Visit 1 Presentation, DeA at UTCL APCW Tadipatri

Presentation on
Detailed Energy Audit

at
Ultratech Cement Limited, APCW
02nd December 2014
Visit 1
Confederation of Indian Industry
At the outset
Thank You
Opportunity
Support
Hospitality
Objective
Ultratech Cement Limited, APCW
Should achieve maximum Energy
savings
Ultimately achieve the status of
Excellent Energy Efficient Unit
Past EnCon Activities at Ultratech, APCW

Installation of WHRS from cooler gases
Installation of VFDs for several process fans
Installation of VFDs for compressors
Installation of Light pipe
Utilization of AFR - Rice Husk
Committed Technical Team

Open Mind and Commitment

In
spite
of
in-house efforts
successful
CII invited
Methodology
Data Collection
Measurements
Identification of projects
Discussion
Now the Final Presentation..
ROLE OF CII
Catalyst / Facilitator role
Supplement in-house activities
Identify energy saving proposals
All possible assistance
Monitoring
Vendor identification
Not fault finders !!

Calculation Basis
Energy Cost
4.23 Rs /kWhr
Coal Cost
Kiln
Kiln Production -
Rs 1000 / MCal
7440 TPD
PROCESS
Raw Mill
Optimize the air volume in Line-1 Raw

mills
Observations:
Air flow through mill depends on
Louvre velocity
Drying requirement
Separator requirement
Air requirement:
High efficiency separator = 0.6-0.8 kg
matl./kg air
Conventional separator = 0.4 0.5 kg matl.
/ kg of air

mills
Observations:
Present separator loading
RM 1: 0.389 Kg material/kg air
RM 2: 0.383 Kg material/kg air
Fan SEC is observed high i.e.
RM 1: 7.45 KW/MT Material
RM 2: 7.60 KW/MT Material

mills
Parameters
Operating detail
Raw Mill 1 Fan
Operating detail
Raw Mill 2 Fan
Volume
761407
772893
Head
707
713
Power
2165
2124
Speed
88 %
87 %
Efficiency
75.66
74.71
Speed control type
SPRS
SPRS

mills
Sl.
No
.
1
2
3
Description
Unit
Plant 1
Plant 2
UTCL,
Tadipatri
RM 1
UTCL,
Tadipatri
RM2
Atox Mill
Atox Mill
Atox Mill
Atox Mill
TPH
325
410
285
285
m3/hr
8, 02, 245
9, 96, 213
7, 61, 407
7, 72, 893
Model
Production
Air volume
Concentratio
n at mill
outlet
g/m3
405
411
374
369
Nozzle
Velocity
m/s
51
51
40
41.8

mills
Increase material concentration at the
outlet of the mill
Optimize the raw mill fan volume by taking trial
by reducing the fan speed
Maintain the present nozzle ring velocity of 42
m/s by blocking some of the nozzle area
Monitor mill performance, Reject BE load, RABH
fan power & Mill fan power

mills
Recommendation:
Increase material concentration at the outlet of
the mill
Reduce the flow and maintain same nozzle
velocity by reducing the louvre area
Reduce the flow by 5 % and observe the
operation
Conduct trail in 1 mill and replicate in other mills
Savings possible:
RM 1: 108 KW
RM 2: 106 KW

mills
Annual Saving
Rs 62.39 Lakhs
Investment
Nil
Replace Raw Mills Fan with High

Efficiency Impeller
Raw Mill 1
-725 mm WC
Raw Mill 2
-15 mm WC
-15 mm WC
-715 mm WC
-728 mm WC
-722 mm WC
Parameters
Operating detail
Raw Mill 1 Fan
Operating detail
Raw Mill 2 Fan
Volume
761407
772893
Head
707
713
Power
2165
2124
Speed
88 %
87 %
Efficiency
75.66
74.71
Speed control type
SPRS
SPRS

Efficiency Impeller
Observation
Present Raw Mill fan efficiency
Raw Mill 1- 75.66 %
Raw Mill 2- 74.71 %
Raw Mills fans generally designed for

over 85 % efficiency

Efficiency Impeller
Recommendation:
Replace the existing fan impeller with new
correct size fan head of 85% efficiency
Saving Potential:
Raw Mill 1: 164 KW
Raw Mill 2: 188 KW
Considering operating efficiency of at least 82 %

Efficiency Impeller
Annual Saving
Investment
Payback
Raw mill 1
Rs 47.3 Lakhs
Rs 35.0 Lakhs
9 Months
Annual Saving
Investment
Payback
Raw mill 2
Rs 55.6 Lakhs
Rs 35.0 Lakhs
8 Months
Reduce Pressure drop across baghouse

outlet to fan inlet in RABH Fan
- 161 mmWC
Pressure drop across

bag house outlet
venturi: 34 mmWC
- 195
mmWC
RABH fan

Observation
Pressure drop across bag house outlet to fan
inlet 34 mmWC
Possible reasons
Pressure drop across venturi

Recommendation
Conduct CFD study for bag house outlet to fan
inlet duct
Remove the Venturi and implement the
recommended modifications
Atleast 15 mm WC pressure drop can be
reduced
Saving potential: 78 kW

