Professional Documents
Culture Documents
June 2014
CONTENTS
Chapter
No.
Description
Page
No.
Executive Summary
Introduction
II
Acknowledgment
III
IV
50
Annexure
53
Backup Calculations
75
EXECUTIVE SUMMARY
K R Pulp & Papers Limited is among Indias leading manufacturers of ecofriendly paper enriched with the expertise and experience of around two
decades in making paper from non conventional raw material i.e. Bagasse, a
residue of sugar cane.
Incorporated in 1995, the company has two fully integrated pulp and paper
manufacturing facilities situated in Shahjahanpur district in the state of Uttar
Pradesh in India. The Unit-1 is used to manufacture Kraft paper while Unit-2 is
used to manufacture White paper.
CII has conducted the Detailed Energy Audit at K R Pulp & Papers Limited,
Shahjahanpur Plant from 10th to 17th April, 2014. A detailed presentation was
made to the plant team covering various energy conservation opportunities on
17th April, 2014. The combined efforts of K R Pulp & Papers Limited and CIIGodrej GBC team have together identified, annual energy saving potential of
Rs. 434.10 Lakhs, based on present energy cost.:
No. of
Proposals
Annual
savings in
Lakhs
23
434.10
107.30
19
326.80
Investment Required
19
183.90
Months
Details
CHAPTER - I
INTRODUCTION
K R Pulp & Papers Limited, Shahjahanpur evinced interest in availing the
services of Confederation of Indian Industry for conducting a detailed energy
audit in their factory.
This report on the detailed energy audit carried out at K R Pulp & Papers
Limited, Shahjahanpur, is in accordance with CIIs proposal, agreed by K R
Pulp & Papers Limited, Shahjahanpur vide their work order No.
KRPL/UNIT-2/2013-14/260274 dated 28th February 2014.
The detailed energy audit comprised of the following activities:
Detailed data collection of power consuming equipments, production
capacities of major equipment, operating parameters and section wise
specific power consumption.
Power measurements of major electrical energy consumers.
Measurement of efficiency of major power consuming equipment such as
fans etc.,
A detailed training programme on energy management was conducted to
seek more inputs from the plant personnel
Analysis of collected data and measurements to develop specific energy
saving proposals.
Discussion with the plant personnel on the identified proposals.
Presentation on the findings of detailed energy audit to plant personnel.
We are pleased to mention that all the identified energy savings proposals
have been discussed with plant executives concerned before finalising the
Projects.
The contents of the report are based on the data provided by K R Pulp &
Papers Limited, Shahjahanpur plant personnel during the detailed energy
audit.
The plant personnel should implement the suggestions made in the report
after verifying safety aspects. It is the responsibility of the plant personnel to
observe statutory regulations, if any, as applicable to the factory.
CHAPTER - II
ACKNOWLEDGMENT
CII acknowledges with thanks the co-operation and the hospitality extended to
the CII energy audit team during the detailed energy audit at K R Pulp &
Papers Limited, Shahjahanpur.
The interactions and deliberations with K R Pulp & Papers Limited team
were exemplary and the whole exercise was thoroughly a rewarding
experience for CII.
The arrangements and support during the energy audit were excellent. We
deeply appreciate the interest, enthusiasm and commitment of K R Pulp &
Papers Limited, Shahjahanpur team towards the energy conservation.
We would also like to place on record our sincere thanks and appreciation for
all the senior plant executives.
CHAPTER - III
LIST OF ENERGY SAVING PROPOSALS
Sl.
No
Annnual Savings
(Rs.Lakhs)
Investment
Required
(Rs.Lakhs)
Payback
Period
(Months)
100.00
2.10
5.00
2.00
56.80
47.40
10
8.80
8.0
11
8.40
10.00
15
43.00
19.50
4.00
4.50
14
9.00
5.00
10
27.00
1.00
11
4.80
8.0
20
12
2.40
1.00
13
2.0
14
4.00
3.00
15
32.00
8.00
16
3.20
17
2.00
1.50
18
3.20
1.00
19
16.40
10.00
20
6.00
5.00
15
21
55.20
25.00
22
34.40
20.00
23
4.40
4.00
11
434.10
183.90
Total
Chapter IV
Energy Saving Proposals
15000 kVA
Number of phase
3 phase
Number of poles
4 pole
Rated voltage
11 kV
Rated current
787 A
Rated Power
12000 kW
0.8 pf
Rated speed
1500 rpm
15000 kVA
Number of phase
3 phase
Number of poles
4 pole
Rated voltage
11 kV
Rated current
787 A
Rated Power
12000 kW
0.8 pf
Rated speed
1500 rpm
Proposed system
We recommend to reduce the frequency and operate it at 49 Hz. The
reduction in frequency will majorly reduce the power consumed by
centrifugal equipment. The power consumed by centrifugal equipment are
is proportional to cube of speed and the power consumed by positive
displacement equipment arepower consumed by positive displacement
equipment is proportional to the speed. WithAlso, by reducing the the
reduction in frequency the power consumed by individual motors also
reduce, due to the reduction in no load losses of the motor. In order to
obtain the savings on a conservative basis only 40% of centrifugal
equipment are considered for calculation of energy savings.
Since the alternator TG1 is operating isolated from the grid and also due
to the margin available in the equipment, there is a good potential to
optimize the frequency of the plant to 49 Hz.
A small variation in speed will lead to appreciable reduction in the power
consumption of the plant. The frequency reduction is only possible for the
situation when plant is running without synchronization with grid.
Steps involved in frequency reduction
1
2
3The frequency of the alternator can be reduced by reducing the turbine
speed. In K R Pulp and Paper a trial was taken along with the plant team
and the frequency was reduced to 49.5 Hz. CII congratulates the plant
team on the excellent effort.
With the reduction in frequency the power consumed by individual
motors also reduce, due to the reduction in no load losses of the
motor. The turbine rpm can be reduced to 10545 rpm to maintain
the alternator frequency as 49 Hz.
Abstract of Trial Taken at siteTrial to reduce alternator frequency
to 49.5 Hz
A trial was taken with discussions from the plant team and the frequency
was reduced to 49.5 Hz from 50 Hz. CII thanks the plant team for helping
extending all the support in taking the trial. us take the trial.
The speed of the prime mover corresponding to 50 Hz of operation is
10760 rpm, which in turn corresponds to 1500 rpm of the alternator. This
rpm was reduced from 10760 rpm to 10653 rpm. The speed of the prime
mover and correspondingly the frequency of the alternator was reduced
from 50 Hz from 49.5 Hz.
When the frequency of the alternator was reduced from 10760 50 to
10653 49.5 rpmHz, the power produced by the alternator showed an
immediate reduction of 180 kW. This reduction of 180 kW of
reductionobserved is instantaneous, as the frequencies of VFDs readjust
itself to the required frequency of operation within few cycles. Also, during
this reduction in power produced by the alternator, a reduction of 1.55
TPH of steam consumption was also observed.
The immediate change of values observed during the trial arechange of
values/results observed during the trial is mentioned in the table below:
Parameter
Frequency of the
Alternator
50 Hz
49.5 Hz
10760 rpm
10653 rpm
Generation MW
10.97 MW
10.79 MW
Capacity TPH
79.42
77.87
The graph shown above is drawn for loading at , , and full load. For
each loading of the motor there is an optimum voltage point where the
total motor loss is at minimum for that condition of loading. Reducing the
voltage below the optimum point, the motor capacity gets derated and
the current flowing through the motor increases i.e. voltage below the
optimum point derates the motor.
Confederation of Indian Industry
The motor has to draw a fixed amount of power to satisfy the shaft power
for specific loading conditions. Since, the terminal voltage of the motor
reduces the current is increased to meet the shaft power. This causes an
increase in current and hence increases copper losses in the stator and
the rotor and during this condition of low voltage the no load loss is lower
as compared to the higher voltage applied to the motor.
The voltage drop at the motor terminals should be seen based on the
length of the cable, size of the cable installed, based on the power factor
of the motor and also due to any loose connections in lugs or the wiring of
the motor. According to IEC 60038 a 415V motor can be safely operated
with a range 230/400V +10% and -6% at the MCC and also 4% voltage
drop is allowed at the supply terminals. The motors are generally
designed to handle a voltage variation of 10% from the rated value.
Motors consuming low power factor may have higher voltage drop and
can be compensated by installing capacitor banks at the motor terminals
or motor DBs. Care should be taken while installing capacitor banks at the
motor terminals, that the installed kVAR of the capacitance should not
exceed the no load kVAR of the motor.
Since the voltage maintained at the motor terminals may lie below the
optimum voltage point as explained above, the current consumed by the
motors may increase, which may increase the copper losses in the motor.
But the reduction of voltage reduces the magnetization losses of the
motor and can be significantly reduce the energy consumed in the plant.
The loading of the motors in the plant has been observed to be 70 85%,
the current consumed by the motors will not exceed the full load current
of the motor, due to the reduction in voltage and the motor can be safely
operated.
Proposed system
In general for an AC induction motor operating at a higher voltage than
rated, the no load losses can be reduced by reducing the voltage to the
rated value. As a thumb rule there is 1% reduction in power consumption
for every 4% reduction in voltage. Based on this the thumb rule of 1%
reduction in power consumption for every 4% reduction in voltage, power
savings of 6 kW can be achieved in the plant by reducing one tap setting
of the distribution transformers(11kV/433V).
Taps setting of the Transformers and corresponding HT and LT
Voltages
Tap Position
HT Voltage (V)
11650
2(Recommended)
11275
3(Current)
11000
LT Voltage (V)
10725
10450
10175
9900
433
Proposed system
In general for an AC induction motor operating at a higher voltage than
rated, the no load losses can be reduced by reducing the voltage to the
rated value. As a thumb rule there is 1% reduction in power consumption
for every 4% reduction in voltage. Based on this the thumb rule of 1%
reduction in power consumption for every 4% reduction in voltage, power
savings of 6 kW can be achieved in the plant by reducing one tap setting
of the distribution transformers(11kV/433V).
