Professional Documents
Culture Documents
AAICSET-2015
ISBN: 9-780993-909238
Gheewala Ruturaj D.
Niraj K. Shah
Dinkar M. Jethva
Executive Engineer
NIRMA University
NIRMA University
Ahmedabad, India
ruturaj9491@gmail.com
Ahmedabad, India
niraj.shah@nirmauni.ac.in
2009 was 96 kWh in rural areas and 288 kWh was in urban
areas for those with access to electricity in comparison to the
worldwide per capita annual average of 2,600 kWh and 6,200
kWh in the European Union[6]. Electric energy consumption
in agriculture is highest (18%) in India. The per capita
electricity consumption is lower compared to many countries
despite cheaper electricity tariff in India[7].
High demand for electricity, especially in the developing
countries are raising power generation technologies. At the
same time the discussion about causes of global warming has
focused on emissions originating from power generation and
on CO2 reduction technologies such as:
Alternative primary energy sources
Capture and storage of CO2
Increased efficiency for converting primary energy
content into electricity
Focusing on the third point, relatively little attention has been
paid to the efficiency of auxiliary processes in thermal power
plants, which account for about 5-8% of the gross generation
capacity. Out of the total installed capacity the 87.55% is
constituted by the Non-Renewable Plants of which around
60%(134.39GW) is constituted by Coal and Lignite based
Thermal Power Plant. Of these 8.4%(11340MW) of energy is
consumed by the Power Plant equipments as Auxiliary
Power.[8] So it is the at most need to reduce this auxiliary
power consumption through planned procedures. Examples of
auxiliary processes in thermal power plants:
Conveying and preparing the fuel
Moving the necessary air into the furnace
Moving the flue gases from the furnace
Returning the condensed water back to the steam
generator
Maintaining the necessary cooling effect in the
condenser
Operating various emission cleaning processes.
A majority of these processes are run by centrifugal pumps,
fans and compressors driven by large electrical motors.[9]
Objective of present work is to compare the performance of
Boiler Feed Pump(BFP), Condensate Extraction Pump(CEP)
and Cooling Water Pump(CWP) with design and explore
energy saving strategies.
I. INTRODUCTION
The electricity sector in India had an installed capacity of
254.049 GW as of end September 2014[2]. India became the
world's third largest producer of electricity in the year 2013
with 4.8% global share in electricity generation surpassing
Japan and Russia [3]. Non Renewable Power Plants constitute
87.55% of the installed capacity, and Renewable Power Plants
constitute the remaining 12.45% of total installed Capacity
[4]. As of March 2013, the per capita total electricity
consumption in India was 917.2 kWh[5]. The per capita
average annual domestic electricity consumption in India in
Akshar Publication 2015
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B) Test Procedure
Energy audit of pumps can be done by knowing specific
power consumption and pump efficiency. To determine these
quantities input parameters are flow rate, net head and power
consumption.
Following steps were followed for calculating different
parameters.
i.
Flow measurement
The measurement were taken by using Ultrasonic Flow
Measurement method. First the diameter of the pipe was
measured. Then two probe sender and receiver were attached
on the pipe line on the either side of pipe. Then readings were
taken at interval of 10 mins.
ii.
Head measurement
The measurement were taken using installed pressure gauges.
The suction head was measured from the inlet pressure gauge
of the pump. The discharge head was measured from the outlet
pressure gauge of the pump. Then difference was taken and
total head was estimated.
iii.
Power measurement
The power consumption by each pump were taken using
installed power analyzer in plant.
i.
Hydraulic Power
Hydraulic power of a pump is gives by:
Ph(kW)= QX (hd-hs) XX g/1000
Q= Volume Flow rate (m3/s)
=Density of fluid(kg/m3)
g= Acceleration due to gravity (m/s2)
(hd-hs)= Total Head in meters
ii. Motor Input Power
Input Power can be calculated using Power Analyzer.
iii. Pump Shaft Power
It is calculated by multiplying the motor input power by motor
efficiency.