Annual Saving
Rs 26.43 Lakhs
Investment
Rs 15.0 Lakhs
Payback
7 Months
Pyro Section
Lower Dispersion Box in riser ducts and

increase heat transfer in Line-1
PH system heat transfer
Overall Counter current
Each Stage Co-current
Maximum heat transfer in riser ducts
80% in Ducts
20% in Cyclones
Separation of material & air in cyclones
Very little heat transfer in cyclones

Latest approach

Locate feed pipe as low as possible

Increases heat transfer in riser ducts
Lowers PH gas exit temperature
Discussions with Suppliers & other

Cement Plants

Favour this step (Upto 1 m, easy)

Implemented in several plants

Observations:
Material feed dispersion box heights
Kiln String cyclone 4 riser = 3 m
Kiln String cyclone 6riser = 3.2 m
Good potential to lower the feed point in

above identified cyclones


Recommendations:
Reduce the dispersion box height by 2
meters
Results in reduction in preheater exit
temperature by at least 10 Deg C
Saving possible
2 kcal/kg clinker
Monitor temperature and pressure profile

closely

Annual Saving
48.8 Lakhs
Investment
10.0 Lakhs
Payback
5 Months
Improve heat transfer in Kiln String

Line 1
UTCL, APCW
303 oC
Case Study
Plant
274 oC
465oC
414 oC
575 oC
3
677
4
740oC
522 oC
3
oC
753oC
632 oC
820oC
792oC
820oC
811oC
Kiln Inlet
- 1200
Kiln Inlet
- 1200

Line 1
Observations:
Heat transfer rate is low from 6th outlet to
5th cyclone outlet & 5th outlet to 4th outlet
Possible reasons
Improper material distribution
Worn out immersion tube

Line 1
Recommendations:
Check the dip tube,
dispersion box and riser duct
in cyclone 5
Conduct CFD study for 6th
stage outlet to 5th stage &
5th stage outlet to 4th stage
stage to analyse the reasons
for lower heat transfer
Exit temperatures can be
reduced by at least 15 Deg C
Saving potential: 3 Kcal/kg
Clinker

Line 1
Annual Saving
Rs 73 Lakhs
Investment
Rs 25 Lakhs
Payback
4 Months
Reduce suction side pressure drop in

cooler fans Line 1
255 mm WC
-105 mm WC
Operating
Cooler Fan 10
Power: 157 kW
Flow: 119595 m3/hr
Head: 360 mm WC
Temp.: 26oC
Reduce Suction Loss in Cooler fans

Suction
Cooler
fan No.
pressure
Suction Fan head Operating

Saving
Loss
power
potential
mm WC
mm WC
kW
kW
1R
-70
4.76
841
88
4.18
2L
-61
3.94
787
86
3.39
3L
-65
4.22
830
68
2.87
3R
-64
5.47
622
61
3.33
-108
13.15
593
141
18.41
-105
16.67
450
101
23.5
-73
7.77
553
106
8.24
10
-105
20.83
360
157
32.7

cooler fans Line 1
Radius of bell mouth

- 0.25 x effective diameter
Flow measurements using aerofoil

cooler fans Line 1
Recommendation:
Widen the bell mouth opening
Ensure suction pressure should not be more
than 30 mm WC
Total saving potential: 96 KW
Recalibrate the flow after modifying the fan
inlet

cooler fans Line 1
Annual Saving
Rs 32.45 Lakhs
Investment
Rs 8.00 Lakhs
Payback
3 Months
Reduce pressure drop in preheater

downcomer duct Line 1
C STRING
K STRING
-600 mm WC
- 650 mm WC
-630 mmWc
- 700mm WC
1B
Gas velocity:
Gas velocity:
20.9 m/s
20.3 m/s
-650 mmWc
-730 mmWc
-690 mmWc
- 730 mmWc
-690 mmWc
- 735 mmWc
- 25 mmWc
Total Pressure drop

80 mmWC
1A
- 25 mmWc
Total Pressure drop

90 mmWC

Observations:
High pressure drop in Preheater downcomer
duct
Calciner string: 90 mm WC
Kiln string: 85 mm WC
Pressure drop from cyclone outlet to first bend

before horizontal duct
Kiln string: 50 mm WC
Calciner string: 30 mm WC

Observations:
Possible reasons for high pressure drop across
Kiln down comer
Improper flow distribution
High gas velocity in low diameter duct before
straight vertical down comer duct
Possible reasons for high pressure drop across

Calciner down comer
Pressure drop in bend from cyclone outlet to vertical
down comer

Recommendation:
Conduct CFD study for kiln and calciner string
down comer ducts
Best observed down comer pressure drop: 35
mmWC with 15 m/s down comer velocity
At least 20 mm WC pressure drop can be
reduced in both strings
Saving potential:
Kiln string: 38 KW
Calciner string: 54 KW
Reduce pressure drop in PH

down comer duct

Kiln String:
Annual Saving
12.7 Lakhs
Investment
10.0 Lakhs
Payback
10 Months
Calciner String:
Annual Saving
18.1 Lakhs
Investment
10.0 Lakhs
Payback
7 Months
Replace Line 1 Kiln String & Calciner String

fans with high efficiency impeller
-705 mmWC
-670 mmWC
-710 mmWC
-670 mmWC
K String Fan
-25 mmWC
-25 mmWC
C String Fan
Parameters
Operating detail
K String
Operating detail
C String
Volume
463154
664821
Pressure
685
645
Power
1301
1771
70.65
70.15
Speed
Efficiency
Speed control type
Confederation
of Indian Industry
SPRS
SPRS

