8.igen gidelines chp ahp
TRANSCRIPT
Coal Handling Plant – Energy Audit Methodology
Crushers
Conveyers
Feeders
Tipplers
Stacker Reclaimers
Major Equipments used are
Measurement and Observations to Be Made
Drive speed, belt speed ,roller condition, belt condition and belt loading with respect to design.
Power consumption of equipments load & unload condition
Loss of energy in the coal in stock yard due to spontaneous combustion
Equipments operations and throughput comparison
with design conditions Unit load of plant
Instrument used and frequency of measurement.
Measurement and Evaluation
Measure the power input i.e. electrical parameters such as kW, kVA, Current, Voltage, power factor, for all drives for no load and load conditions
-Coal throughput rate: Study track hopper management/ coal unloading. It is also desired to study time-motion study. Note the coal throughput using coal totalisers or other alternative methods.
Steps Involved Data Collection
Observations and Analysis of Drives Speed Belt Tension Roller Conditions Belt Conditions Belt Loading
Energy Conservation Measures
Steps Involved
Evaluation of specific energy consumption and capacity utilisation
Comparing design and PG values of
Overall CHP
Stage wise
Equipment wise - conveyor belts,paddle feeders,
crushers, vibro feeders, belt feeders,wagon tippler,
stacker, stacker,reclaimer ….
Data Collection
Design details of overall CHP Capacity,specific power consumption etc
Process flow diagram Track hoppers
Number , length , capacity, power, layout etc. Paddle feeders
Number, capacity, travel, speed ,power Wagon tippler
Number , type,capacity,maximum weight,time cycle, motor rating
Data Collection Crushers
Number, type, capacity, coal size at inlet and outlet, motor rating, power consumption, number of vibrating feeders
Coal Design parameters and sizes Belt Conveyors
Capacity , number, speed, width, motor rating power consumption
Stacker Reclaimer Quantity, capacity, travel speed. Number of buckets and
length of boom, motor rating Other equipments
Vibrating feeders, dust suppression system pumps , belt feeders, dust extraction fans etc
Evaluation of Equipment Loading and Specific Energy Consumption
For direct bunkering , reclaiming and stacking use the table for power consumption and throughput
Direct Bunker in Design capacity Average capacity tph Hrs operation
Equipment
MotorRated
kWMotor
No loadMotor
Average load
Specific Energy Consumption
Average Rated
A kW A kW kW /MT kW /MT
Equipment Ref.
Capacity Motor Input Kw
Speed of driven equipment
LengthFor belts
Hours of operation
Specific energy consumption
NL Load
Paddle feeders TPH
Belt Conveyors TPH
Vibro Feeders TPH
Grizzly Feeders
TPH
Belt Feeders TPH
Dust Extraction Fans
Nm3/h
Dust Suppression pumps
M3/h
Crushers TPH
Stacker Reclaimers
TPH
Other Equipments
TPH
Key Specification parameters to be measured stream wise
Parameter Unit Tracke hopper Bunker End
Total Coal Receipt Lakh tons
Total Electrical Related load MW
Overall operating load MW
Energy Consumption of CHP Kwh
Plant Equipment Operating Hours
Hrs
Plant Utilization Factor %
Total Gross Generation of Station
MU
Total auxiliary power consumption of station
MU
Total Power Consumption by CHP plant
MU
% of power consumption of CHP with respect to total auxiliary power consumption
%
Specific energy Consumption kwh./MT
Equipment wise operating hrs hrs
Production and Operating Data
Coal Parameters
Unit Design Actual Remarks
Upstream of crusher size of coal
mm
Downstream of crusher size of coal
mm
Total coal in bunker filling
tph
Major Performance Parameters
Calculation of Specific Energy Consumption
Calculate kWH /MT for existing operations i.e. bunkering, stacking, and reclaiming both activity wise & equipment wise for last one year.
Based on energy meter reading & coal receipt data, calculate month wise kWh / MT for last one year.
Plot kWh/MT on Y-axis & months on X-axis.