Ps= Pm X motor
motor=Synchronous speedXRated SpeedX100/
Synchronous Speed
iv. Pump Efficiency
It is calculated by dividing the hydraulic power by pump shaft
power.
pump= Ph/Ps[11]
v.
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44
S.N
Pumps
Flowrate
(m3/s)
Head
(mWC)
Moter
(kW)
Efficiency
(%)
BFP-4A
0.0853
1725.7
3010
58
0.83
BFP-4B
0.0853
1587.2
2880
57.88
0.88
BFP-4C
0.0853
1593.2
2670
58.27
0.84
BFP-5A
0.1096
1645.9
3022
67.41
0.77
BFP-5B
0.1069
1782.41
3216
69.51
0.82
BFP-5C
0.1086
1798.81
2890
75.08
0.74
BFP-6A
0.0973
1535
2750
64.33
0.79
BFP-6B
0.1027
1559
2850
65.71
0.77
BFP-6C
0.1001
1590
2680
70.44
0.74
10
CW-4a
3.7167
22
1166
76.52
0.09
11
CW-4b
3.8194
22.5
1170
81.06
0.09
12
CW-4c
2.7778
29
1190
77.35
0.12
13
CW-5a
3.4917
21.6
1133
73.72
0.09
14
CW-5b
3.1806
21.1
1144
64.01
0.1
15
CW-5c
3.1389
21
1290
59.08
0.11
16
CW-6a
4.0639
21.6
1273
76.1
0.09
17
CW-6b
2.9722
21.1
1144
61.91
0.11
18
CW-6c
3.1389
23.5
1282
62.79
0.11
19
CEP-4A
0.1528
201
480
73.22
0.87
20
CEP-4B
0.1611
192.2
510
73.15
0.84
21
CEP-5A
0.1472
202
470
74.18
0.89
22
CEP-5B
0.1514
193
475
68.76
0.87
23
CEP-6A
0.1500
215.4
453
83.62
0.84
Pumps
Efficiency
Remark
Problem
0.97
BFP-4A
58
1,5,6
BFP-4B
57.88
6,11,12
2.Noise
BFP-4C
58.27
15
3.Cavitation
BFP-5A
67.41
5,6
4.Shaft Deflection
BFP-5B
69.51
5,6
5.Throttling
24
CEP-6B
0.1333
221.2
467
68.22
SEC
Fig. 4.
E) Summary
The Efficiency of all 9 BFP, 9 CWP and 6 CEP are
summarized in following Fig 2 ,Fig 3 and Fig 4 respectively.
Fig. 2.
Fig. 3.
Pump Problems
BFP-5C
75.08
15,6
6.Leakage
BFP-6A
64.33
8,14
7.Valve
BFP-6B
65.71
8.Internal Rotation
BFP-6C
70.44
15,6
9.Impeller Size
CW-4a
76.52
14
10.Friction
CW-4b
81.06
11.Bearing
CW-4c
77.35
12.Low Discharge
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CW-5a
73.72
13
13.High Resistance
CW-5b
64.01
12
14.Seal leakage
CW-5c
59.08
15,7,11,6
15.Intermettant use
CW-6a
76.1
14
CW-6b
61.91
1,3
CW-6c
62.79
15,7,12
CEP-4A
73.22
6,12
CEP-4B
73.15
6,10
CEP-5A
74.18
13
CEP-5B
68.76
3,5,8
CEP-6A
83.62
[3]
[4]
CEP-6B
68.22
12,4,11,2
[5]
Table. 3.
REFERENCES
[1]
[2]
Problem
Remedial Action
[8]
Overhauling
Shaft Alignment, Maintaining inlet and
outlet pressure
[9]
2. Noise
3.Cavitation
4.Shaft Deflection
[7]
5.Throttling
[10]
Use VFD
6.Leakage
Check Leakage
[11]
7. Valve
Replace/Repair
[12]
8.Internal Rotation
9.Impeller Size
[13]
Calibrate size
10.Friction
Coating
11.Bearing
Replace/Repair
12.Low Discharge
Check Leakage
13.High Resistance
Overhauling
14.Seal leakage
Replace/Repair
15.Intermettant use
VFD
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