Observations:
Present preheater fan efficiency
Kiln String- 70.6 %
Calciner String- 70.1 %
Preheater fans generally designed for over 85
% efficiency

Recommendation:
Replace the existing fan impeller with new
correct size fan head of 85% efficiency
Saving Potential:
K String: 180 KW
C String: 256 KW
Considering operating efficiency of at least 82 %

Annual Saving
Investment
Payback
K String
-
Rs 60.8 Lakhs
Rs 50.0 Lakhs
10 Months
Annual Saving
Investment
Payback
C String
-
Rs 54.85 Lakhs
Rs 70.0 Lakhs
16 Months
Coal Mill
Avoid damper loss across coal mill vent

fan
25 mm WC
100 % Open
-870 mm WC
-914 mm WC
Operating
Power: 725.5 kW
Flow: 231238 m3/hr
Head: 939 mm WC
Speed: 97 %

fan
Observation:
Fan operating with SPRS for speed control
Pressure drop across damper is found to
be 44 mmwc
This pressure drop is equal to 4.69% of
the head developed by the fan

fan
Recommendation
Inspect the louvers in next immediate
opportunity
Open the Damper fully
At least 20 mm WC pressure drop can be
reduced
Reduce the fan speed
Saving potential : 15 KW

fan
Annual Saving
Rs 4.57 Lakhs
Investment
NIL
Cement Mill
Avoid damper loss across mill vent fan

Cement Mill 1
3 mm WC
35 % Open
-340 mm WC
- 525 mm WC
Operating
Power: 61.26 kW
Flow: 23155 m3/hr
Head: 528 mm WC
Temp.: 90oC

Cement Mill 1
Observation
Fan is presently operating with damper control
Damper opening is 35 % during normal
operation
Pressure loss across damper is found to be 185
mmwg
This pressure drop is equal to 35 % of the total
head developed by the fan

Cement Mill 1
Recommendation
Install VFD for mill vent fan
Remove the Damper
Convert existing pulley driven to direct couple
Maintain same ventilation by reducing fan
speed
Similar opportunity available in CM 2

Cement Mill 1
Annual Saving
Rs 6.1 Lakhs
Investment
Rs 6.6 Lakhs
Payback
13 Months
Avoid Damper Loss Across Line 2 Cooler

Hot Gas Booster Fan
+ 27 mm WC
-39 mm WC
-80 mm WC
Operating
Power: 160 kW
Flow: 327300 m3/hr
Head: 107 mm WC
Temp.: 195oC

Hot Gas Booster Fan
Observation:
Fan utilized for moving hot cooler exit gases to
Line 2 cement mills
VFD installed for varying operating conditions
Presently operating with fan inlet damper 100 %
open
Pressure drop across damper is found to be 41
mmwc
This pressure drop corresponds to 36 % of the
head developed by the fan

Hot Gas Booster Fan
Recommendation
Remove the Damper
Control the hot gases flow by VFD only
Much higher savings possible during
transferring hot gases from Line 2 to Line 1
WHRS systems
Avoid Damper Loss Across Line 2

Cooler Hot Gas Booster Fan
Annual Saving
Rs 19.5 Lakhs
Investment
NIL
Optimise suction in Raw Mill silo top bag

filter fans
Raw Mill Silo top bag filter fan
-4 mm WC
- 140 mm WC
- 159 mm WC
- -161 mm WC
Raw
Mill
Silo

filter fans
Observation
Raw Mill silo ventilation
To exhaust feeding & Extraction air qty
To avoid condensation inside silo
Observed high suction pressure of -140 mm WC
indicating higher capacity of bag filter fan

filter fans
Bag Filer
Raw Mill Silo
Present
Suction
pressure
Norm for
silo
suction
pressure
Fan
Head
Fan
Power
Saving
potential
Mm WC
Mm WC
mm WC
KW
KW
-140
-50
157
23
13

filter fans
Recommendation:
Install VFD
Interlock the fan speed with silo suction
pressure
Target silo suction pressure at 50 mm WC
Saving potential: 13 KW
Optimise suction in Cement silo top bag

filter fans
Annual Saving
Investment
Payback
Rs 4.64 Lakhs
Rs 1.50 Lakhs
4 Months
Observation 1
Reduce suction pressure at Raw

Mill Inlet
P=- 715 mmWC
To bag house
inlet
P=- 610 mmWC
VRM fan
cyc
P=- 58 mmWC
P=- 70 mmWC
P=- 60
mmWC
P=-60 mmWC
P=- 25
mmWC
PH fan
Reduce suction pressure at Raw

Mill Inlet
Observations:
Higher suction pressure was observed at mill
inlet
RM 1: -74 mm WC
RM 2: - 77 mm WC
Suction pressure after junction box to mill inlet

duct: - 60 mm WC
Higher suction pressure leads to increase head
developed by mill fan
Possible reasons:
Higher resistance in recirculation duct leading to
higher mill inlet pressure
Observation 2
Reduce Excess air in Kiln Line 1