Major Performance parameters
Coal Sample Analysis Send 2-3 samples of coal taken from the belts feeding to
the crushers for sieve analysis to determine extent of coal particles below 20 mm size and above 200 mm size or design size which ever is applicable. This analysis will help in optimising crusher operation
Lub Oil Inspection
Performance of CrushersIf significant quantity of coal >20 mm size is observed on down side of crusher then it may led to substantial decrease in mill performance
Identification of Energy Conservation Possibilities
Performance improvement options: Possibilities in Improving the throughput this is a major
energy saving area which offers substantial saving at minimum investment.
Reducing the idling time. Increasing the loading. Modifications and changes in coal feeding circuits. Need for automation and controls. Identification of combination of various least power
consuming equipments and recommending merit order operation.
Use of natural daylight through conveyor galleries and use of fire resistant translucent sheet.
Identification of Energy conservation possibilities
Maximum Mechanical Handling : Minimum Bulldozing:
Sequence of coal handling operations like receipt, unloading, stacking and reclaiming and the selection of machinery is to be made in such a way that all the handling operations are accomplished without the use of semi mechanized means like bulldozers which are more energy intensive equipments.
However Principal of “FIRST IN FIRST OUT” is to be adopted for coal receipt & consumption and at any time coal need not to be stocked in yard for more than incubation period (duration between coal mined and getting self ignited)
The major energy consumers in ash handling
plant are ash water pumps and ash slurry
series pumps.
The contribution of wet ash handling plant in
auxiliary power consumption varies between
1.5 to 2%.
Many systems have dry ash handling plant.
Major Objectives
Evaluation of ash water ratio
Analysis of higher consumption of water if any
Comparison of the ash water ratio with design
value, P.G. Test value and previous energy
audit values
Equipments performance
Steps Involved
Data collection
1) line diagram
2) detailed specification pertaining to type,handling capacity,design ash %ash collection rates,fly ash and bottom ash extraction capacities,operating hours,design bulk densities
Steps Involved
3) PG test values/design values of coal parameters, ash generation, ash to water ratio,
slurry velocities, no.of pumps involved.
4) Energy Consumption details
5) Water consumption details
6) Performance characteristics curves of all pumps, if in parallel then curve for parallel operation.
Operating parameters to be monitored
Water supply rate Water velocity Discharge Head Valve position Temperature Operating hours and schedule Pressure drop in system Pump/motor speed Load of the plant Discharge throttle valve position Flow control frequency % loading of pump on flow and head % loading on motor
ID code
Application
Make , type and model
Fluid to be pumped
Density of fluid
No.of stages
Rated suction pressure
Rated Discharge pressure
Rated total pressure
Rated flow m3/h
Rated Efficiency
Input KW of pump
Speed of pump
Motor KW
Motor voltage,current
Motor rpm
Motor Efficiency
Minimum Recirculation required
Performance Parameters for Pumps
Hydraulic power in KW =
( Q(m3/s)*total head (m)*density (kg/m3) ------------------------------------------------------
1000
Measurement of Electrical parameters and motor loading
Ash water and ash slurry water pressure and flow measurement.
ObservationsSuction abstractionsImpeller pittingShaft alignmentThrottle controlRe-circulationClearancesBearing conditionInter-stage leakages
Evaluation of ash to water ratio
Parameters Fly ash Bottom ash CombinedDesign ash generation
Actual ash generation
Design ash to water ratio
Actual ash to water ratio
Design density of slurry
Actual density of slurry
Total power consumption of pump
Specifc energy consumption kw/ton of ash evacuationDesign ash evacuation rate
Parameter Fly ash Bottom ash Combined
Actual ash evacuation rate
Actual ash slurry velocity
Design head drop in ash slurry pipe line
Actual head drop in ash slurry pipe
While conducting the energy audit of the pumping, the following aspects need to be explored in detail for Optimisation / improving the ash to water ratios
Possibilities of reducing the operating hours of the AHP
Adequacy of pipe sizes
Improvement of pumping systems and drives.
Use of energy efficient pumps
Replacement of inefficient pumps Use of high efficiency motors High Performance Lubricants: The low
temperature fluidity and high temperature stability of high performance lubricants can increase energy efficiency by reducing frictional losses.
Booster pump application