The tap settings of Transformer 5 are mentioned in the table above. The
current tap setting of the transformer is at 3 rd tap. The current tap setting
maintains a voltage of 427 V. This voltage can be reduced closer to 415 V,
at which the motors in the plant are designed. This gives us a good
opportunity to reduce the plant voltage to 415 V.
The tap settings of Transformer 5 are mentioned in the table below. The
current tap setting of the transformer is at 3 rd tap. The current tap setting
maintains a voltage of 427 V. This voltage can be reduced closer to 415 V,
at which the motors in the plant are designed. This gives us a good
opportunity to reduce the plant voltage to 415 V.
Recommendation
Currently all the distribution transformers are rated for 11kV/433V. The
tap position is in the normal tap of 43. It is recommended to reduce the
tap settings of Transformer 5 4th to 3rd tap in order to:
Maintain 415 420 V as the distribution transformer output voltage
IMPROVE
THE
POWER
FACTOR
OF
PURCHASED FROM ELECTRICITY BOARD
POWER
Benefits
Annual energy savings of Rs 5.00 Lakhs can be achieved. The
investment required for the capacitor banks are Rs 2.00 Lakhs, which is
paid back in 5 months.
INSTALL
VARIABLE
FREQUENCY
IDENTIFIED PUMPS IN PULP MILL
DRIVES
IN
During the Detailed Energy Audit conducted at K R Pulp & Papers Ltd.,
Shahjahanpur, the pumping systems were studied for energy saving
potential.
Present Status
Many of the pumps in the pulp mill in Unit-II were found to be controlled
through control valves. The flow requirement in the below mentioned
pumps varies on the basis of production levels and the consistency to be
maintained in the respective chests. The pumps would have been
designed for maximum production and hence the flows are generally
controlled through valves.
Closing of the valve creates an artificial resistance to the flow, additional
to the system resistance. This pressure drop across the valve is a
mechanical energy loss which is also included in the work done by the
pump. It is estimated that about 10-40% of the pump power consumption
is lost across the valve.
All these pumps as mentioned below operates at varying load depending
upon the rate of production. The present method of controlling the flow is
through valve throttling which is an inefficient way of controlling the flow.
This energy loss can be prevented saved by varying the capacity flow of
the pump according to the requirement. The flow of the pump can be
varied by varying the speed of the pump using a Variable frequency drive.
By reducing the speed of the speed of the pump, the required flow can be
maintained without closing the throttle valves. As pump power is directly
proportional to the operating head of the pump, there is good potential to
for saving power.
The details of the various pumps operated with valve throttling is as given
below
Valve
Power
Opening
kW
%
Name of Pump
Tag
Name
PU 76
57
Continuous Digester
Dilution Pump
PU 74
48
kW
Saving
Flow
m3/hr
35-60
11
440
35
14
72.8
PU 119
60
12
18
400
PU 100
17
50
120
PU 96
66
25
19.5
500
PU 101
17
50
130
Washed HD Tower
Pump
PU 116
71
80
HD Dilution Pump
PU 126
54
50
16
Secondary Screen
Pump
PU 132
21
30
Screened HD Tower
Pump
PU 146
24
50
LC Chest Pump
PU 150
24
15
Screened HD Tower
Dilution Pump
PU 165
54
25, 14
16
PU 169
15
28
4.5
PU 171
54
60
10.5
Thus there is excellent potential to save energy by installing VFDs for the
pumps and varying flow as per requirement.
Recommendation
We recommend the following:
Install Variable Frequency Drives for the identified pumps
Operate these pumps with suggested VFD feedback
Vary speed of pump to maintain required flowOptimize the power
consumption
Benefits
INSTALL
VARIABLE
FREQUENCY
DRIVES
CENTRICLEANER PUMPS IN PULP MILL
IN
During the Detailed Energy Audit conducted at K R Pulp & Papers Ltd.,
Shahjahanpur, the pumping systems were studied for energy saving
potential.
Present Status
The Centricleaner pump in the pulp mill in Unit-II was found to be
controlled through a control valve. The flow requirement in the pump
varies on the basis of production levels.
2.6 bar
0.6 bar
To Screen Washer
Primary Centricleaner
Primary Centricleaner
Standpipe
40% open
3.4 bar
PU 128
84 kW
This energy loss can be prevented by varying the capacity of the pump
according to the requirement. This can be achieved by installing variable
frequency drive to the pump. The flow of the pump can be varied by
varying the speed of the pump using a Variable frequency drive. By
reducing the speed of the speed of the pump, the required flow can be
maintained without closing the throttle valve.
Recommendation
We recommend the following:
Install Variable Frequency Drives for the primary centricleaner pump in
pulp mill
What is the feedback to the VFD???????????????
Vary speed of pump to maintain required flow
Benefits
The annual savings of Rs. 8.80 Lakhs can be achieved by implementing
this project. The investment required is Rs. 8.0 Lakhs which is paid back
in 11 months.
INSTALL
VARIABLE
FREQUENCY
DRIVES
IDENTIFIED PUMPS IN PAPER MACHINE
IN
During the Detailed Energy Audit conducted at K R Pulp & Papers Ltd.,
Shahjahanpur, the pumping systems were studied for energy saving
potential.
Present Status
Many of the pumps in the paper mill in Unit-II were found to be controlled
through control valves. The flow requirement in the below mentioned
pumps varies on the basis of production levels and the consistency to be
maintained in the respective chests. The pumps would have been
designed for maximum production and hence the flowsflows need to be
controlled to meet the operating production levels. The flow is being
controlled are generally controlled through valves.
Closing of the valveValve throttling creates an artificial resistance to the
flow, additional to the system resistance. This pressure drop across the
valve is a mechanical energy loss which is also included in the work done
by the pump. It is estimated that for these pumps about 10-40% of the
pump power consumption is lost across the valve.
This energy loss can be prevented saved by varying the capacity flow of
the pump according to the requirement without creating any artificial
resistance. This can be achieved by installing variable frequency drive to
the pump.The flow of the pump can be varied by varying the speed of the
pump using a Variable frequency drive. By reducing the speed of the
speed of the pump, the required flow can be maintained without closing
the throttle valves. As pump power is directly proportional to the
operating head of the pump, there is good potential to for saving power.
Name of Pump
Tag
Power
Valve
kW
Flow
Name
kW
Opening Saving m3/hr
%
PM
181
< 10
28
22
PM
190
19
48
5.5
77
PM
194
24
76
215
PM
185
45
50
13.5
Thus there is excellent potential to save energy by installing VFDs for the
pumps and varying flow as per requirement.
Recommendation
We recommend the following:
Install Variable Frequency Drives for the identified pumps
Vary speed of pump to maintain required flow as per the process
requirement
Optimize the power consumption of the pumping system
Benefits
The annual savings of Rs. 8.40 Lakhs can be achieved by implementing
this project. The investment required is Rs. 10.00 Lakhs which is paid
back in 15 months.
INSTALL
VARIABLE
FREQUENCY
DRIVES
CENTRICLEANER PUMPS IN PAPER MACHINE
IN
During the Detailed Energy Audit conducted at K R Pulp & Papers Ltd.,
Shahjahanpur, the pumping systems were studied for energy saving
potential.
Present Status
The Centricleaner pumps in the paper mill in Unit-II were found to be
controlled through control valves. The flow requirement in the pumps
varies on the basis of production levels.
2.9 bar
0.8 bar
To Primary Screen
through PM 234
2 bar
0.5 bar
Primary Centricleaner
From CL Box
40% open
40% open
4 bar
PM 100
234 kW
3.5 bar
PM 42
75 kW
reducing the speed of the speed of the pump, the required flow can be
maintained without closing the throttle valves .
Recommendation
We recommend the following:
Install Variable Frequency Drives for the identified Centri cleaner
pumps
Vary speed of pump to maintain required flow
Optimize the power consumption of the pumps
Benefits
The annual savings of Rs. 43.0 Lakhs can be achieved by implementing
this project. The investment required is Rs. 19.5 Lakhs which is paid
back in 6 months.
30 m3/hr
Head
600 m
Rated Power
90 kW
No. of stages
9 stages
Each feed control valve controls the quantity of the flow w.r.t the boiler
drum level. It is observed that the control valve open percentage is
varying from 45 to 50%.
The common header pressure is 60 kg/cm 2 and the drum pressure is
around 45 kg/cm2. Because of the severe throttling, there is huge
pressure drop across the feed control valve. Approximately, 10 kg/c m2 is
the pressure drop is taking place across the control valve .
Boiler drum level is being controlled by three element control valve. This
automatic flow based control valve operates based on the level of the
boiler drum. As per the drum level the open % of the control valve varies.
Flow controlling with the control valve is not an energy efficient
mechanism. The loss happening across the control valve can be
minimised / reduced by reducing optimizing thethe speed of the pump
with the help of VFD.
As the pump is already installed with VFD and running in manual mode.
Power consumption of the pump can be optimized by operating the VFD in
auto mode.
Recommendation
We recommend to
Operate the pump with a closed loop feedback to the VFD
o Option 1: Feedback can be same that of to the valve (3
element signal)
o Option 2: Feedback can be pressure difference of 2 kg/cm 2
across the control valve
Benefits
By implementing the above recommendation annual savings of Rs 4.0
Lakhs will be achieved. This requires an investment of Rs 4.50 Lakhs for
VFD, which will be paid back with in 14 months.
AVOID
PASSING
THROUGH
MINIMUM
RECIRCULATION LINE BY INSTALLING MULTISTAGE
DRAG VALVES FOR BOILER FEED PUMP IN UNIT 1
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur CII and plant team jointly taken the flow and pressure
measurements of all pumps was carried out for possibility of reducing the
power consumption in detail. The observations made during the energy
audit are given below.
Present status
One BFP is in continuous operation for supplying feed water to boiler
drum from the deareator. Automatic Recirculation valves (ARVs) are
installed to protect the pump when the flow happening through the pump
is less than 30% of its rated capacity. These valves open and discharge
high pressure feed water to de-aerator.
Because of higher operating pressure differences across these valves,
normal ARVs tend to erode faster. To ascertain if any erosion has taken
place for the ARVs for feed pumps connected to Boiler, CII and plant team
jointly measured the re-circulation flow is measured.
