Ultratech, AP Cement Works
Ultratech, AP Cement Works
Ultratech, AP Cement Works
Welcome to all
2
4x25 MW TPP 1x4 MW WHRPP 2x11.7 MW WHRPP
First ISO:50001:2011 certified unit
Hods/
SH Engineer Engineer Project
Step Project Initiation FH
(Opern) (E) (Electrical) leader
(TPP)
1 Data collection I R I A I
Equipment wise power consumption data
2 R R R A/C I
analysis
3 Identifying Power saving potential area R R R A C
4 Conduct Brain storming session R R R A C
5 Project Execution -PROCESS R I I A I
6 Project Execution -E&I I R I A I
7 Project Execution -MECH I I R A I
8 Post Evaluation R R R A C
9 Sharing of Outcome R R R A I
Total TPP
Aux.
Common
Unit-1 Aux. Unit-2 Aux. Unit-3 Aux. Unit-4 Aux
Loads
Boiler Boiler Boiler Boiler
Fans CHP
Fans fans Fans
ESP AC &
ESP ESP ESP
PNV
Higher
Wind loss Moisture in Stem Sub cooling
Makeup
fuel dumping loss loss
water
TG Aux Moisture in
Heaters TTD
Air
Remarks
86.7 4th GCW 1st
VC
Plant load factor %
Aux. Consumption %
86.3 RDCW 11.47 RWCW
83.6 KCW
11.37 GCW
78 10.6
75.8
SCW 10.12 ACW
RCW 9.69 RCW
72.4 9.57
RWCW SCW
70.2 9.37
AC RDCW
56.9 9.25
50.8 VC 9.08 KCW
HCW APCW
0 5 10 15
0 20 40 60 80 100
RDCW
3305 334
Heat Rate Kcal/Kwh
VC 4th
AC
3172 325 ACW
APCW
3159 Generation 286
KCW
3127 ACW 281
3109 7th RCW 248 RCW
3103 RWCW 237 RWCW
3103 195 SCW
AC 112
3055 SCW 64 VC
3036 KCW HCW
0 100 200 300 400
2900 3000 3100 3200 3300 3400
CFBC TPP Power share
with
APC % Net apc
ACC
12 10.95
10 13.31%
A
7.737.828.15 7.69
u 8 6.966.92
x
6
.
4
% 86.69%
2
0
15 18 25 25 27 30 250
Plant Capacity MW
Action plan to Reduce Auxiliary power from present 9.3% to 7.6%
Expected Per day
S.NO Area Actions FPR Saving Target date
(KWH)
1 TPP Improve PLF by Power wheeling / selling to IEX VPG 1350 Continue
1. Reduce PA fan flow from 20 to 17.5 Kg/s.
2. Optimization of Oxygen in Boilers.
2 Boiler-PA Fan SKR 1250 30.12.17
3. False air entry to be arrested in APH.
4. Reduction of Bed Height from 1010 to 950 mm
1. Avoid parallel unloading of Raw meal Bowzers.
2. Stop Ash handling operation while Unloading of Raw meal
bowzers.
Target-7.2% APC in
3. Ensure Ash handling system operation in probe mode only and
optimize ash handling cyclic time.
Dalmia Cement CPP
4. Avoid Air Cleaning with compressed air.
5. Shut off Air valves of Phase-1 equipments while running only
3 Compressor
Phase-2 TPP is in operation.
,Karnataka SKR 1230 20.03.18
6. Run only VFD operated compressors.
7. Installation of low pressure Air Compressor for raw meal
unloading
8. Air audit to be conducted for CHP,AHP & boiler area
Operate SA Fan in close loop with Bed temp and its logic
10 Boiler-SA Fan SKR/VPG 180 30.12.17
preperation in DCS
30.01.17
Re-calibration of fuel feeder bed height from 30 TPH to 12 TPH
13 Boiler-Fuel Feeder VPG/VM 60 30.11.17
and logic preperation in DCS
20
Intgrity - commitment- Passion -Seamlessness -Speed
Sn Savings in
o Project Status Kwh Savings in Thermal
1 Install Auto Star delta star convertor for identified under loaded belt conveyor motors Not feasible, It should be considered factor of safety. NA
2 Replace 150 W HPMV Lamps with 48 W LED lamps in TG hall Completed 1787
4 Reduce the pressure drop across the damper in L91BF1,L51BF2,L11BF1 Completed, All dampers removed 36500
5 Optimisation of instrument air Completed ,Auto drain valve timing adjusted 73000
Total-13
Completed-10
Completed, Reduces the compressor set point as equal
6 Optimisation of service air Not feasible -3 ,isnos
with IFC set point about 3.8 Kg/cm2 at end point 54750
12 Reduction in radiation losses in Boiler Completed ,Identified areas insulation completed 507480 Kcal
90 3400
14.00
13.71
88
88
87 3200
12.00 11.60 3167
11.03 3118
10.01 10.27 3034 3030
86 85.53003 3000
10.00
PHR Kcal/Kwh
APC %
84 2800
8.00
6.00
82
81 2600
81
4.00 80 2400
2.00 78 2200
0.00 76 2000
2013-14 2014-15 2015-16 2016-17 2017-18 2013-14 2014-15 2015-16 2016-17 2017-18
• Planted 200 No's Trees in CPP for Last year 16-
17 in the view of Vanam –Manam.