Nava Bharat Ventures Limited Power Division

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Jonathan Rice
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1 Nava Bharat Ventures Limited Power Division

2 Encon in compressed air systems Best Practices in Power Plant

3 Encon in compressed air systems

4 Encon in compressed air systems

5 Encon in compressed air systems

6 Encon in compressed air systems Maintenance 3% Capital 9% Water 8% Energy 80%

7 Encon in compressed air systems A properly managed compressed air system can save energy, reduce maintenance, decrease downtime, increase production throughput, and improve product quality.

8 Encon in compressed air systems Compressed air usage in Power Plants

9 Compressed air usage in Power Plant Instrument Air For valves and dampers operation Service air For Cleaning floors. Ash handling systems To convey ash from various ESP and Boiler collection points

10 Compressed air usage in Power Plant De dusting systems Reverse air for pulse jet systems, Bags cleaning Fire Fighting systems Auto operation of fire fighting Deluge valves Miscellaneous Tools

11 Compressors details at NBVL Plant air compressors Make Model Capacity Total compressors :Kirloskar Pneumatic co.ltd. :TBDQM :20.34 M 3 /min(fad) :4 numbers

12 Compressors details at NBVL Ash Handling Compressors Make :Chicago Pneumatic. Model :1 HX2-31x31 Capacity :20.34 M 3 /min(fad) Dis. pressure : 4 Kg/sq.cm Total compressors :4 numbers Make Model Capacity Dis. pressure Total compressors :Kirloskar pneumatic co.ltd. :TBDQL :38 M 3 /min(fad) : 4 Kg/sq.cm :3 numbers

13 Encon in compressed air systems Initial condition Main air compressors 2 numbers in operation ENERGY : 4000 kwh/day AHP Air compressors 2 numbers CP Make 2 numbers kirloskar make ENERGY :10,000 kwh/day

14 Encon in compressed air systems Measures taken towards energy conservation

15 Measures towards energy conservation Compressor efficiency monitoring & improvement. Pressure tuning of compressors. Piping layoutmodifications to reduce pressure drops. Leakage points identification & arresting.

16 Measures towards energy conservation Cleaning of bags with transvector nozzles. Conversion of pneumatic appliances to electrical operated. Separation of Low pressure applications. and high pressure

17 Measures towards energy conservation Pressure regulators installation for Low pressure /Volume required equipments. Adopted a systematic preventive maintenance schedule with previous experience for all compressors and its systems. Training the employees for efficient operation and maintenance of compressor systems.

18 Measures towards energy conservation Usage of DP switches for jet pulse filters for reducing the wastage of air. Avoided usage of high pressure air for cleaning. (using Pressure 3.5 Kg/cm 2 instead of 6.7 Kg/cm 2 ).

19 Encon in compressed air systems Major projects

20 Major projects Pressure tuning of compressors:

21 Major projects Earlier main air compressors were operating at 8 kg/cm 2 as per design conditions. During the in house energy consumption monitoring activities, it was proposed to reduce the operating pressures. System losses were considered on higher side during initial design stage. Gradually operating pressure of compressors brought down to 6.5 Kg/cm 2, with out disturbing the plant operations.

22 Major projects Advantages: Power savings are 340 kwh/day Annual 2.48 Lakhs Investment Nil Pay back period ---

23 Major projects Installation of Godrej control Air IFC Model GE-30

24 Major projects Godrej make, Intelligent flow controller was installed in compressed air system.

25 Major projects Advantages: Isolates compressors from demand side peaks &troughs. Reduces load period of compressors. Saves compressed air energy through reduction in artificial demand.

26 Major projects Advantages: Reduces leakage losses in the plant. Ensures constant & stable air pressure at the end use point. Operating the plant air system at optimum pressure.

27 Major projects Advantages: Power savings are 600 kwh/day Annual savings 4.38 Lakhs Investment 3.77 Lakhs Pay back 11 months

28 Major projects Separation of Low pressure and High pressure air: During the initial design stages both the course ash and fine ash was designed to convey with a pressure of 4 kg/cm 2. Air required for ash conveying separated based on the density of ash.

29 Major projects Separation of Low pressure and High pressure air Course ash was conveyed with High pressure air of 4 kg/cm 2 Fine ash was conveyed with low pressure air of 2 kg/cm 2 For this purpose, compressors, air receiver tanks, and air conveying lines were separated.

30 Both systems operating at different pressures

31 Major projects Advantages: Power savings are 2500 kwh/day Annual savings 18 Lakhs Investment 1 Lakhs Pay back 1 Month

32 Major projects DP monitoring for compressors suction filters: Increase in energy consumption will be 2% for increase of every 250 MMWC suction filter DP.

33 Major projects To ensure the healthiness of the suction filters following steps were taken. Increased the frequency of suction filter cleaning. On line monitoring provided for suction filter DP. Replacing suction filters as per schedule.

34 Continuous monitoring arranged for suction filter DP

35 Major projects Advantages: Power savings are 80 kwh/day Annual savings 0.6 Lakhs Investment Nil Pay back ---

36 Major projects Cleaning floors with low pressure air : Avoided Cleaning of Equipment,floors etc. with high pressure air 6 Kg/cm 2. Tapings are taken from ash handling Air lines which is 3.6 kg/cm 2 for cleaning activities By using transvector nozzles.

37 Major projects Advantages: Power savings are 400 Units/day Annual savings 2.90 Lakhs Investment 0.30 Lakhs Pay back 1 month

38 Major projects Activities taken up in ash handling system for reduction in air consumption: 1. Cleaning blow valve once in a week. 2.Replacing of orifice plates once in a month. 3.Ensuring cycle completing at vessel pressure at 0.35kg/cm 2 4.Monitoring and arresting air leakages in the convey line.

39 5.Phase density (solids to air ratio) is monitored and adjusted. 6.Identifiyng cause for line blocks and taking necessary preventive action. 7.Regular calibration of level Probes. 8.Running the system in probe mode.

40 Major projects Advantages: Power savings are 1500 Units/day Annual savings 10.9 Lakhs Investment 0.50 Lakhs Pay back < 1 month

41 Other activities Cleaning of bags with transvector nozzles:

42 Other activities DP across bag filters was maintained at MMWC by increasing purging cycle. Thus reducing energy consumption.

43 Brief Tips Adopt a systematic preventive maintenance schedule with previous experience. Good housekeeping practices in compressors house. Ensure condensation can be removed swiftly from the distribution network, or does not occur. Avoid delivering higher pressure to the entire plant just to meet the requirements of one user. Use high efficiency motors in place of standard motors.

44 Brief Tips Keep motor belts tight. Routinely check the compressor s v-belts for proper tightness loose belts slip more frequently which reduces compressor efficiency. Minimize system leaks.

45 Thank you

CPC PRODUCT DESCRIPTION

CPC PRODUCT DESCRIPTION CPC 40 60 PRODUCT DESCRIPTION The CHICAGO PNEUMATIC CPC 40-60 compressor is a quiet, complete and readyfor-use unit for the production of compressed air in industrial applications. OVERVIEW The CHICAGO