The measured re-circulation flow in BFP-1 is 10.0 m 3/hr & BFP-2 is 9
m3/hr. The percentage of passing is around 28%.
106 m3/hr
Head
983 m
Rated Power
90 kW
No. of stages
9 stages
Each feed control valve controls the quantity of the flow w.r.t the boiler
drum level.
The common header pressure is 95 kg/cm 2 and the drum pressure is
around 70 kg/cm2. Because of the severe throttling there is huge
appreciable pressure drop across the feed control valve. Approximately,
22 kg/cm2 is the pressure drop is taking place across the control valve.
Boiler drum level is being controlled by three element control valve. This
automatic flow based control valve operates based on the level of the
boiler drum. As per the drum level the open % of the control valve varies.
Flow controlling with the control valve is not an energy efficient
mechanism. The loss happening across the control valve can be
minimised / reduced by reducing the speed of the pump.
As the pump is already installed with VFD and running in manual mode.
Power consumption of the pump can be optimized by operating the VFD in
auto mode.
Recommendation
We recommend to
Operate the pump with a closed loop feedback to the VFD
o Option 1: Feedback can be same that of to the valve (3
element signal)
o Option 2: Feedback can be pressure difference of 2 kg/cm 2
across the control valve
Benefits
By implementing the above recommendation annual savings of Rs 27.0
Lakhs will be achieved. This requires a marginal investment of Rs 1.0
Lakh for automation, which will be paid back with in 1 month.
AVOID
PASSING
THROUGH
MINIMUM
RECIRCULATION LINE BY INSTALLING MULTISTAGE
DRAG VALVES FOR BOILER FEED PUMP IN UNIT 2
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur flow and pressure measurements of all pumps was
carried out for possibility of reducing the power consumption in detail. The
observations made during the energy audit are given below.
Present status
One BFP is in continuous operation for supplying feed water to boiler
drum from the deareator. Automatic Recirculation valves (ARVs) are
installed to protect the pump when the flow happening through the pump
is less than 30% of its rated capacity. These valves open and discharge
high pressure feed water to de-aerator.
Because of higher operating pressure differences across these valves,
normal ARVs tend to erode faster. To ascertain if any erosion has taken
place for the ARVs for feed pumps connected to Boiler, re-circulation flow
is measured.
The measured re-circulation flow in unit-2 BFP-1 is 5.0 m 3/hr & BFP-2 is
5.5 m3/hr. The percentage of passing is 4.5%.
Re-circulation results in increased power consumption for the same useful
work done.
Recommendations
We recommend the following:
Install multi-stage pressure reduction drag valves in lieu of normal
ARVs. These are typically represented as shown below:
AVOID
RECIRCULATION
OF
CONDENSATE
BY
INSTALLING VFD AND REDUCING SPEED OFIN
CONDENSATE EXTRACTION PUMP
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, operation of condensate extraction pump is studied in
detail for possible energy savings.
Present Status
Two pumps are installed for pumping condensate, one pump is running
continuously.
A schematic diagram of the existing setup is as shown:
Air infiltration increases the load on the induced draft fan which in turn
increases the power consumption of the fan. The % infiltration across the
flue gas path is given in the below table:
Description / Boiler number
2.5 MW
AFBC
Boiler Outlet
4.6
Economizer Outlet
7.7
ID Fan outlet
10.3
Calculation
Air ingress across the total system
% infiltration in boiler
=
=
15.70
The % air infiltrations in the boiler isinfiltrations in the boiler are 34%.
Major areas of leakage are Air pre-heater, cyclones and washer. There is
good potential to decrease the power consumption of the ID fan by
arresting the air infiltration across the APH, cyclones and washer. Maintain
the overall infiltration to be less than 10 %.
Checking the air leakages with the leak detector and arresting the
leakages for avoiding the % air infiltration in APH, cyclones and washer.
Recommendation
We recommend to arrest the air infiltration in the boiler flue gas path by
arresting the leakages in APH, cyclones & washer.
Action plan
Form a leakage reduction team
Procure a combustion analyzer & monitor infiltration levels regularly
Identify and arrest leakages points
Maintain the overall infiltration at less than 10%
Do the periodic inspection of once in a fortnight
Benefits
Reducing the air ingress in unit-1 boiler flue gas path will save Rs 2.0
Lakhs annually. This requires a marginal investment.
Cooling tower has three cells with one fan each cell. All the three cells are
being used for heat exchange. During favorable conditions, plant team is
switching off the fans one by one. At present, only one fans is running
continuously.
Switching off one fan leads to partial savings as the heat transfer area is
not fully utilized. By switching on all the fans, flow handled by each fan
reduces. By installing VFD and reducing the speed of all the fans reduces
the power consumption of the fans drastically.
Recommendation
We recommend to
Install VFD for all the fans
Confederation of Indian Industry
Operate VFDs of the fans with the cold well temperature feedback of
300C
Increase and decrease the speed of all the fans based on cold well
temperature.
Benefits
Operating all the cooling tower fans and reducing the speed by
installing VFDs for all the fans in unit-2 power plant will save Rs 4.0
Lakhs annually. This requires an investment of Rs 3.0 Lakhs, which
will be paid back with a simple payback period of 9 months.
Condenser
T
Recommended
operating
T
4
11 m3/hr
Head
75 m
Rated Power
15 kW
The automatic flow based throttle valve operates based on the level of the
condenser. When the condenser level reaches minimum level, the throttle
valve closes and when condenser reaches maximum level, the throttle
vanve valve opens.
As throttling is an ineffective method of controlling flow. Power gets lost in
the form of pressure drop across control valve.
The estimated pressure drop across different equipment in the circuit is as
follows:
Sl. No.
Parameters
Pressure drop
(kg/cm2)
Steam ejector
0.5
3.0
Deaerator
2.0
Total
5.5 kg/cm2
Operate the VFD in closed loop with the hot well level
Benefits
Implementing the above recommendations will save Rs 2.0 Lakhs
annually. This requires an investment of Rs 1.50 Lakhs for VFDs for two
pumps, which will be paid back with a simple payback period of 9
months.
Parameters
Pressure drop
kg/cm2
Heat exchanger
0.5
2.5
Deaerator
2.0
Total
5.0 kg/cm2
50 m3/hr
Head
50 m
Rated Power
15 kW
Pressure
Suggested
kW Savings
%
Pr
(Pr reduction
Reduction
& Unloading)
Loading Unloading reduction
CFM
%
Unloading
Compressor-1
at PM
380
0.00
380.00
6.5
6.90
5.5
15.6
Compressor-2
at PM
380
0.00
380.00
6.5
6.90
5.5
15.6
Compressor-3
at PM
380
75
95.00
6.5
6.90
5.5
15.6
28
6 bar
Recommendation
Interconnect the compressed air pipe lines of both paper plant and
power plant and stop the compressor in power plant
As we can see from the above table that the unloading percentage
of compressor-3 is very high, it would easily accommodate the
compressed air requirement from power plant.
Install VFD in Compressor-3 and reduce the operating pressure
setpoint to 5.5 bar. This would have two benefits
o It would reduce the operating pressure thereby reducing the
operating power
o It would completely avoid the loss due to unloading
Press roll user requires 6 bar pressure, hence to cater its need, a
small booster compressor needs to be installed near the user
Benefits
The annual energy saving potential is Rs. 16.40 Lakhs. This will require an
investment of Rs. 10.00 Lakhs, which will have a simple payback period of
7 months.
CFM
Compressor1
Suggested
kW Savings
%
Actual
Pr
%
(Pr reduction &
Unloading requirement Loading Unloading reduction Reduction Unloading)
380
24
289.25
6.3
5.5
20.2
15.0
Recommendation
Install VFD and reduce the operating pressure setpoint to 5.5 bar.
This would have two benefits
o It would reduce the operating pressure thereby reducing the
operating power
o It would completely avoid the loss due to unloading
Press roll user requires 6 bar pressure, hence to cater its need, a
small booster compressor needs to be installed near the user
Confederation of Indian Industry
Benefits
The annual energy saving potential is Rs. 5.00 Lakhs. This will require an
investment of Rs. 6.00 Lakhs, which will have a simple payback period of
15 months.
User
Source Pr
User Pr
Delta P
120
Wire bivac
300
120,140,150, 150,
140,180
Trivac
250
180,180
70
280
240
40
540
520
20
580
420
160
580
420
160
500
340
160
5
Suction Press (high zone)
6
7
Pickup Roll
10
390
60
380
320
440
310
130
440
310
130
As seen in the table above, the pressure drop between the user and the
pump in each area is hugevery high. The possible reason for the same
could be
Recommendation
As it is observed that there is a huge high pressure drop between the user
and the pump, it is evided that the line sizing in each user is not proper. It
is highly recommended to call a third party to conduct a detailed
engineering study only for the pipe sizing so that it could be brought
down to acceptable limits. While conducting the study the following points
needs to be kept in mind
The pressure drop across the complete pipeline should not be more
than 20 mmHg
A detailed study on the pipe sizing alone should be done and the
pressure drop should be brought down to acceptable limits
Also VFD needs to be installed for all vacuum pumps and vacuum needs
to be maintained based on the user requirement from DCS.
Savings
The saving potential is calculated only for those pumps as shown in the
table below where the pressure drop between the source and the user is
high.
Vacuum
Pump No
1
5
6
7
10
11
User
Wire bivac
Suction Press (high zone)
Pickup Roll
1&4 press felt, uhle box
Source Pr in
mmHg
User Pr in
mmHg
Delta P in
mmHg
300
580
580
500
440
440
Max 180
420
420
340
310
310
50
90
90
90
60
60
Savings calculation
Sample calculation for Wire Bivac
20(piping)
300180-50(separator)-
= 50mmHg
=
Pressure
drop
Power
consumption
Head developed
= 50mmHg x 102 kW
300 mmHg
= 17 kW
Similarly, saving for others is shown in the table below
Vacuum
Pump
No
1
5
6
7
10
11
Source
Pr in
mmHg
User
Wire bivac
Suction Press (high
zone)
Pickup Roll
1&4 press felt, uhle
box
Total
300
580
580
500
440
440
User Pr
in
mmHg
Max
180
420
420
340
310
310
Delta
P in
mmHg
Power
consumption in
kW
50
90
90
90
60
60
102
180
147
141
174
153
savings
in kW
17
28
23
25
24
21
138
Benefits
The annual energy saving potential is Rs. 55.20 Lakhs. This will require
an investment of Rs. 25.00 Lakhs, which will have a simple payback
period of 6 months.
