Energy Efficiency Bulletin Case Study Bulletins from CII-Sohrabji Godrej Green Business Centre Bulletin No. 17 17
Reduction in Generating Frequency in Captive Power Plant During Island Mode Operation
Company Compa ny detai details ls manufacturers urers of Asian Pai Asian Paints nts Lim Limite ited d is one of the leading manufact paint in India. It is a multi-national company of Indian origin having hav ing man manufa ufactu cturin ring g fac facilit ilities ies acr across oss the glo globe. be. Asi Asian an Paint Pai nts s Li Limi mite ted d ha has s it its s ch chem emica icall di divi visio sion n at Cu Cudd ddal alor ore, e, Tamilnadu, manufacturing various grades of Pentaerythritol, Sodium Format and Formaldehyde. Asian Paints Limited, Cuddal Cud dalore ore is an ISO 140 14001 01 cer certif tified ied com compan pany. y. Project Proje ct detai details ls At Asian Paints Ltd, a 500 kVA Turbo generator, operating in island isla nd mode, mode, was running running at a frequenc frequency y of 49.5 Hz on a cont co ntin inuo uous us ba basi sis. s. In ca case se of an any y ma main inte tena nanc nce e of tu turb rbo o generator, power is drawn from the state Electricity Board (EB) grid, which supplies electricity at 49.9 Hz for most of the time.
October 2007
At Asian Paints, Cuddalore 90% of the connected load in the plan pl antt ar are e ce cent ntri rifu fuga gall lo load ads s lik like e pu pump mps s an and d fa fans ns.. In ce cent ntri rifu fuga gall loads, loa ds, the spe speed ed of ope operat ration ion (RP (RPM) M) is dir direct ectly ly pro propor portio tional nal to freque fre quency ncy of ele electr ctrica icall sup supply ply.. The pow power er con consum sumpti ption on of the centri cen trifug fugal al equ equipm ipment ent is pro propor portio tional nal to cub cube e of spe speed ed (RPM (R PM3) 3).. Th Ther eref efor ore, e, wh when enev ever er th ther ere e is a de decr crea ease se in operat ope rating ing fre freque quency ncy,, the there re wil willl be a red reduct uction ion in pow power er consumption. A 10 % reduction in frequency would result in 27% 27 % re redu duct ctio ion n in th the e po powe werr be bein ing g co cons nsum umed ed by th the e centrifugal centr ifugal equipm equipment. ent. Majority of the centrifugal Majority centrifugal equipm equipment ent were operat operated ed with excess capacity margins. This was indicated by throttling of cont co ntro roll va valv lves es in th the e ex exte tent nt of 70 70% % to90%. A detailed loading analysis (kW measurement) was carried out for all the equipment across various sections and it was conc co nclu lude ded d th that at al alll eq equi uipm pmen ents ts ha had d ex exce cess ss ma marg rgin ins s at lea least st to thetuneof10 15%. Applying the above concept, plant team started reducing the gene ge nera rati ting ng fr freq eque uenc ncy, y, in st step eps. s. At ea each ch st step ep th the e pl plan antt operat ope ration ion was allo allowed wed to sta stabili bilize. ze. Fin Finally ally the tur turbo bo gen genera erator tor was wa s op oper erat ated ed at a fr freq eque uenc ncy y of 48 Hz Hz.. All ele electr ctrica icall equipment is designed to operate at a frequency range of 47.5to 47 .5to 51Hz. By reducing the supply frequency, the built in excess design marg ma rgin in of eq equi uipm pmen entt wa was s re redu duce ced d to ma matc tch h th the e ac actu tual al requirement requir ementof of the proce process. ss.
The pla The plant nt te team am ob obse serv rved ed th that at fo forr th the e sa same me pr prod oduc ucti tion on capacity, the total power consumed was higher when ever the th e pl plan antt wa was s op oper erat ated ed ta taki king ng po powe werr fr from om th the e gr grid, id, as compar com pared ed to bei being ng ope operat rated ed usi using ng cap captiv tive e pow power. er.
Issues Issu es faced duri during ng imple implementa mentation tion
The detail detailed ed analys analysis is of produ production ction and energ energy y param parameters eters indicated that the variation in supply frequency resulted in wide wid e var variat iation ion in pow power er con consum sumpti ption. on.
There Ther e ar are e fe few w pr prec ecau auti tion ons s to be co cons nsid ider ered ed be befo fore re implementing implem enting this projec project: t:
The pla plant nt tea team m red reduce uced d the gen genera eratio tion n fre freque quency ncy in ste steps. ps. At each step the plant was allowed to stabilize. There were no major maj or issu issues es fac faced ed dur during ing the imp implem lement entati ation on of the pro projec ject. t.