6.8 % O2
1
4
5
5.7 % O2
6
Kiln Riser
4.8 % O2
Reduce Excess air in Kiln Line 1

Observations:
Measured Kiln inlet O2: 4.8 %
CCR Kiln inlet O2: 3 3.5 %
Excess air is also indicated by high NOx at kiln
inlet
Total excess air to Kiln: 16 - 20 %
Present Kiln String flow: 0.62 Nm3/kg Clinker
Excess air to Kiln: 0.10 Nm3/kg Clinker
Electrical
Activities Carried Out - Electrical

Electrical measurements of all motors
above 11 kW of phase-1, Packing Plant and
CPP ( 1 unit) have been carried out
Analysis conducted during Audit are
Motor loading analysis for all motors
Harmonics measurements in transformers and
other major feeders
Lighting Measurements :in Phase-1
More than 150 measurements carried out

Improve Loading of Packing Plant Belt

Conveyors
Detailed power measurements carried
out for motors above 11 kW
15 motors are under loaded in packing
plant
Under loaded motors
Higher voltage related losses
Lower power factor
Lower operating efficiency
Optimize Capacity of Motors in Packing

plant
Running
Power
(kW)
Power
factor
Rated
Power
(kW)
%
Loading
P2U01
2.82
0.24
11
22.8
P2U09
3.92
0.43
15
23.3
P2U02
2.2
0.24
11
17.8
P2U19
0.71
0.38
15
4.2
P2U07
2.49
0.22
22
10.1
P2U13
2.61
0.24
22
10.6
3.3
0.35
22
13.4
2.57
0.26
11
20.8
P2U14
P2U03
Optimize Capacity of Motors

Actual
Power
(kW)
Power
factor
Rated
Power
(kW)
%
Loading
P2U12
2.34
0.32
15
13.9
P2U04
1.32
0.65
11
10.7
P2U17
2.73
0.22
22
11.0
P2U18
3.72
0.41
22
15.0
P2U10
3.29
0.47
22
13.3
P2U06
2.47
0.41
11
20.0
P2U11
2.85
0.46
15
16.9
Tag No

OPTION 1: Recommended to convert
delta connection to star connection
L1
IL = 3 Ip
VL
VP =
3
L1
Delta connection
VL
VL =
VP
L2
L2
L3
L3
Star connection

Effect on motor performance operating
in star mode
Reduction in voltage related Iron
losses
Reduction in copper losses

Operates with improved P.F
Motor operating efficiency improves
Option 2:- Recommended to replace the

identified motors with next size spare
motors

Saving potential : 6%
Annual Saving
Rs 0.49 Lakhs
Investment
Nil
Optimize Lighting Voltage

Detailed lighting measurements carried out
during detailed energy audit
Plant team has installed energy savers in
majority of areas
Excellent Initiative by Plant Team
Voltage is high in few areas

Sl.N
o
LOCATION
1
MRSS
Cement
mill
Cooler &
gypsum
yard
Rawmill &
Coal mill
Operating
Voltage
(V)
Operating
Power
(kW)
Recommended
Voltage
(V)
225
9.57
210
222
90.37
210
212
32.13
210
207
111.15
210

Optimum Voltage for lamps is 210
Higher Voltage results
Higher Power consumption
Increased failure rate of lamps
10% reduction in Voltage

10% reduction in Power consumption

Recommendation
Reduce the tap setting of energy
saver in MRSS and Cement mill to
210V
Annual Saving
Rs 1.02 Lakhs
Investment
Nil
Harmonics Measurements
Harmonics are produced due to non
linear equipment
Variable frequency drives
DC drives
UPS, Computers, etc
Harmonics are measured at

All transformers and major vfd feeders and
cooler fans
Harmonic Distortion - IEEE Norm

Harmonic Voltage Distortion limits at any point on the system
Total
Supply System
Voltage (kV) at
Harmonic
Voltage
point of common
coupling
Distortion VT
(%)
0.415
6.6 and 11
33 and 66
132
Individual
Harmonic
Voltage
Distortion (%)
5
4
3
1.5
Odd
4
3
2
1
IEEE G.5/3 Sept. 1976 : Limits for Harmonics.
Even
2
1.75
1
0.5
Harmonics Measurements in Plant

TAG NAME
% V-THD
% I-THD
Cooler fan 1L
8.0
31.0
Cooler fan 1R
8.1
30.4
Cooler fan 2L
8.3
32.1
Cooler fan 2R
8.2
31.1
Cooler fan 3L
8.1
58.3
Cooler fan 3R
7.9
34.9
7.2
61.9
7.6
36.8
Cooler fan 5
8.1
32.6
Cooler fan 6
7.1
29.3
Cooler fan 4L
Cooler fan 4R
Harmonics Measurements
TAG NAME
% V-THD
% I-THD
Cooler fan 7
7.6
34.9
Cooler fan 8
7.5
40.5
Cooler fan 10
7.4
38.8
Incomer 1
2.3
9.6
Incomer 2
2.4
14.1
Incomer 3
7.8
24.8
Install Harmonic Filters for cooling fans

Harmonics leads to
Reduction in life of power equipment
Degraded efficiency and performance
Harmonic distorted current are prevented

from flowing back into power system by
diverting them through low impedance
shunt path called HARMONIC FILTER
Install Harmonic Filters in Cooler Fans