From the above graph it is clear indication that the flat belt is operating at
98% efficiency when the drive is 100% loaded, but V-belt is operating at
the 94% efficiency only. There exists good potential to replace V-belt with
the flat belt drives.
These drives are ideal for steady load applications, such as fans,
compressors, and blowers. However, it should be ensured that the area
around the equipment is free from oil or water spillage.
Also, proper preventive care must be taken to ensure proper alignment
between the drive and driven equipment.
Recommendation
We recommend converting the identified V-belt drives into flat belt drives
for the major auxiliary bag filter fans. The list of identified fans is given
below. Ensure that the area around the equipment is free from oil or
water spillage (cover could be used for protection)
S.No
1
2
3
4
5
6
7
8
9
10
11
Equipment
Mixing Chest
Machine Chest
Pulp dump chest
Agro pulp chest
Vacuum pump - cautisizing plant
ETP drain pump
Bagass chest agitator
Vacuum pumps - 11 nos
Unit-1 Boiler 7TPH FD Fan
Unit-1 Boiler 7TPH ID Fan
Vacuum pumps - 5 nos
Total
Operating kW
33
15
33
30
130
45
55
1398
28
23
366
2156
Saving Potential
1.32
0.6
1.32
1.2
5.2
1.8
2.2
55.92
1.12
0.92
14.64
86.24
Savings
On a conservative basis 4% saving is calculated for the identified
equipments
Benefits
The annual energy saving potential is Rs. 34.40 Lakhs. This will require
an investment of Rs. 20.00 Lakhs, which will have a simple payback
period of 7 months.
- 13 TPH
Recovery
- 55%, 7TPH
- 22 TPH
Recovery
- 75%, 16 TPH
The condensate levels in flash tank and vacuum tank at paper machine
section is maintained by individual pumps associated with each tank with
the help of control valves. The condensate collected in each tank is
Confederation of Indian Industry
Install VFD in pumps associated with Flash tank and vacuum tank and the
logic to VFD would be to maintain the tank level.
Stop the pump that transfers condensate from the recovery tank to the
deaerator
The savings with this modification is as follows
Confederation of Indian Industry
The energy loss associated with the pressure drop across the control
valves in Flash tank and vacuum tank pumps can be completely
eliminated.
As the new operating parameters will be matching with the design
values, the pump will be working with better efficiency
Stopping of the recovery tank pump will be saving power to the
tune of 11 kW (operating power)
Flash steam generated from 10TPH of condensate would be
= 152 kg/ hr
Hence 152 kg/ hr of flash steam could be avoided if directly introduced to
deaerator, this would inturn reduces the extraction steam to the deaerator
from the turbine.
Install new pump at the evaporator section, the new pump will have a
specification which will aid the condensate to be sent directly into the
deaerator. The new specification will be as follows
Capacity
-20 m3/ hr
Head
- 50 mtr
Motor
- 5 kW
Savings
Stoppage of recovery tank pump
= 11 kW
Benefits
The annual energy saving potential is Rs. 4.40 Lakhs. This will require
an investment of Rs. 4.00 Lakhs, which will have a simple payback
period of 11 months.
Observation
OBSERVATION NO. 1
Power
Consumed (W)
Efficacy
(Lumens/Watt)
Lamp Life
(hours)
38
68
12000
36
75
15000
28
103
16000
Recommendation
OBSERVATION NO. 2
The scotopic curve and photopic curve mention the day time lighting
and night time lighting respectively. The eye colour is more sensitive
towards the green colour for photopic curve and is correspondingly for
blue colour in the case of scotpic vision. This data of relative sensitivity of
eye helps us in designing the correct colour of the lamp required for
different lighting conditions. The scotopic vision is well suited for night
environment such as street lights, basements, closed rooms where
sunlight is not available. The photopic on the other hand will be closer to
day time environment.
The earlier system of lighting wherein the quantity of light delivered was
mentioned in lumens and not in pupil lumens considered only the photopic
curve.
Comparison of Lamps
The table below shows a brief comparison of all the lamps. The latest
trend is to go for LED lamps. These LED lamps have very high scotopic to
photopic ratio of 2.4. This is very well suited for street lighting and
lighting in dark surroundings.
S.No
Parameter
LED
Metal
Halide
HPSV
CFL
FTL T5
INDUCTION
Life
50000
Hours
+
Lamp
Efficacy
90-100
Lumen
30% @
Depreciation 50,000
Hours
60008000
Hours
1200015000
Hours
80000
Hours
65 to
90
90-140
60-65
70-104
60-80
Upto
40% @
12000
Hours
Upto
40% @
15000
Hours
1520%
till end
of life
1520% till
end of
life
15-20% till
end of life
CRI
70-90
65-90
22- 25
65-85
60-95
>80
Color
Variety
White
Yellow
White
White
white
4000k5000k
2100K3000K
30006000K
30006500K
2700
-6500K
1.6
0.62
1.32.2
1.3-2.2
1.85
color
2100temperature 10000K
S/P Ratio
upto
2.4
Warm up
time 90%
Lumens
Instant
Flicker free
yes
5
4
1
10-50
minutes minutes minute Seconds
No
No
No
No
Instant
yes
Advantages of LEDs
Lower energy consumption
1W/LED
Longer lifetime (50,000 to 100,000 hrs)
High Scotopic to photopic ratio
Smaller size
Faster switching
Greater durability and reliability
Good CRI > 80
The HPSV lamps used for lighting have very low scotopic to photopic ratio
of 0.62 and even though the lamp efficacy is high, 90 140 lumens/watt,
considering only lumen levels and not pupil lumens. Multiplying this
efficacy with the scotopic to photopic ratio from the table will give us the
pupil lumens/watt which is 56 87 pupil lumens/watt. Comparing with
LED the actual pupil lumen/watt will be around 216 240 pupil
lumens/watt, which gives us a good opportunity to replace the existing
HPSV lamps with LEDs. In order to achieve the same amount of pupil
lumens the power consumed by LED is atleast 50% lesser in comparison
to HPSV lamps.
Similarly HPMV lamps can also be replaced with LEDs. Replacement of
sodium vapour and mercury vapour lamps with LEDs are mentioned in the
table below.
Sodium Vapour
Mercury Vapour
LED
75 W
125 W
33 W
150 W
250 W
70 W
250 W
400 W
120 W
Recommendation
It is recommended to replace HPSV and HPMV lamps with LEDs. The
recommended values for standard lamp sizes are mentioned in the table
above.
OBSERVATION NO. 3
HARMONICS MEASUREMENTS
Background
As a part of theDuring the detailed energy audit detailed energy audit at a
harmonic survey was conducted at K R Pulp and Papers Limited,
Shahjahanpur for major feeders. Harmonic levels are measured using a
Harmonic analyzer at all the PCC (point of common coupling) and the values
are enclosed.
To elaborate the basics of harmonics, a brief write up is enclosed.
What are Harmonics?
A normal supply system operates at 50 Hz power frequency. However, due
to any reason if voltage / current signal of higher frequencies (higher than
50 Hz) are introduced in the supply system, they are termed as
harmonics, e.g. if a waveform of 250 Hz is introduced in a 50 Hz system,
it is termed as 5th harmonic.
Any non-sinusoidal wave which is periodic in nature can be
mathematically decomposed into sine waves of fundamental and higher
frequency which are multiple of the fundamental frequencies.
How does it get into Power Systems?
In case of a linear load the current wave shape are of the same nature as
the applied voltage wave form, for e.g. if we apply a sine wave across
passive elements like resistor, reactor or capacitor, the resulting current
flowing into the circuit is also sinusoidal in nature.
The phase angle between the applied voltage and current depends on
whether the resultant circuit is inductive, resistive, capacitive. Please refer
to Fig. 1 below.
V
I
t
t
I
Some of the loads which are used in a modern power system which
generate harmonics are as below:
Any loads which uses a non linear solid-state device like diode,
thyristor, IGBT, etc. e.g. AC / DC drives, induction furnaces, rectifiers,
etc.
Electronic Ballast
Ferromagnetic Devices like
Transformers operating near saturation level
Induction heating equipment
Arcing Devices
Arc-Discharge lighting, e.g., fluorescent,
Electric arc furnaces
Thyristor welding machine
What are the effects of harmonics?
The harmonics have a multifold effect on various network elements present
in a system. Whenever a harmonic current flows through an equipment,
It causes additional losses due to its higher frequency, devices such as
motors, transformers, etc. which has a laminated core have higher
losses due to higher frequency of the harmonic current.
In cables, the harmonic current tend to flow through the outer skin of
the conductor due to skin effect and results in heating of these
conductors.
Harmonics can cause nuisance tripping of the relays and failure of
capacitors installed in distribution system for power factor
improvement.
Certain harmonic currents (for e.g. 5th harmonic) has the reverse
phase sequence which means any electro mechanical device used for
metering will not register true values. Similarly, in a polluted network a
normal induction motor may not develop necessary torque because of
harmonic current generating a torque in the reverse direction.
Higher order harmonics interfere with telecommunication system also.
Whenever a telephone line runs parallel to a power line having
harmonics, a noise is introduced in the telephone line.
This
phenomenon is known as telephonic interference.
at
Pulp
and
Papers
Limited,
During the audit, the total voltage harmonic distortion (%VTHD) & total
current harmonic distortion (%ITHD) at point of common coupling was
measured for the harmonic distortion. The total harmonic distortion is the
vector sum of all the harmonic content present in system, thus %THD
shows the actual total harmonics present in system. This is taken for
voltage and current separately. The total harmonic distortion voltage and
current are mentioned in a few places.