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The opt optimi imizat zation ion of fre freque quency ncy is app applic licable able,, only whe where re generators are operated in island mode and not in paralle par allell wit with h the Gri Grid d
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The level of reduction in frequency varies with respect to the actual capacity margins available in the various equipment spread across in the plant. In case there is no ca capa paci city ty ma marg rgin in av avai aila lable ble in eq equip uipme ment nt,, th the e frequency reduction could be counter productive. Also majority of the connected load should be centrifugal in nature Electrica Electr icall equ equipm ipment ent are des design igned ed to ope operat rate e fro from m 47.5 Hz to 51 Hz electrical supply frequency. Hence operat ope ration ion of equ equipm ipment ent wit within hin thi this s ran range ge wou would ld not affect aff ect the elec electri trical cal per perfor forman mance ce of the equ equipm ipment ent.. Any frequency other than the range mentioned above, is also als o notwarra notwarrante nted d eve even n if ext extra ra mar margin gins s are ava availab ilable le
Commen Com ments ts fro from m theplant tea team m The pr The proj ojec ectt was im impl plem emen ente ted d by As Asia ian n Pa Pain ints ts Lt Ltd. d. Cuddal Cud dalore ore,, Tam Tamiln ilnadu adu in the yea yearr 200 2003. 3. Optimizat Optimi zation ion of ope operat rating ing fre freque quency ncy is an exc excelle ellent nt met method hod to skillfu ski llfully lly uti utilisethe lisethe mar margin gins s ava availab ilable le in ind individ ividual ual equ equipm ipment ent.. Financ Fin ancing ing of theproje theproject ct Thisprojectt was imp Thisprojec implem lement ented ed wit withou houtt any inv invest estmen ment. t. Result Res ults s of the pro projec jectt Implementation of this project resulted in reduction of 35 kW of pow power er sav saving ing and red reduct uction ion in spe specif cific ic pow power er con consum sumpti ption on by 70 kWh kWh/TP /TPE. E. The annual savings achieved was Rs 1.03 million (USD without ut any invest investment. ment. 0.082 mill million) ion) witho Replication potential Similarr sa Simila savi ving ng po pote tent ntia iall is po poss ssibl ible e in se seve vera rall pl plan ants ts,, especially the continuous process Industry, where captive power pow er plan plants ts are ope operat rating ing in isla island nd mod mode. e. Benefits of the project l
Utilization of excess margins available in centrifugal centrifugal equipm equipment ent
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Reduction in Specif Reduction Specific ic Energy Consumption
Fo r
Mr T Rajasekar Factory Manager Asian Paints India Ltd. B5-B10 Sipcot Industrial complex Cuddallore - 607005 Ph: 04142- 239247, 239248 Email:
[email protected]
Cost benefit analysis l
Investment – Nill
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Annual savings – Rs 1.03 million (USD 0.082 million)
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Paybac Pay back k – NA
About Abo ut CII& CII CII-Go -Godre drejj GB GBC C CII is a non non-go -gover vernme nment, nt, not not-fo -for-p r-prof rofit, it, ind indust ustry ry led and industry managed organisation, playing a proactive role in India's Ind ia's dev develo elopme pment nt pro proces cess. s. Fou Founde nded d ove overr 112 yea years rs ago ago,, it is In India dia's 's pr prem emie ierr bu busi sine ness ss as asso socia ciati tion on,, wi with th a dir direc ectt membership membe rship of over 6500 organi organisation sations s from the privat private e as well as public sectors, including SMEs and MNCs, and an indirect membership of over 90,000 companies from around 350 natio national nal and region regional al secto sectoral ral associ associations ations.. Cll-Go CllGodr drej ej GB GBC C is a Ce Cent ntre re of Ex Exce celle llenc nce e in En Ener ergy gy Ef Effi ficie cienc ncy, y, Green Buildings, Renewable Energy, Water, Environment & Recycl Rec yclingand ingand Cli Climat mate e Cha Changeactiv ngeactiviti ities es in Ind India. ia. About Abo ut 3 Cou Countr ntry y Ene Energy rgy Eff Effici icienc ency y The Proj Project ect "De "Develo veloping ping Fina Financia nciall Int Interm ermedia ediation tion Mechanisms for Energy Efficiency Projects in Brazil, China and India" aimed to substantially increase investments in energy efficiency by the domestic financial sectors in Brazil, China Chi na and Ind India. ia. The project was a partnership between the World Bank, the United Nations Environment Programme (UNEP) through the UNEP UN EP Ris Risoe oe Cen Centre tre on Ene Energy rgy,, Cli Climat mate e and Sus Sustai tainab nable le Develo Dev elopme pment nt (UR (URC),and C),and ins instit tituti utions ons in Bra Brazil zil,, Chi China na and Ind India. ia. Additional Additi onal infor informatio mation n is availa available ble at www.3countryee.org This Energy Efficiency Bulletin comprises of a series of case studi st udies es on su succe ccessf ssful ul ene energy rgy ef effic ficien iency cy pr proje ojects cts implemented implem ented by Indian Indian industry. industry. The bulletin bulletin is supported supported under und er the"3 Cou Countr ntry y EE" init initiat iative ive and by USA USAID. ID.
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