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EXECUTIVE SUMMARY. Break up of Electricity Consumption . Scope of Study – Electrical System Network. Electrical System Network

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scope of study electrical system network
Scope of Study – Electrical System Network
  • Electrical System Network
  • Review of electricity bills, contract demand and Power Factor for last one year, in which possibility will be explored for scope of further reduction of Contract Demand and improvement of Power Factor.
scope of study transformers
Scope of Study - Transformers
  • Transformers of various capacities/ rating
  • This would involve analysis of the loading patterns and estimation of the losses to evaluate the possibility of load rationalization
scope of study motive load
Scope of Study – Motive Load
  • HT equipments including motors/pumps, ID/FD Fans.
  • LT motors/Pumps/ Fans/ Borewell motors and Blowers above 25 KW.
  • Study the loading pattern flow etc. in case of pumps/ fan so as to evaluate the operating efficiency and possibility of reducing the energy consumption. Also the feasibility of using electronic drives would be worked out
scope of study motive load1
Scope of Study – Motive Load
  • Belt conveyor motors/ Dust extraction fan/ Main chain motors above 25 KW.
  • Study of the mechanical power transmission systems and assess the feasibility of using more efficient power transmission systems.
scope of study compressors air ammonia
Scope of Study – Compressors (Air/Ammonia)
  • Air compressors
  • Ammonia compressors 2 Nos. in the Ammonia Storage Plant.
  • Evaluate the Specific Power Consumption, free air delivery capacity, operational scheduling and other parameters so as to work out the cost of compressed air and feasibility for further optimisation. Also the leakages (if any) in the distribution system would be identified using ultrasonic leak detection equipments
scope of study air conditioning
Scope of Study – Air Conditioning
  • Air Conditioning Plant (above 80 TR each).
  • CO2 Compressors in Urea – Iand Urea – II.
  • Compressors in AC Ammonia Control Room and AC Ammonia Compressor House.
  • The audit would involve analysis of various parameters like co-efficient of performance, Tonnage Delivered, Effectiveness of the Ducting and allied systems
scope of study cooling tower pumps fans
Scope of Study – Cooling Tower Pumps / Fans
  • Cooling Tower Pumps/ CT Fans above 25 KW.
  • This would include detailed study of the operational performance of the Cooling towers through measurements of temperature differential, air/ water flow rate to enable evaluate specific performance parameters like approach, efficiency etc.
scope of study gtg
Scope of Study – GTG
  • GTG’s (2 Nos. in the Power Plant) :
  • Study of the operational scheduling, cost of power generation, effectiveness of the heat recovery systems etc. and feasibility of energy savings would be worked out
scope of study illumination
Scope of Study – Illumination
  • Lighting and allied systems.
  • A comprehensive study of the entire Lighting systems covering the Light Source (Lamps), Luminaries (Reflectors etc), and the Gears (Ballasts) would be taken up. Besides this the illumination levels required vis-à-vis available would also be studied
scope of study boilers
Scope of Study – Boilers
  • Power Plant Service Boiler (150 MT/ hr).
  • Waste heat Boilers (3 Nos. in Ammonia – I and 3 Nos. in Ammonia – II).
  • Detailed study of the boiler operations to evaluate the combustion performance -both by direct and indirect method. In the direct Efficiency method measurements of fuel consumption vis-à-vis steam generation would be done continuously for 24 hours - provision for measuring the fuel/ water flow during the test period has to be provided by the plant. Energy balance would be worked out giving different losses prevalent in the boilers. Also, the study of steam generation and distribution system /network would be carried out
scope of study steam distribution network
Scope of Study – Steam Distribution Network
  • Steam Distribution system inAmmonia – I & II, Urea I and II, Power Plant.
  • Condensate recovery/ Handling system.
  • Steam Traps (approx. 1000 Nos.) (sample 25% will be checked).
  • This would include study of the steam and condensate distribution networks to evaluate the appropriateness of the pipe size, insulation levels, steam trap performance, feasibility of flash steam recovery etc
scope of study furnaces
Scope of Study – Furnaces
  • Heat Recovery Steam Generators (HRSG’s) – 2 Nos. of 80 MT/hr each in the Power plant and 1 No. HRU of 120 MT/hr in Ammonia – II.
  • Operational performance evaluation and suggest measure for improvements
other points