Limits of THD Voltage and current
According to IEEE the harmonic distortion levels for voltage and current
are as follows
Total harmonic Distortion voltage
415 Volts
< 5% THD
11 kV
< 4 % THD
132 KV
Section
V-THD
I-THD
Unit 1 TG Incomer
7.7
6.6
TG Incomer
5.6
0.3
Transformer 1
5.7
27
Transformer 2
5.4
24
Transformer 3
5.5
2.7
Transformer 4
5.3
Transformer 5
6.1
3.7
Transformer 6
5.8
6.7
Transformer 7
5.4
6.9
Transformer 8
5.2
2.0
Transformer 9
5.5
25
Transformer 10
5.4
22
Transformer 11
5.2
8.1
Transformer 12
5.3
2.9
OBSERVATION NO. 4
INSTALL
Background
During the detailed energy audit, a possibility of energy savings by
reducing lighting voltage in the plant was studied. Since the economics of
this proposal is on the higher side this proposal is projected as an
observation.
Present status
The operating voltage for lighting in the plant is around 240V. The
recommended voltage for lighting is 210V. There is a good potential to
reduce the power consumption of lighting by reducing the voltage for
lighting by installing lighting transformers for various sections.
Usually a thumb rule of 10% reduction in power consumed by lighting is
possible for every 10% reduction in lighting voltage. This thumb rule is
taken on a conservative basis. Different types of lamps have different
reduction in power consumed as mentioned in the table below.
Lamp type
Fluorescent lamps
HPMV lamps
HPSV lamps
LPSV lamps
CHAPTER - V
THE OBJECTIVES OF K R
SHAHJAHANPUR SHOULD BE
PULP
&
PAPERS
LIMITED,
7.2
Specific Recommendation
The K R Pulp & Papers Limited, Shahjahanpur team had
already done commendable jobs in Energy conservation. CII
strongly feels that Plant team should form an energy management
committee which involves senior persons from all departments and
the committee should continue the work and progress towards
World Class Energy Efficient Unit.
The main responsibility of implementing the proposals and
achievement of savings should be with the concerned operating and
maintenance personnel and not with the energy manager.
The immediate task of K R Pulp & Papers Limited,
Shahjahanpur should be to implement the identified proposals and
get the savings.
We would recommend, K R Pulp & Papers Limited,
Shahjahanpur to introduce a suggestion scheme for energy
Confederation of Indian Industry
7.4
Monitoring of Proposals
All the implemented proposals are to be monitored on a proposalby-proposal basis for actual achievement of savings on a monthly
basis.
7.5
Motivational Aspects
The successful management of energy depends on motivation of
technical personnel and their commitment. For this reason, J K
Fenner should carry out the following motivational aspects to
sustain energy conservation activities.
Send operating / Maintenance personnel for training programmes
in specific areas like
Fans & Blowers
Compressors
Heat Treatment system
Motors
Conduct in-house training programme on energy management.
Organise visits for executives to similar units to know the energy
conservation / process development, etc.
Present papers on energy conservation activities at the plant, in
other seminars.
7.6
Conclusions
Confederation of Indian Industry
Annexure
AnnexureA
SUPPLIER ADDRESS
VFD and other drives
1. Rockwell Automation India
Pvt. Ltd. (Allen-Bradley India
Ltd.)
C - 11, Industrial Area
Site - 4, Sahibabad
Ghaziabad - 201 010
Tel: +91 120 2895245, 2895252
Fax: +91 120 2895226
2.
3.
6.
5.
2. Excellent Industrial
Instruments
1/63, E Type, SIDCO Nagar
Villivakkam, Chennai 600 049
Tel : 044 26172977
Fax : 044 26172531
Email: xlenergy@vsnl.net
Web: www.xlntenergy.com
5. Muskaan Engineers
423, Industrial area A
Ludhiana 03
Ph: +91-161-5088381
Fax: 5022381
Mob: 99157-03056, 94170-33948
E-mail:
info@muskaanengineers.com
6. Power Engineers &
Consultants
E-731, Phase-VIII, focal point,
Opp. Hero cycle Ltd,
Ludhiana-10
Ph: +91-161-3294989
Fax: 0161-2303021
Mob: 9317562989, 9872862989
E-mail:
business@powerengineer.biz
LED LAMPS
1. Binay Opto Electronics Pvt
Ltd.
44, Armenian Street
Calcutta 700 001
Ph: 033 22103807, 22429082,
22102039
Fax : 033 22421493
Email: binay@vsnl.com
info@binayLED.com
INDUCTION LAMPS
Bajaj Electricals Ltd
H. No. 6-3-1090/2, 3rd Floor
Vithal Das Chambers,
Rajbhavan Road, Somaji guda,
Hyderabad - 500 082
Phone : 040-23442932, 23442933,
23442934
Fax : 040-23302745
Email :
gv.reddy@bajajelectricals.com
naveenk@bajajelectricals.com
CAPACITORS
1. Momaya Capacitors
401, Madhav Apartments
Jawahar Road, Opp. Rly. Stn.
Ghatkopar (East)
Mumbai - 400 077
Tel: 022 - 25168281/82,
65754001/02
Fax: 022 - 2516 0758
2. Baron Power
No. 3, Karpagambal Nagar,
Mylapore, Tamil Nadu, India
Ph: +91-44-24356383/84/86,
42131849/50
Fax: +91-44-24356385
3. Meher Capacitors
11th Floor
28 Dr. Gopal Das Towers
Barakhamba Road
New Delhi- 110 001
Tel: + 91 11 23 70 41 43
+ 91 11 23 70 41 44
Fax: + 91 11 23 70 41 46
3. KLG Systel
Plot No. 70A,
Sector - 34, Gurgaon - 122 004
Haryana (India)
Telephone: +91 (0) 124-4129900
Fax: +91 (0) 124-4129999
e-mail : klg.ho@klgsystel.com
Flat belts
1. Elgi Ultra Industries Ltd.
India House, Trichy Road
Coimbatore - 641 018. India.
Phone: 91 (422) 2304141
Fax: 91 (422) 2301377
Email: info@elgiultra.com
Agitators
1. Fluidyme Technologies
E-2/4, Popular Prestige,
Near Highway Bridge, Warje,
Pune-411058
Maharashtra, INDIA
TeleFax : +91-20-25293397
Mobile : 09422009479
E-mail :fluidyme@sanchaernet.in
fluidyme@yahoo.co.in
2. Pinnacle Equipments
Gat No - 103, Jyotiba Nagar
Talawade Road, Pune
Maharashtra - 412 114
Ph: 020-27690413/27690890 /
32661602
Fax: 020-27690413/32661602
3. Indofab Industries
Street Address: C/3, Hatkesh
Udyog Nagar
City: Thane
Maharashtra 400 606
Ph: + (91)-9820077092
4. Elof Hansson (India) Pvt. Ltd.
Old No 11, New No. 23
2nd Main Road
Raja Annamalai Puram
Chennai - 600 028
India
Ph: +91-44 461 7901/ 7905
Fax: +91-44 461 7907 / 790
baronpower@satyam.net.in
corporate@baronpower.com
Crompton Greaves Limited.
CG House, 6th Floor
Dr. Annie Besant Road
Worli, Mumbai - 400 030
India
Tel: +91 022 2423 7777
Fax: +91 022 2423 7788
Neel Controls
#112, Minerva Industrial Estate
P K Road, Near Hercules Hoist
Mulund (W), Mumbai 400 080
Ph: 022 2560 3371 / 2569 5047
Fax: 022 2568 3211
Contact Person
ABB Limited
Khanija Bhavan, 2nd Floor
East Wing, No. 49, Race Course Road
Bangalore - 560 001
Ph: 080 - 22949150 to 54
Fax: 080 - 22949148
Mr. S Ravichandran
General Manager
Mob: 098220 93785
Email:
subramaniam.ravichandran@cummin
s.com
UPS
APC
# 16, Row House, Goyal Inter City
Behind Drive in cinema, Thaltej
Road, Thaltej
Ahmedabad, Gujarat 380 054
India
Ph: (079) 2684 0124/ 324
APC
# 5, Lake Avenue,
Near Mudiali Bus Stop
Kolkata, West Bengal 700 026
India
Ph: (033)2465 5519, 2463 0064
Thermax Limited
Process Heat Division
Fathima Akhtar Court
3rd Floor, 453, Anna Salai
Thermal Systems (Hyd) Pvt. Ltd.
Plot No.1, Apuroopa Township
IDA, Jeedimetla
Hyderabad - 500 055
Tel: 91-040-23091801-06
Fax(s): 91-040-23097433
info@thermalindia.com
Aquatherm Engineering
Consultants
St. Thomas Building
Luz Church Road
Chennai
Tamil Nadu
India.
Ph: 91-44-24660462, 24994032,
24660464, 91-44-24996085
Email: auather@vsnl.com
aquather@eth.net
ECONOMISERS
Megatherm Engineers & Consultants Pvt. Ltd.
33, Oliver Road, Mylapore
Chennai - 600 004
Tel: 044 2498 7614/38/58
Fax: 044 2498 7638
Furnace
Thermal Systems
Plot No.150, SIDCO Industrial Estate (NP)
Ambattur, Chennai - 600 098
Tamil Nadu, India
Ph: 044 - 42140877, 26257625, 26255790
Fax: 044 - 42140977
Email: thermalsystems@yahoo.com
thermalsystems@airtelbroadband.in
Radiant Recuperative Heaters
Thermax Babcock & Wilcox Limited
Energy Building, D1 Block, Plot No. 7/2
RD Aga Road, MIDC, Chinchwad,
Pune 411019,
Tel: 020 6612 6464, 6612 6411
Fax: 020 6612 6612
Frp Blades For Mancoolers & Air Washers
ENCON (INDIA)
2B/06, Shivkripa,
N. C. Kelkar Road, Dadar (West)
Mumbai - 400 028, India.
Ph: +91 22 2437 2949 / 2430 6578
Fax: +91 22 2431 0992 / 2432 1929
Email: enconindia@vsnl.com
Email: akrai@encongroups.com
Amalgamated Indl. Composites P. Ltd.