Recommended to
Recommended to install Filter in incomer-3
Anticipated Savings-3 %
Annual Saving
Rs 12.32 Lakhs
Investment
Rs 25.00 Lakhs
Simple pay back -
25 Months
Improve Transformer Loading in Raw Mill

section
Raw Mill & stacker reclaimer Load is
supplied from 3 transformers
T-5,T-6 & T-7
Transformers
are
independent mode
operating
in
During detailed energy audit the loading

of all transformers was studied.
The transformers in above area were
partially loaded
Improve Transformer Loading in

Raw Mill section
Rated
(KVA)
Load
(kW)
Actual
(KVA)
%
Loading
T5
2000
399.72
524.13
26.2
T7
2000
251.16
342.9
17.14
T6
2000
92.00
125.00
6.25
Transformer
No.
Improve Transformer Loading in Raw

Mill section
6.6kV
Rated 2 MVA
Actual 524 KVA
26% Load
T-5
Rated 2 MVA
Actual 125 KVA
7% Load
T-6
0.433kV
Existing system
Rated 2 MVA
Actual 343 KVA
17% Load
T-7

Mill section
Losses due to the operation of two
transformers T5 & T6
7.44 kW
Isolate one of the transformer from

operation
Total losses= 5.05 kW
Saving potential = 2.4 kW

Mill section
6.6kV
Rated 2 MVA
Actual 649 KVA
32.5% Load
T-5
Rated 2 MVA
Actual 0 KVA
0Load
T-6
0.433kV
Proposed system
Rated 2 MVA
Actual 343 KVA
17% Load
T-7
Improve Transformer Loading in

Raw Mill section
Isolate transformer-6 and shift the load
on T-5
This will avoid the losses in transformer
T6 and improve loading of T-5
Keep transformer T-5 as stand by

Mill section
Annual Savings
Rs 0.81 Lakhs
Investment
Nil
Replace 150W MV lamps with 70W

MH/HPSV lamps
150 W MV lamps are installed in packing
plant
50 Nos
Mercury vapor lamps are inefficient and
poor efficacy
Luminous efficacy- 50 Lm/W
These lamps can be replaced with 70W

Metal Halide / HPSV lamps
Luminous efficacy- 105 Lm/W - HPSV
Luminous efficacy- 80 Lm/W- MH lamp
Replace 150W MV lamps with 70W

MH/HPSV lamps
Annual Savings
Rs. 0.75 Lakhs
Investment
Rs. 1.25 Lakhs
Simple Payback period -
20 months
Install Energy Efficient Fluorescent

Lamps in Packing Plant
Majority of the lamps in the plant
36W/40W conventional fluorescent lamps with
Electronic ballasts
Few Lamps are operating with Copper Ballast
Copper ballasts consumes 14-15W

Power consumption of each lamp-50W
There are about 50 lamps

Latest trend is to use T5 lamps
Consumes 28W

Comparison
Conventional
FTL
T5 lamps
Power
consumption
50W (36+14W)
28W
Life
20000 hrs
25000hrs
Luminous
efficacy
68lm/W
104lm/w

Annual Saving
Rs 0.34 Lakhs
Investment
Rs 0.25 Lakhs
Simple Pay back -
9 months
Compressed Air System
Approach for Energy Saving in

Compressors
1. Generation
Generating at optimum pressure

Use of energy efficient compressors
Lower specific power consumption
(kW/CFM)
2. Consumption
Optimum usage of compressed air
at optimum pressure
Segregating HP & LP users

Compressors
3. Distribution
Reducing the loss in the distribution
system
Arresting leakages
Avoiding unwanted use of
compressed air

Compressors
Approach
System studied
Operating parameters - observed
Measurements done
Specific observations made
Installed Capacity
Total Installed HP Compressors
capacity in Line-1:9 No's
230 m3/min or 8144 CFM
Users: Poking, Inter coal transport,
WHR and other plant operations
Total Installed HP Compressor

capacity in Line-2: 4 No's
106 m3/min or 3745 CFM
Best Practice's Implemented by

UTCL team
Installation of SX Controller in
Line-1
Installation of VFD in Line-2 and
Cement Mill compressors
Isolation of dryers for Poking Line
Installation of Timers and Level
Based systems for Auto draining
moisture
Capacity Test
The
performance
of
the
compressors analyzed
Free Air Delivered is evaluated by
conducting the capacity test
FAD= P2- P1 x Vr
PO x T
FAD Test
Area
Rated
Actual
Actual
Avg
capacity capacity capacity pressure
(m3/min) (m3/min)
CFM
(bar)
Actual
Actual
Norm
power
SEC
(kW) (kW/CFM) (kW/CFM)
Line-1
Compressor-1
25.0
25.00
883.3
6.15
154
0.17
0.16
Compressor-2
23.5
23.50
830.3
6.15
142
0.17
0.16
Compressor-3
27.5
24.41
862.4
6.15
142
0.16
0.16
Compressor-4
27.5
23.40
826.7
6.15
142
0.17
0.16
Compressor-6
27.5
21.99
776.9
6.15
142
0.18
0.16
Compressor-7
25.0
22.80
805.5
5.75
144
0.18
0.15
Compressor-9
23.5
22.31
788.2
6.05
132
0.17
0.16
Line-2
Compressor-1
25
25.00
883.3
5.65
155.1
0.18
0.15
Compressor-2
25
24.84
877.6
6.25
150.2
0.17
0.16
Improve SEC of Identified