1. Operation of Gas Turbines on naptha is not recommended due to reduced efficiency and maintenance issues

  • 2. Operation of HRSG in auto mode is not recommended
  • 3. Potential for saving energy by use of variable frequency drives exists in DM Plant also; however, as the number of pumps are large, some discussion is required to develop better understanding of the utilization and operating hours
  • 4. The operating efficiencies of cooling tower pumps are estimated to be in the range of 84% to 88%, which reasonably acceptable considering site variations

Other points

other points1

5. Compressed air leakage survey was done; list of identified leakage points have been provided

6. About 100m3/hr process condensate at 100°C comes out of process condensate stripper after transferring heat to incoming condensate; this condensate is cooled in cooling water heat exchanger before sending to DM water plant. This hot water can be used for a 300 TR absorption chiller for supplying cooling to control rooms or process applications.

7. The efficiencies of some process pumps in Ammonia – I & II and Urea – I & II have been reviewed

8. On request of plant managers, cooling water flows at a number of process heat exchangers were measured in Ammonia – I & II and Urea I & II

Other points

other points2

9. The transformer efficiencies of majority of the operating transformers have been estimated; no changes for efficiency improvement are envisaged in this area. The possibility of use of “low loss” amorphous core transformers for non-critical loads in future projects.

10. Measurements were made on majority of the working electric motors above 50 hp. The loading levels are generally good and no specific recommendations are made for motors.

Other points

other points3

1.Drinking water requirement in the factory is reported to be around 500 m3 per day which for the 1200 nos. of employees appear to be very high. Assuming that there is additional staff of contractors of about 600 and the company employees of 1200 (total 1800 persons) using water for drinking and sanitary purpose the consumption at any point of time should not exceed 150 m3 per day, which means there is scope in this area to reduce the consumption by about 350 m3 per day i.e. 127750 m3 per annum.

Other points

other points4

2. The maximum number of people at any point of time in the town ship (colony) including the employees and outsiders (contracted workers) is not likely to exceed 2500. Taking Indian standard of water consumption at the rate of 100 litres per person/day, the consumption is not likely to exceed 250 m3/day. As per the international standard about 150 litres of water is consumed per person per day. Applying the mean standard of 120 litres per person per day, the water consumption should not exceed 300 m3/day. However, from the record made available to us, it appears that the daily consumption is in excess of 600 m3/day and this it self offers scope to reduce the consumption by about 300 m3/day i.e. 109,500 m3/annum.

Other points

concluding remarks

Energy Cost Savings:

  • 1.The total energy cost savings with zero or minor investments is estimated Rs 117 lakhs/year. The payback will be immediate or less than 6 months in these cases.
    • 2.The total energy cost saving for measures with payback period between 6 months and 2 years is estimated Rs. 80.5 lakhs/year savings with an investment of 119 lakhs.
    • 3.The total energy cost saving for measures with payback period more than 2 years is Rs 2.39 crores/year with an investment of Rs 12.0 crores. It may be noted that the Investment for Turbo Expander and Centrifugal compressor account for about Rs 10.5 crores of the above projected investment.
    • 4.The total energy saving potential identified in this report in about 4.36 Crores/annum.

Concluding Remarks

water cost saving

1. Total water cost saving potential identified is Rs 72.6 lakhs/year.

2. The plant has already invested in change of intercooler tubes of Syngas compressor, and has planned for condensate recovery schemes so that stripper operation can be minimized.

Water Cost Saving