Unit No.111 /112, Ashok Service Industrial Estate
L.B.S. Marg, Bhandup (West)
Mumbai - 400 078. India
Tel: 022-25964566, Tele Fax: 022-25346920 / 25963611
Email: info@aicomposites.com
HOC Dryers
Gaso Energy Systems (I) Pvt. Limited
T-122 , M.I.D.C., Bhosari, Pune - 411 026
Tel. : + 91 20 2712 8823 / 3068 5256
Fax: 020 - 27119573
Email:kgiram@gasoenergysystems.com
Drytech Engineers
Sh. No. 12-15, Sapana Co.op. Hsg. Soc.,
Opp. Konark Vihar, Off. Pune-Satara Road
Dhankawadi, Pune - 411043.
Maharashtra, INDIA
Tel : +91-20-24371445, 24376601
Fax : +91-20-24376789
Email: drytechengineers@eth.net, vbk_drytech@yahoo.co.in,
jmd_drytech@yahoo.co.in, response@drytechengineers.com
Fax: +91
20 24440824,
2444-
Insulations
Megha Insulations Pvt Ltd.
A-11/6th Floor, Dada Saheb Flats
Kalanala, Bhavnagar 364001
Ph: 0278-3004523/26
Fax: 0278-3004728
Email: mipl@meghainsulation.com
Contact Person
Mr H V Shah -98252-07723 & 94262-12823
Mrs. Madhu: 98795-46523
2.
Disclaimer
While every care has been taken in compiling this list, Confederation
of Indian Industry does not accepts any claim for compensation, if any
entry is found to be wrong, abbreviated, omitted or inserted
incorrectly either as to the wording space or position in the list. While
attempts are being made continuously to make the list as elaborate,
as possible CII wishes to inform that neither the list of technologies
nor list of suppliers for a given product / technology is
comprehensive. The list is only an attempt to create awareness on
energy conservation and sharing of best practices being adopted in
Indian Industry.
Annexure-B
FORMAT FOR MONITORING THE IMPLEMENTATION OF ENERGY SAVING PROPOSALS
Sl.
No
Annnual
Savings
(Rs.Lakhs)
Investment Payback
Required
Period
(Rs.Lakhs) (Months)
100.00
2.10
5.00
2.00
56.80
47.40
10
8.80
8.0
11
8.40
10.00
15
43.00
19.50
Person/
Department
Responsible
Target
Date
Remarks
10
11
12
13
14
15
16
4.00
4.50
14
9.00
5.00
27.00
1.00
4.80
8.0
20
2.40
1.00
2.0
4.00
3.00
32.00
8.00
3.20
17
18
2.00
1.50
3.20
1.00
19
16.40
10.00
20
6.00
5.00
15
21
55.20
25.00
22
34.40
20.00
23
4.40
4.00
11
434.10
183.90
Total
Backup Calculations
10.97 MW at 50.0 Hz
(Speed3) 3
4.10 MW
=
~
4.36 4.10
250 kW
=
=
HT Voltage (V)
11650
2(Recommended)
11275
3(Current)
11000
10725
10450
10175
9900
LT Voltage
(V)
433
Reduce the tap setting for the transformer 5 to tap position 2 from tap position
5
Total load of transformers
975 kW
Power savings
0.00625 x 975 kW
6 kW
=
=
=
Annual Savings
=
=
=
248000 kVAh
236000 kWh
0.95
0.995
236000/0.99
238383 kVAh
Savings kVAh/month
=
=
248000- 238383
9,617 kVAh
Annual savings
9617kVAh x Rs 5.0/kVAh
x 12 months
Rs.5,77,020/Say Rs.5.77 Lakhs
=
KVAR required:
Maximum instantaneous kW
Capacitor required
=
=
=
=
=
660kVA x 0.98
647 kW
KW (tan1 tan2)
647 (0.203)
129.4 kVAr
Say 120 kVAr
=
=
Payback in months
Rs.1.80 lakhs x 12
Rs.5.77lakhs
3.77 months
Say 4 Months
Name of Pump
Tag
Name
kW
Saving
Flow
m3/hr
PU 76
57
35-60
11
440
Continuous Digester
Dilution Pump
PU 74
48
35
14
72.8
PU 119
60
12
18
400
PU 100
17
50
120
PU 96
66
25
19.5
500
PU 101
17
50
130
Washed HD Tower
Pump
PU 116
71
80
HD Dilution Pump
PU 126
54
50
16
Secondary Screen
Pump
PU 132
21
30
Screened HD Tower
Pump
PU 146
24
50
LC Chest Pump
PU 150
24
15
Screened HD Tower
Dilution Pump
PU 165
54
25, 14
16
PU 169
15
28
4.5
PU 171
54
60
10.5
For Savings, considering 10% savings for 75100% open valve; considering
20% savings for 6075% open valve; 30% savings for 1060% open valve
For Example, consider Continuous Digester Dilution Pump PU 74
Saving Potential
=
=
Say
0.2 x 48 kW
14.4 kW
14 kW
146.5 kW
Annual Savings
=
=
Payback period
=
Benefits
The annual savings of Rs. 58.60 Lakhs can be achieved by implementing this
project. The investment required is Rs. 47.40 Lakhs which is paid back in 10
months.
INSTALL
VARIABLE
FREQUENCY
CENTRICLEANER PUMPS IN PULP MILL
DRIVES
IN
Present Status
The Centricleaner pump in the pulp mill in Unit-II was found to be controlled
through a control valve. The flow requirement in the pump varies on the basis
of production level.
2.6 bar
0.6 bar
To Screen Washer
Primary Centricleaner
Primary Centricleaner
Standpipe
40% open
3.4 bar
PU 128
84 kW
Closing of the valve creates an artificial resistance to the flow, additional to the
system resistance. This pressure drop across the valve is a mechanical energy
loss which is also included in the work done by the pump. The necessity for
controlling the valve is due to higher design head or design flow.
There is pressure loss of 0.8 bar across the valve for primary Cetricleaner
pump which accounts to more than 30 % of the pump head. As pump power is
directly proportional to the operating head of the pump, there is good potential
to save energy.
Savings
Pump Discharge Pressure
3.4 bar
Pump Head
=
=
=
=
Pump Power
84 kW
=
=
Say
0.8 bar x 84 kW
3 bar
22.4 kW
22 kW
Annual Savings
=
=
Rs. 8 Lakhs
Payback period
=
Benefits
The annual savings of Rs. 8.80 Lakhs can be achieved by implementing this
project. The investment required is Rs. 8.0 Lakhs which is paid back in 11
months.
Tag
Power
Valve
kW
Flow
Name
kW
Opening Saving m3/hr
%
PM
181
< 10
28
22
PM
190
19
48
5.5
77
PM
194
24
76
215
PM
185
45
50
13.5
For Savings, considering 10% savings for 75100% open valve; considering
20% savings for 6075% open valve; 30% savings for 1060% open valve
For Example, consider Broke Chest Pump PM 190
Saving Potential
=
=
Say
0.3 x 19 kW
5.7 kW
5.5 kW
21 kW
Annual Savings
=
=
Rs. 10 Lakhs
Payback period
Benefits
The annual savings of Rs. 8.40 Lakhs can be achieved by implementing this
project. The investment required is Rs. 10.00 Lakhs which is paid back in 15
months.
INSTALL
VARIABLE
FREQUENCY
DRIVES
CENTRICLEANER PUMPS IN PAPER MACHINE
IN
Present Status
The Centricleaner pumps in the paper mill in Unit-II were found to be
controlled through control valves. The flow requirement in the pumps varies on
the basis of production levels.
2.9 bar
0.8 bar
To Primary Screen
through PM 234
2 bar
0.5 bar
Primary Centricleaner
From CL Box
40% open
40% open
4 bar
PM 100
3.5 bar
PM 42
234 kW
75 kW
Closing of the valve creates an artificial resistance to the flow, additional to the
system resistance. This pressure drop across the valve is a mechanical energy
loss which is also included in the work done by the pump. The necessity for
controlling the valve could be due to higher design head or design flow.
There is pressure loss of 1.1 bar across the valve for primary Cetricleaner
pump which accounts to more than 25 % of the pump head. Similarly, there is
a 1.5 bar pressure loss across the valve for the secondary centricleaner pump
which is more than 40 % of the pump head. As pump power is directly
proportional to the operating head of the pump, there is good potential to save
energy.
Savings Calculations
Considering Primary Centricleaner pump
Pump Discharge Pressure
4 bar
Pump Head
=
=
4 0.4 bar
3.6 bar
=
=
4 2.9 bar
1.1 bar
Pump Power
234 kW
=
=
1.5 bar x 75 kW
3.1 bar
36 kW
107.5 kW
Annual Savings
=
=
Payback period
=
Benefits
The annual savings of Rs. 43.0 Lakhs can be achieved by implementing this
project. The investment required is Rs. 19.5 Lakhs which is paid back in 6
months.
: 30 m3/hr
Head
: 600 m
Rated Power
: 90 kW
No. of stages
: 9 stages
Each feed control valve controls the quantity of the flow w.r.t the boiler drum
level. It is observed that the control valve open percentage is varying from 45
to 50%.
The common header pressure is 60 kg/cm 2 and the drum pressure is around
45 kg/cm2. Because of the severe throttling there is huge pressure drop across
the feed control valve. Approximately, 10 kg/cm 2 is the pressure drop is taking
place across the control valve.
Boiler drum level is being controlled by three element control valve. This
automatic flow based control valve operates based on the level of the boiler
drum. As per the drum level the open % of the control valve varies.
Flow controlling with the control valve is not an energy efficient mechanism.
The loss happening across the control valve can be minimised / reduced by
reducing the speed of the pump.
As the pump is already installed with VFD and running in manual mode. Power
consumption of the pump can be optimized by operating the VFD in auto
mode.