Compressors in Plant
Higher SEC might be due to
Wear out of the internals
Increase in the tolerances
Ageing of the compressor
The volumetric efficiency of the

compressor can be improved by
Complete overhauling of the
compressor
Improve SEC of Identified

Compressors in Plant
Recommendation
Carry out complete overhauling for
the compressors
Repeat FAD test after the
overhauling
Annual Saving
Rs 11.43 Lakhs
Investment
Nil
Reduce Fly Ash Unloading System

Pressure
Fly ash unloading is done through two
Screw compressors
G2 CP1- 5.4 bar @ 133 kW
G2 CP2- 5.8 bar @ 143 kW
Higher pressure generation leads to higher

power consumption
Power
Pressure
Maximum system pressure required during

tanker unloading (from tanker to hopper) is
2.0bar
Many plants are using 2 bar for dry fly ash
unloading application
Reduce Fly Ash Unloading System

Pressure
It is suggested to
Install
Low
Pressure
compressor
(2.5 bar)
Maintain pressure at 2.0 bar
Plant team has already planned for this
project and it may get completed by next
February
Immediate step can be Reduction of

pressure setting at least possible
Load Pressure
Unload Pressure
- 4.5 bar
- 5.2 bar
Reduce Fly Ash Unloading

System Pressure
Annual Saving
Rs 21.13 Lakhs
Investment
Rs 30.00 Lakhs
Simple Pay back -
17 months
Avoid Compressed air leakage in the

plant
Leakage test was carried out in
Line-2
Leakage is coming around 30%
The leakages are observed in following

sections

Coal Mill
Cooler
Preheater
Raw Mill
Identified Leakage points: Line-2

1. In Raw Mill Cylinder Valve By passed near
363 MW2 reject Bucket Elevator
2. Preheater 8th Floor Oil filter for Lubrication
Cylinder near 431 PG7
3. Preheater 7th Floor Poking Header dummy
leakage
4. Preheater 6th Floor Poking Header dummy
leakage
5. Preheater 1st Floor Oil Filter leakage near
PH APDB2F6

6. Pyroclone -2 dryer hose leakage in Coal
mill First Floor
7. Compressed Air Pipe Line Leakage near
L61FN2 in coal mill
8. Coal Mill JPF Cylinder Air Line Gate valve
by passed near L9SC11
9. L91FN2 Bag Filter Solenoid Valve
Leakage
10. Cylinder valve by pass near L21BF1

11.Burner Platform Air Blaster Junction
Box Union Leakage
12.Valve Leakage near 461 FN7 fan
13.Cooler Hopper ground floor near
471FN4

14.Preheater 8th floor hose damaged
( large hole)
15.Preheater 3rd Floor near Air Blaster
valve leakage
16.Solenoid valve air leakage near 48 no
air blaster
17.Calciner Air blaster line leakage near
swivel gate
18.Blaster 34 air line

19.Blaster 28 air line
20.Cooler area tertiary duct hose
leakages
21.Blower line pipe leakage near kiln
22.Coal Mill bag house leakage on stack
side
23.Solenoid valves leakage in coal mill
bag house

24.Coal Mill Bag filter near K203 hose
leakage
25.Bag house top J1C06 hose leakage
26.J1C06RA
27.J1C15RA two ball valves leakage
28.J1C12Ra cylinder piston

29.J1C01A near oil filter
30.J1C08A cylinder
31.Hopper area near additive feeder
valve joint leakage
32.Compressor House Air drier-4 pipe
line leakage
33.Air drier-3 hose leak

plant
Recommendation
Implement red tag system
Arrest all the identified leakage
areas
Conduct leakage test regularly &
monitor the improvement
Maintain compressed air leakage
less than 10% in the plant
Saving potential : 15 kW
Considered only 10% of total power
consumption

plant
Annual Saving
Rs 5.08 Lakhs
Investment
Nil
Improve Operation Of Poking

Compressor
Presently Compressor-7 is used
for Poking operation
Compressor is rated for 25m3/min
and rated for 160 kW
Compressor loading details
Loaded for 85% past history
Loaded for 72% during Audit
Present and past history shows

the capacity is in excess
Improve Operation Of Poking

Compressor
Trial can be taken with stand by
compressor 23.5 m3/min
It improves utilization factor and
reduces unloading time
Annual Saving
Rs 1.93 Lakhs
Investment
Nil
Reduce Generating Pressure of

Compressors
Total
Plant
is
operating
6.1- 6.3 bar pressure in Phase-1
with
Measured Pressure in various areas

Poking Line
- 5.75 bar
WHR
- 6.0-6.1 bar
Cooler
- 6.0 bar
Coal Mill
- 6.0 bar
Higher operating Pressure results in

higher power consumption

Compressors
Compressor operating power is directly
proportional to operating pressure
Compressed air applications & pressure
requirements
Bag filter
- 5.0 bar
Instrument Air
- 5.5- 5.8 bar
Air Blaster
- 5.5 bar
FK pump seal air - 4.5 bar

