low PLF and high auxiliary power
consumption.
NTPC made substantial improvements on both
achieving PLF better than 85 % and auxiliary
consumption at approx 12 %.
Station has 4 x 210 MW units
Case Study contd.
Plateauing of further gains in Auxiliary Power
consumption occurred.
Unit auxiliaries were in focus for reduction but station
auxiliaries not given adequate attention.
Coal Handling plant tended to be neglected being out
of sight.
Plant authorities decided to focus on CHP.
Case Study contd.
Energy meters were installed in CHP.
Consumption was measured in conveyors and
crushers.
No opportunity for reduction could be established.
Use of power analyser also could not result in
substantial reduction.
It was decided to have a demo energy management
system.
Case Study - Conclusion
EMS provided on line data of consumption with relation
to time.
Conveyor was observed to be consistently
underloaded.
Crusher was actually operating for only a few hours
per day but remained on all the time.
With improvements in operation indicated by EMS the
station has achieved further gains.
Operation of Crusher
Next slide shows from actual coal crusher the
trend of energy consumption on a particular
day.
On line data shows crusher operation is
proper in the beginning and towards the later
part.
In the middle portion for considerable period
the crusher is not optimally loaded
Case : 2
On Line Monitoring System
Other Applications
On Line Monitoring - Applications
In the previous slide daily energy
consumption of main auxiliaries for four units
of a thermal power plant can be seen
together. By comparison within the plant it is
possible to see the most efficient pump from
similar units.
In the next slide an actual measurement of
phasewise power factor of auxiliary motor is
seen for imbalance in motor winding which
results in excess power consumption.
MILL-1 A 0.778 0.765 0.786 MILL-2A 0.746 0.738 0.752
MILL-1 B 0.737 0.714 0.740 MILL-2B 0.729 0.722 0.752
MILL-1 C 0.734 0.717 0.738 MILL-2C 0.687 0.670 0.699
MILL-1 D 0.724 0.715 0.720 MILL-2D 0.781 0.775 0.787
MILL-1 F 0.705 0.680 0.717 MILL-2F 0.714 0.710 0.727
MILL-3 A 0.744 0.733 0.749 MILL-4A 0.787 0.779 0.800
MILL-3 B 0.752 0.736 0.753 MILL-4B 0.713 0.701 0.721
MILL-3 C 0.000 0.000 0.000 MILL-4C 0.726 0.725 0.735
MILL-3 D 0.759 0.744 0.762 MILL-4D 0.712 0.699 0.718
MILL-3 E 0.754 0.746 0.739 MILL-4E 0.716 0.704 0.723
MILL-3 F 0.682 0.662 0.678 MILL-4F 0.000 0.000 0.000
ASH P/P-A2 0.000 0.000 0.000 CW -1B 0.725 0.713 0.729
ASH P/P-B1 0.709 0.687 0.730 CW -2A 0.723 0.725 0.731
ASH P/P-B2 0.723 0.696 0.739 CW -2B 0.733 0.730 0.740
ASH P/P-C1 0.731 0.711 0.753 CW -3A 0.716 0.707 0.719
ASH P/P-C2 0.762 0.752 0.774 CW -3B 0.751 0.745 0.755
ASH P/P-D1 0.000 0.000 0.000 CW -4A 0.709 0.700 0.713
ASH P/P-D2 0.000 0.000 0.000 CW -4B 0.715 0.701 0.721
BCW -1 0.000 0.000 0.000 CW -9 0.685 0.663 0.695
BCW -2 0.852 0.849 0.866 CRUSHER-A 0.191 0.103 0.164
BCW -3 0.817 0.807 0.836 CRUSHER-B 0.201 0.116 0.166
BCW -4 0.855 0.840 0.847
Coal Mill Operation
In the next three slides daily report of coal
mills is shown.
Mill D shows increasing power consumption
trend from 18/3 to 23/3.
18-03-06 19-03-06
EQUIPMENT AVG. AVG. AVG. AVG. AVG. AVG. AVG. AVG.
NAME KW KW KW KW KW KW KW KW
FD FAN-A 214 199 192 206 214 199 191 205
FD FAN-B 184 187 175 199 184 185 175 198
MILL-A 163 142 149 152 162 149 161 159
MILL-B 157 140 149 143 147 149 163 146
MILL-C 163 136 156 161 154 148 164 166
MILL-D 147 137 155 160 154 140 160 157
MILL-E 141 144 144 24 162 130 130 0
MILL-F 78 112 106 137 0 0 136 137
20-03-06 21-03-06
EQUIPMENT AVG. AVG. AVG. AVG. AVG. AVG. AVG. AVG.
NAME KW KW KW KW KW KW KW KW
FD FAN-A 215 196 189 202 212 195 188 200
FD FAN-B 186 185 172 196 191 188 170 194
MILL-A 162 159 159 161 161 159 160 144
MILL-B 146 149 154 152 147 154 157 151
MILL-C 158 147 156 165 157 140 142 164
MILL-D 154 140 150 165 151 136 145 151
MILL-E 143 130 119 131 144 120 129 143
MILL-F 145 0 141 144 129 0 76 124
22-03-06 23-03-06
EQUIPMENT AVG. AVG. AVG. AVG. AVG. AVG. AVG. AVG.
NAME KW KW KW KW KW KW KW KW
FD FAN-A 214 192 191 201 222 192 192 202
FD FAN-B 178 189 172 195 190 195 173 196
FD FANS 196 190 182 198 206 193 182 199
MILL-A 156 162 161 150 156 154 158 158
MILL-B 163 134 168 154 149 144 161 150
MILL-C 169 149 161 161 145 137 158 160
MILL-D 157 144 153 154 155 132 156 150
MILL-E 164 124 151 146 150 142 146 144
MILL-F 146 134 109 0 143 143 0 0
Coal Mill Operation
On 26/3 , Mill D had a breakdown.
Thus by monitoring energy consumption it
maybe possible to anticipate breakdowns.
Effect of Voltage Variation
Ideally, voltage at secondary of UATs and
STs should be kept constant. Many power
plants do not control voltage.
Variation in voltage effects auxiliary power
consumption – increase as well as decrease
– can take place.
On line system can be used to know the
effect of variation.
Specific Power Consumption In
Main Auxiliaries
The next slide shows daily Specific energy
consumption report of various auxiliaries of
four units with best ones in blue and worst in
red.
For the calculation of SEC data for air or
water flow is obtained from DCS
SPECIFIC ENERGY CONSUMPTION REPORT
System Fan Unit -1 Unit-2 Unit-3 Unit-4
Fan-A 1.61 1.86 1.75
Fan-B 1.57 1.81 1.64
ID Fans
Fan-C 1.92 1.67
Fan-A 1.45 1.35 1.14 1.42
FD Fans
Fan-B 1.25 1.24 1.12 1.50
Fan-A 9.69 9.21 10.52 8.77
PA Fans
Fan-B 9.55 9.48 10.10 8.85
Pump-A 7.91 8.07 9.0 7.15
BFPs Pump-B