Recommendation
We recommend to
Operate the pump with a closed loop feedback to the VFD
o Option 1: Feedback can be same that of to the valve (3 element
signal)
o Option 2: Feedback can be pressure difference of 2 kg/cm 2 across
the control valve
Saving Caculations
At least pressure drop of 8 kg/cm2 can be reduced
% reduction in pressure drop
8 kg/cm2 x 100
60 kg/cm2
13.3%
90 kW
=
=
90 kW x 13.3%
12 kW
=
=
=
Rs 4.50 Lakhs
Payback Period
9.0 m3/hr
FW main flow
32 m3/hr
% passing through
9 m3/hr x 100
32 m3/hr
28%
=
=
Investment
Payback
106 m3/hr
Head
983 m
Rated Power
90 kW
No. of stages
9 stages
Each feed control valve controls the quantity of the flow w.r.t the boiler drum
level.
The common header pressure is 95 kg/cm 2 and the drum pressure is around
70 kg/cm2. Because of the severe throttling there is huge pressure drop across
the feed control valve. Approximately, 22 kg/cm 2 is the pressure drop is taking
place across the control valve.
Boiler drum level is being controlled by three element control valve. This
automatic flow based control valve operates based on the level of the boiler
drum. As per the drum level the open % of the control valve varies.
Flow controlling with the control valve is not an energy efficient mechanism.
The loss happening across the control valve can be minimised / reduced by
reducing the speed of the pump.
As the pump is already installed with VFD and running in manual mode. Power
consumption of the pump can be optimized by operating the VFD in auto
mode.
Recommendation
We recommend to
Operate the pump with a closed loop feedback to the VFD
o Option 1: Feedback can be same that of to the valve (3 element
signal)
o Option 2: Feedback can be pressure difference of 2 kg/cm 2 across
the control valve
At least pressure drop of 16 kg/cm2 can be reduced
% reduction in pressure drop
=
=
16 kg/cm2 x 100
95 kg/cm2
16.8%
405 kW
=
=
405 kW x 16.8%
68 kW
Annual Savings
=
=
=
Rs 1.0 Lakhs
Payback Period
5.5 m3/hr
FW main flow
115 m3/hr
% passing through
=
=
=
Investment
Payback
AVOID
RECIRCULATION
OF
CONDENSATE
BY
INSTALLING
VFD
AND
REDUCING
SPEED
OFIN
CONDENSATE EXTRACTION PUMP
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, operation of condensate extraction pump is studied in detail
for possible energy savings.
Present Status
Two pumps are installed for pumping condensate, one pump is running
continuously.
A schematic diagram of the existing setup is as shown:
Condensate extraction pump is pumping water from hot well to deaerator. Hot
well level is being controlled with help of recirculation valve. At present, the
recirculation valve is opened to 93% open and the maximum of the
condensate is being recirculated back to the hot well.
The measured condensate flow is 26m 3/hr and the recirculation flow is
24m3/hr.
Recirculation is the most ineffective method of controlling flow. Therefore,
should be avoided to save the power consumption of the pump.
Generally, recirculation is provided to maintain sufficient condensate flow
through the steam ejector heat exchanger. Otherwise, operation of steam
Confederation of Indian Industry
ejector will get affected. The required condensate flow through steam ejector is
35% of design condensate flow of the pump.
At the present condition, more than 90% of the flow is being circulated back to
hotwell. Flow of the condensate flow can be reduced by reducing the speed of
the pump by installing VFD and operating it with hot well signal. To maintain
the required 35% of the condensate flow, VFD should be locked at minimum
frequency level of 22 Hz.
Recommendation
We recommend to
Install VFD for the pump
Operate it directly based on the hot well level signal
Lock the minimum frequency level at 22 Hz
Close recirculation valve completely and the valve should open only
when the frequency falls below 22 Hz
Saving calculation
Operating power of the pump
12 kW
22 Hz
=
=
(50-22) x 100
50
56%
Power saving
=
=
56% x 12kW
6kW
Annual savings
=
=
=
Investment
Rs 1.0 Lakhs
Rs 1.0 Lakhs x 12
Rs 2.40 Lakhs
5 months
Air infiltration increases the load on the induced draft fan which in turn
increases the power consumption of the fan. The % infiltration across the flue
gas path is given in the below table:
Description / Boiler number
2.5 MW
AFBC
Boiler Outlet
4.6
Economizer Outlet
7.7
ID Fan outlet
10.3
Calculation
Air ingress across the total system
% infiltration in boiler
=
=
15.70
The % air infiltrations in the boiler is 34%. Major areas of leakage are Air preheater, cyclones and washer. There is good potential to decrease the power
consumption of the ID fan by arresting the air infiltration across the APH,
cyclones and washer. Maintain the overall infiltration to be less than 10 %.
Checking the air leakages with the leak detector and arresting the leakages for
avoiding the % air infiltration in APH, cyclones and washer.
Recommendation
We recommend to arrest the air infiltration in the boiler flue gas path by
arresting the leakages in APH, cyclones & washer.
Form a leakage reduction team
Procure a combustion analyzer & monitor infiltration levels regularly
Identify and arrest leakages
Maintain the overall infiltration at less than 10%
Savings Calculations
Boiler ID fan power consumption
45 kW
=
=
Annual savings
=
=
=
Investment
Nil
Payback
Immediate
Cooling tower has three cells with one fan each cell. All the three cells are
being used for heat exchange. During favorable conditions, plant team is
switching off the fans one by one. At present, only one fans is running
continuously.
Switching off one fan leads to partial savings as the heat transfer area is not
fully utilized. By switching on all the fans, flow handled by each fan reduces.
By installing VFD and reducing the speed of all the fans reduces the power
consumption of the fans drastically.
Recommendation
We recommend to
Install VFD for all the fans
Confederation of Indian Industry
Operate VFDs of the fans with the cold well temperature feedback of
300C
Increase and decrease the speed of all the fans based on cold well
temperature.
Savings calculation
Operating power of the fan
19.5kW
39 kW
0.672
44.5%
Power saving %
55%
N1
50% x(3x19.5kW)
29kW
Power saving
=
Operating power of two fans New
power consumption of three fans at reduced speed
=
39 kW 29kW
=
10kW
Annual saving
=
=
=
Rs 3.0 lakhs
Rs 3.0 Lakhs x 12
Rs 4.0 Lakhs
9 months
T
Recommended
operating
T
Condenser
=
=
81kW x 2
162 kW
30C
60C
=
=
30C x100
60C
50%
50%
Power saving
50% x 162kW
Annual saving
81kW
=
=
=
=
=
Rs 8.0 Lakhs
Rs 8.0 Lakhs x 12
Rs 32.0 Lakhs
3 months
11 m3/hr
Head
75 m
Rated Power
15 kW
Recirculation line is provided in the condensate line after the steam ejector
back to hot well, which will open during the starting of the turbine & at lower
loads. At present condition, the valve is completely closed. Flow in this line is
measured and found to be 1.4m3/hr, indicates there is a passage in this line.
Therefore, potential exists to save the power consumption of the pump by
avoiding the passage in the recirculation line.
Recommendation
We recommend to
Switch off one pump completely
Avoid passage in recirculation line by maintaining the recirculation valve
Savings calculation
Operating power of the pump
8 kW
Annual saving
=
=
=
Investment
Nil
Immediate
The automatic flow based throttle valve operates based on the level of the
condenser. When the condenser level reaches minimum level, the throttle
valve closes and when condenser reaches maximum level, the throttle vanve
opens.
As throttling is an ineffective method of controlling flow. Power gets lost in the
form of pressure drop across control valve.
The estimated pressure drop across different equipment in the circuit is as
follows:
Sl. No.
Parameters
Pressure drop
(kg/cm2)
Steam ejector
0.5
3.0
Deaerator
2.0
Total
5.5 kg/cm2
The pump discharge header pressure is 7.8 kg/cm 2. Therefore, pressure drop
of more than 2 kg/cm 2 is happening across the control valve. Thus there is
good potential to avoid the pressure drop by installiing VFD and control the
speed of the pump as per the level.
Control the capacity of the pump based on the level in the condenser. Open
the control valve fully and give the condenser level signal to the VFD and
increase the rpm of the CEP pump when the level of the condenser increase
and vice versa and operate the VFD in closed loop.
Therefore, there exists potential to save the power consumption of the pump
by avoiding the pressure drop across hot well level control valve.
Recommendation
We recommend to
o
Operate the VFD in closed loop with the hot well level
Savings calculation
Pressure drop across control valve =
Pump discharge header pressure
2 kg/cm2
7.8 kg/cm2
23kW
5.75 kW
5 kW
Annual Saving
=
=
=
Investment
Rs 1.50 Lakhs
Payback
Parameters
Pressure drop
kg/cm2
Heat exchanger
0.5
2.5
Deaerator
2.0
Total
5.0 kg/cm2
The estimated pressure drop in the circuit to pump DM water from DM water
tank to deaerator is 5 kg/cm2. The DM water transfer pump can meet this
requirement.
The design specification of the DM transfer pump is as follows
Flow
: 50 m3/hr
Head
: 50 m
Rated Power
: 15 kW
Rs 1.0 Lakh
Rs 1.0 Lakh x 12
Rs 3.20 Lakhs
4 months
OF
INSTRUMENT
AIR
During the detailed energy audit at KR Pulp and Paper the compressors were
studied in detail and the following observations have been made.
Installed capacity
In paper plant: 5 x 380 CFM screw compressor
o 2 nos with 55 kW rated motor
o 3 nos with 75 kW rated motor
In Power Plant: 2 x 18.5 kW screw compressor
In operation Paper plant
2 nos of 55 kW compressor
1 no of 75 kW compressor
In operation Power plant
1 no of 18.5 kW compressor
The pressure setting of all the identified compressors is as follows:
Capacity
Actual
requirement
Pressure
Suggested
kW Savings
%
Pr
(Pr reduction
Reduction
& Unloading)
Loading Unloading reduction
CFM
%
Unloading
Compressor-1
at PM
380
0.00
380.00
6.5
6.90
5.5
15.6
Compressor-2
at PM
380
0.00
380.00
6.5
6.90
5.5
15.6
Compressor-3
at PM
380
75
95.00
6.5
6.90
5.5
15.6
28
6 bar
There exists a good saving potential to optimize the pressure settings of the
instrument air compressors.