Bag house
- 4.5-4.8 bar

Compressors
Many plants has optimized
generating pressure at 5.5 bar
the
Pressure drop across the compressed

air lines is negligible
Pressure at the user end is almost same as
generating

Compressors
Good potential to optimize the generating
pressure of the compressors
Raw Mill Bag House
Coal Mill & Waste Heat Recovery
Jet Pulse Bag Filters
Recommended to
Reduce the pressure setting of the compressors
in steps of 0.1 bar
After rectifying SX controller
Option of Segregating Low Pressure users also
can be tried

Compressors
Option of Segregating Low Pressure users
also can be tried
Investment considered for any modification in
line
Annual Saving
Rs 7.32 Lakhs
Investment
Rs 5.00 Lakhs
Simple Pay back -
8 months
Reduce Pressure drop in Raw Mill

Bag House circuit
Detailed study of Compressed air
distribution system is studied during
audit
Measured pressures
Generation Pressure -
6.1 bar
Bag house receiver -
5.4 bar
Bag house top
5.0 bar
We recommend to verify pressure

settings with new gauge in shut down
Reduce Pressure drop in Raw Mill Bag

House circuit
CP1
5.0 bar
Bag House
CP2
5.4 bar
6.1 bar
CP5
Receiver
CP9
Stand by/ Auto mode Confederation of Indian Industry
All users
Reduce Pressure drop in Raw Mill

Bag House circuit
Minimize pressure drop in compressed
air line
Operate compressed air line at
optimum pressure settings
Annual Saving
Rs 0.74 Lakhs
Investment
Nil
CAPTIVE POWER PLANT
Install New efficient pump for CEP in

Units 1 & 2
CEP 1 Running
100 % close
Deaerator
5 kg/cm2
CRT
LPH
105 m3/hr
CEP - 1
8.9
kg/cm2
Ejector
Operating
Parameters CEP 1
105 m3/hr
9.0 bar,
CEP 2
67 kW

Units 1 & 2
CEP 2 Running
100 % close
Deaerator
5 kg/cm2
CRT
LPH
104 m3/hr
CEP - 1
CEP 2
9.0
kg/cm2
Ejector
Design Parameters
CEP
Operating
Parameters CEP 1
104 m3/hr
104 m3/hr
14 bar
8.9 bar,
68 kW

Units 1 & 2
Condensate extraction pump is pumping the water
to deaerator
One pump is running continuously
CEP-1 with VFD and CEP -2 without VFD
CEP Speed interlocked with Discharge Pressure 9 kg/cm2
CII congratulates plant team for excellent step
Unit
No.
Pump
Flow
Head
m
Power
Efficienc
y
CEP
105
91
67.7
41
CEP
104
93
60.2
46

Units 1 & 2
Recommendation
Install new Efficient pumps for CEP with
VFD
125 m3/hr, 120m, 75 % efficiency
Annual Saving
Investment
Pay back period
Rs 10 Lakhs
Rs 10 Lakhs
12 months
Observation: Potential in BFP in Unit 1 & 2

Unit -1 & 2
4.5 kg/cm2
105 kg/cm2
Deaerator
DRUM
1&2
Economizers
Flow
control
valve
ARC valve
HPHs
Common
Header
126 kg/cm2
220
m3/hr
BFP -
Operating
Parameters
Flow > 220 m3/hr
BFP -3
Head - 120 kg/cm2

Power = 667, 691
kW
Feed water pump is catering for the boiler water

requirement
2 feed water pumps is operation
BFP discharge pressure
: 126 kg/cm2
Drum pressure
: 105 kg/cm2
Possibility of Inefficiency in pump should be studied
further
Valve control is an inefficient way of controlling the flow
Part of energy lost across the valve as the pressure drop
Pressure Drop across the valve can be reduced by varying
speed to maintain required discharge pressure
Estimated Pressure drop in Line across

various equipments in FW circuit
Sl. No.
Parameters
Pressure
drop
FCV (Flow control valve) 4.0
H P Heater
1.0
ECO
2.0
Static head
4.0
Pipe losses
1.0
Total
12 kg/cm2
Plant has removed one stage of pump and

is operating at 126 kg/cm2 discharge
pressure
CII congratulates Plant personnel on their
step
Further potential to tap into in terms of
efficiency and pressure drop required
across system
Optimize the operation of Auxiliary

cooling tower Circuit
Before
32 0C
50 %
Open
2 KG/cm2
Cold well
ACW 1
Heat Exchangers
4.8
KG/cm2
28 0C
ACW 2
130 A
940 m3/hr

cooling tower circuit
After
50 %
Open
31.5 0C
1.5
KG/cm2
Cold well
ACW 1
4 KG/cm2
Heat Exchangers
26.5 0C
ACW 2
80 A
800 m3/hr


Earlier, one cooling fan were operating

Earlier Cold well temperature only 2829 0C
Current cold well temperature 26.5 0 C
Plant has reduced discharge pressure from 4.8 bar
to 4.2 bar and further to 4 bar
Further scope to reduce the discharge pressure
Inlet valve to Cooling tower is heavily throttled at
50 % open
Creating artificial system resistance to increase
pump discharge pressure
At least 0.5 bar can be reduced

Recommedations
Open valve in Cooling tower outlet
Reduce speed of the pump to control
flow at the lesser discharge pressure
Maintain required T across all the Heat
exchangers by throttling
Annual Saving
Investment
Rs 4 Lakhs
Maintenance
Optimize the excess air in Boiler 1 & 2

O2: 6.5 %
CO : 96 ppm
APH
ECO
ESP
Boiler 2
@110 TPH
Load
ID Fans A &
B
348 kW
Design Parameters
Load
- 25 MW
Steam flow
- 110 TPH
Steam Pressure
- 95 kg/cm2

Observations
Flue gas analysis was carried out across the flue gas
path to identify air ingress
Oxygen at ECO inlet for Boiler 1
6.5 %
Excess air: 44 %
CO at Furnace outlet was found to be 96 ppm
Loss in boiler efficiency
5.05 %
Oxygen at ECO inlet for Boiler 2
6.4 %
Excess air: 43 %
CO at Furnace outlet was found to be 124 ppm
Loss in boilerefficiency
4.9 %

Recommendations
Reduce excess air to boiler in steps
Maintain eco inlet oxygen at 5%
Operate SA fan in closed loop with O2 level for better

control of excess air supply
Good potential to improve boiler efficiency

Savings possible:
Maintaining oxygen at 5 % will result in 13 %

reduction in excess air supply
Minimum improvement in boiler efficiency 0.4 %
Reduction in coal consumption:

Boiler 1 & 2: 160 kg/hr
Annual Saving
Rs 30 Lakhs
Optimization of Service Air Compressors

Present system
Four screw compressors are present
Two in each Phase

According to the requirement no of
compressors are in operation
Loading pressure : 4.8 kg/cm2

Unloading pressure : 5.5 kg/cm2
Operating 2 in operation
VFD installed in one compressor
Initially operating at 6 bar, optimized later
to 4.8 bar
Optimization of Service Air Compressors

Maximum Vessel pressure 1.6 bar
Recommendation
Reduce Average pressure of compressors to 4.5
bar
in steps of 0.1 bar

Target Pressure setting of 4 bar pressure
Annual Saving
Rs 10 Lakhs
CPP Observation 1
Install High Energy Efficient ID fans

Unit -1
Operating Parameter
Design
Parameter
Name of fans
ID - 1
ID - 2
ID Fan
Flow (m3/sec)
29.6
26.4
34.9
Head developed by fan

(mm WC)
271
273
551
RPM
734
726
980
Efficiency (%)
46.6
43.6
73
SEC (kW/Mw)
13.96
Best No.
10.45
Install High Energy Efficient ID fans

Possible reasons for low efficiency
Mismatch between the operating & design
parameters
Fan Designed for 550 mm WC
Operating at 280 mm WC
To be studied in detail along with Unit II ID
fan
SUMMARY OF FINDINGS
Parameter
Total Annual Saving
Annual saving without
investment
Annual saving with investment
Investment required
Simple payback period
No. of
Projects
Rs. in Lakhs
28
644
11
152
17
492
17
342
8 Months*
* For capital proposals only excluding nil investment

and long term proposals
To Sum-up
UTCL, APCW - Already several efforts taken
towards energy efficiency
Several projects on anvil
UTCL, APCW & CII- Energy Audit indicates
further Potential
The Present Audit - A Beginning
Thank you

Visit 1 Presentation, DeA at UTCL APCW Tadipatri

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Presentation on

Detailed Energy Audit

Confederation of Indian Industry

Confederation of Indian Industry

Past EnCon Activities at Ultratech, APCW

Committed Technical Team

Open Mind and Commitment

Confederation of Indian Industry

Confederation of Indian Industry

Not fault finders !!

Confederation of Indian Industry

Confederation of Indian Industry

Confederation of Indian Industry

Optimize the air volume in Line-1 Raw

Optimize the air volume in Line-1 Raw

Confederation of Indian Industry

Optimize the air volume in Line-1 Raw

Speed control type

Confederation of Indian Industry

Optimize the air volume in Line-1 Raw

Confederation of Indian Industry

Optimize the air volume in Line-1 Raw

Confederation of Indian Industry

Optimize the air volume in Line-1 Raw

Optimize the air volume in Line-1 Raw

Confederation of Indian Industry

Replace Raw Mills Fan with High

Speed control type

Confederation of Indian Industry

Replace Raw Mills Fan with High

Raw Mills fans generally designed for

Confederation of Indian Industry

Replace Raw Mills Fan with High

Confederation of Indian Industry

Replace Raw Mills Fan with High

Confederation of Indian Industry

Reduce Pressure drop across baghouse

Pressure drop across

Confederation of Indian Industry

Reduce Pressure drop across baghouse

Confederation of Indian Industry

Reduce Pressure drop across baghouse

Confederation of Indian Industry

Reduce Pressure drop across baghouse

Confederation of Indian Industry

Confederation of Indian Industry

Lower Dispersion Box in riser ducts and

Confederation of Indian Industry

Lower Dispersion Box in riser ducts and

Locate feed pipe as low as possible

Discussions with Suppliers & other

Favour this step (Upto 1 m, easy)

Confederation of Indian Industry

Lower Dispersion Box in riser ducts and

Good potential to lower the feed point in

Confederation of Indian Industry

Lower Dispersion Box in riser ducts and

Confederation of Indian Industry

Lower Dispersion Box in riser ducts and

Monitor temperature and pressure profile

Lower Dispersion Box in riser ducts and

Confederation of Indian Industry

Improve heat transfer in Kiln String