Recommendation
Interconnect the compressed air pipe lines of both paper plant and
power plant and stop the compressor in power plant
As we can see from the above table that the unloading percentage of
compressor-3 is very high, it would easily accommodate the compressed
air requirement from power plant.
Install VFD in Compressor-3 and reduce the operating pressure setpoint
to 5.5 bar. This would have two benefits
o It would reduce the operating pressure thereby reducing the
operating power
o It would completely avoid the loss due to unloading
Press roll user requires 6 bar pressure, hence to cater its need, a small
booster compressor needs to be installed near the user
Savings calculation
As a first step, it is recommended to reduce the pressure settings and maintain
the average pressure at 5.5 bar
Loading pressure
6.5 bar
Unloading pressure
6.9 bar
Average Pressure
6.7 bar
=
=
6.7 5.5
6.7 + 1
15.58 %
100 %
55 kW
Power saving
=
=
55 kW x 1.00 x 0.1558
8.56kW
For 3 Compressors
3 x 8.56 kW
25.68 kW
say 25 kW
75 %
22.5 kW
Power saving
=
=
22.5 kW x 0.75
16.87 kW
say 16 kW
=
=
=
Investment for booster compressor and VFD for compressor-3 and piping
Payback Period
7.31 months
Say 7 months
Benefits
The annual energy saving potential is Rs. 16.40 Lakhs. This will require an
investment of Rs. 10.00 Lakhs, which will have a simple payback period of 7
months.
OF
INSTRUMENT
AIR
During the detailed energy audit at KR Pulp and Paper the compressors were
studied in detail and the following observations have been made.
Installed capacity
2 x 380 CFM screw compressor
o 2 nos with 55 kW rated motor
In operation Paper plant
1 nos of 55 kW compressor
The pressure setting of all the identified compressors is as follows:
Capacity
Pressure
CFM
Compressor1
Suggested
kW Savings
%
Actual
Pr
%
(Pr reduction &
Unloading requirement Loading Unloading reduction Reduction Unloading)
380
24
289.25
6.3
5.5
20.2
15.0
Recommendation
Install VFD and reduce the operating pressure setpoint to 5.5 bar. This
would have two benefits
o It would reduce the operating pressure thereby reducing the
operating power
o It would completely avoid the loss due to unloading
Press roll user requires 6 bar pressure, hence to cater its need, a small
booster compressor needs to be installed near the user
Confederation of Indian Industry
Savings calculation
As a first step, it is recommended to reduce the pressure settings and maintain
the average pressure at 5.5 bar
Loading pressure
6.3 bar
Unloading pressure
8 bar
Average Pressure
7.15 bar
=
=
7.15 5.5
7.15 + 1
20.24 %
76 %
55 kW
Power saving
=
=
55 kW x 0.76 x 0.2024
8.5 kW
24 %
16.5 kW
Power saving
=
=
16.5 kW x 0.24
3.96 kW
say 4 kW
=
=
=
Payback Period
Benefits
The annual energy saving potential is Rs. 5.00 Lakhs. This will require an
investment of Rs. 6.00 Lakhs, which will have a simple payback period of 15
months.
User
Source Pr
User Pr
Delta P
120
Wire bivac
300
120,140,150, 150,
140,180
Trivac
250
180,180
70
280
240
40
540
520
20
580
420
160
580
420
160
500
340
160
5
Suction Press (high zone)
6
7
Pickup Roll
10
390
60
380
320
440
310
130
440
310
130
As seen in the table above, the pressure drop between the user and the pump
in each area is huge. The possible reason for the same could be
Improper water
carryover
evacuation from
separators
leading to moisture
Recommendation
As it is observed that there is a huge pressure drop between the user and the
pump, it is evided that the line sizing in each user is not proper. It is highly
recommended to call a third party to conduct a detailed engineering study only
for the pipe sizing so that it could be brought down to acceptable limits. While
conducting the study the following points needs to be kept in mind
The pressure drop across the complete pipeline should not be more than
20 mmHg
A detailed study on the pipe sizing alone should be done and the
pressure drop should be brought down to acceptable limits
Also VFD needs to be installed for all vacuum pumps and vacuum needs to be
maintained based on the user requirement from DCS.
Savings
The saving potential is calculated only for those pumps as shown in the table
below where the pressure drop between the source and the user is high.
Vacuum
Pump No
1
5
6
7
10
11
User
Wire bivac
Suction Press (high zone)
Pickup Roll
1&4 press felt, uhle box
Source Pr in
mmHg
300
580
580
500
440
440
User Pr in
mmHg
Max 180
420
420
340
310
310
Delta P in
mmHg
50
90
90
90
60
60
Savings calculation
Sample calculation for Wire Bivac
= 300180-50(separator)-20(piping)
= 50mmHg
= Pressure drop x Power consumption
Head developed
= 50mmHg x 102 kW
300 mmHg
= 17 kW
Source
Pr in
mmHg
User
Wire bivac
Suction Press (high
zone)
Pickup Roll
1&4 press felt, uhle
box
Total
300
580
580
500
440
440
User Pr
in
mmHg
Max
180
420
420
340
310
310
Delta
P in
mmHg
Power
consumption in
kW
50
90
90
90
60
60
102
180
147
141
174
153
savings
in kW
17
28
23
25
24
21
138
Investment for conducting a complete engineering study on the pipe line sizing
and for new piping
= Rs. 25,00,000
= Rs. 25 Lakhs
Simple payback period
Benefits
The annual energy saving potential is Rs. 55.20 Lakhs. This will require an
investment of Rs. 25.00 Lakhs, which will have a simple payback period of 6
months.
Confederation of Indian Industry
COGGED
FLAT
BELT
IN
Background
During the detailed Energy Audit conducted at KRPulp and paper, various
equipments were studied for possible energy saving opportunities.
Some of the auxiliary bag filter fans, pumps, compressors and blowers use
conventional V-belt drives for power transmission. Use of V belts causes some
energy losses. There is a power transmission loss of about 7% - 8%, when the
V-belts WEDGE IN and WEDGE OUT of the grooved pulleys.
The latest trend in the industry is to use synthetic flat belt drives or cogged
belts in place of the V-belt drives. These belts have the following advantages:
From the above graph it is clear indication that the flat belt is operating at
98% efficiency when the drive is 100% loaded, but V-belt is operating at the
94% efficiency only. There exists good potential to replace V-belt with the flat
belt drives.
These drives are ideal for steady load applications, such as fans, compressors,
and blowers. However, it should be ensured that the area around the
equipment is free from oil or water spillage.
Also, proper preventive care must be taken to ensure proper alignment
between the drive and driven equipment.
Recommendation
We recommend converting the identified V-belt drives into flat belt drives for
the major auxiliary bag filter fans. The list of identified fans is given below.
Ensure that the area around the equipment is free from oil or water spillage
(cover could be used for protection)
S.No
1
2
3
4
5
6
7
8
9
10
11
Equipment
Mixing Chest
Machine Chest
Pulp dump chest
Agro pulp chest
Vacuum pump - cautisizing plant
ETP drain pump
Bagass chest agitator
Vacuum pumps - 11 nos
Unit-1 Boiler 7TPH FD Fan
Unit-1 Boiler 7TPH ID Fan
Vacuum pumps - 5 nos
Total
Operating kW
33
15
33
30
130
45
55
1398
28
23
366
2156
Saving Potential
1.32
0.6
1.32
1.2
5.2
1.8
2.2
55.92
1.12
0.92
14.64
86.24
Savings
On a conservative basis 4% saving is calculated for the identified equipments
Sample savings calculation for Mixing Chest
= 33 kW x 4 % savings
= 1.32 kW
Likewise, calculating for all the equipment, the total savings would be 86 kW
= 86 kW x 8000hrs x Rs 5/ Unit
= Rs 3440000
= Rs 34.40 Lakhs
Investment for pulley change and cogged flat belt
Confederation of Indian Industry
= Rs 20.00 Lakhs
Simple payback period
Benefits
The annual energy saving potential is Rs. 34.40 Lakhs. This will require an
investment of Rs. 20.00 Lakhs, which will have a simple payback period of 7
months.
The following observations were made in the evaporator and paper section
Steam consumption in evaporator section
Average
- 13 TPH
Recovery
- 55%, 7TPH
- 22 TPH
Recovery
- 75%, 16 TPH
The condensate levels in flash tank and vacuum tank at paper machine section
is maintained by individual pumps associated with each tank with the help of
control valves. The condensate collected in each tank is pumped into a
recovery tank through a common header, which is again pumped into the
deaerator with the help of a pump as shown in the figure above.
Confederation of Indian Industry
The condensate from the recovery section is also sent to the recovery tank
which is at 108 deg C.
Observation
Paper Machine: At paper machine section, the individual controls valves are
heavily throttled to the tune of 26% and 49%, which is due to mismatch
between the design and operating condition.
Evaporator Section: As the condensate which is entering the recovery tank
from the evaporator section is at 108 deg C, some portion of the condensate
flashes into steam which is vented into the atmosphere
Recommendation
It is recommended to connect the condensate line from both evaporator
section as well as from paper machine section directly into the deaerator as
indicated by dotted line in the figure below.
Install VFD in pumps associated with Flash tank and vacuum tank and the logic
to VFD would be maintain the tank level.
Stop the pump that transfers condensate from the recovery tank to the
deaerator
The savings with this modification is as follows
The energy loss associated with the pressure drop across the control
valves in Flash tank and vacuum tank pumps can be completely
eliminated.
Confederation of Indian Industry
Enthalpy
= 452 kJ/ kg
= 10 TPH
= 0.015 x 10TPH
= 152 kg/ hr
-20 m3/ hr
Head
- 50 mtr
Motor
- 5 kW
Savings
Stoppage of recovery tank pump
= 11 kW x 8000hrs x Rs 5/ Unit
= Rs 440000
= Rs 4.40 lakhs
Investment is for the piping, VFD and installation of new pump at the
evaporator section
= Rs 4.00 Lakhs
Simple payback period
Benefits
The annual energy saving potential is Rs. 4.40 Lakhs. This will require an
investment of Rs. 4.00 Lakhs, which will have a simple payback period of 11
months.