AUX POWER CALCULATION

ADITYA ALUMINIUM ,LAPANGA

DATE- 3/09/2015

What is Aux Power

The quantum of Energy consumed by a generating
station, expressed as a percentage of the sum of gross
energy generated at the generator terminals of all the
units of a generating station
It is the total energy produced by a power plant minus
the total power put in to the grid from that unit
Aux Power = Gross Power Output Net Power Output
Thus the total saving in Aux Power will directly increase
the Net Power Output of the plant

 It has two components Unit Auxiliary Power and

Station Auxiliary Power

AUX
Unit
POWER
auxiliary

Concentrating to
Equipments

U#4 ACTUAL AUX POWER CONSUMPTION IN MW AT 135 MW

DM PLANT; 0.0414

CT FAN; 0.5106

LIGHTING LOAD; 0.0008

AHP; 0.4267
FOPH; 0.0316
COMPRESSOR;
0.3018

BFP; 2.9995

LT DRIVES; 0.1883
FWPH; 0.0002
CHILLER/HVAC; 0.2200
MILLS; 1.3077

CEP; 0.3201
DMCW ; 0.2048
CW; 1.1065
PA; 0.6401 FD; 0.3009

ID; 1.3904

CHP; 0.1501

% UNIT ACTUAL AUX POWER CONSUMPTION AT 135MW

DM PLANT; 0%

CT FAN; 5% LIGHTING LOAD; 0% CHP; 1%

AHP; 4%
FOPH; 0% 3%
COMPRESSOR;
LT DRIVES; 2%
FWPH; 0%

BFP; 30%

CHILLER/HVAC; 2%
MILLS; 13%

CEP; 3%
DMCW ; 2%
CW; 11%
PA; 6% FD; 3%

ID; 14%

35.000

UNIT % AUX POWER ACTUAL Vs TARGET

30.000

IMPROVEMENT
OPPURTUNITY-3

25.000

20.000

15.000

10.000

IMPROVEMEN
T
OPPURTUNITY
-1

IMPRO
VEMEN
T
OPPUR
TUNITY
-2

IMPROVEMEN
T
OPPURTUNITY
-4

5.000

0.000

TARGET % AUX POWER

ACTUAL % AUX POWER

COMPARISON BETWEEN ACTUAL AND TARGET AUX POWER

3.5000

3.0000

2.5000

2.0000

Axis Title

1.5000

1.0000

0.5000

0.0000

GAP ANALYSIS IN DRAFT

SYSTEM

REASONS OF VARIANCE IN
DRAFT SYSTEM
TARGET-Reduction in ID FAN loading from 1686 amp to
1500amp.
REASONS OF VARIANCE
1. Higher ash content in coal.
2. Seal leakages in APH.
3. Poor ESP performance.
4. High total air flow.
5. Boiler and ESP duct leakages.
6. Air leakage from bottom ash hopper.
7. High primary air flow in mill due to measurement
inaccuracy.
8. ID FAN suction duct design to be as per OEM.

IMPROVEMENT SCOPE
1.Higher ash content in coal. Proper blending of coal
2.Seal leakages in APH. Seal clearance to be inspected and to be
adjusted accordingly.
3.Poor ESP performance. Collection efficiency of ESP to be improved
by proper setting of the charge ratio and lower FGET.
4.High total air flow. SADC modulation to be ensured in accordance
with boiler load for optimum combustion , FLAME PROPAGATION
TEST to be carried out.
5.Boiler and ESP duct leakages. O2 measurement to be carried out at
ESP inlet &outlet.
6.Air leakage from bottom ash hopper. Already cooling doors are
closed, proper sealing of bottom ash system to be done & new
opportunities to be explore.
7.High primary air flow in mill due to measurement inaccuracy
Calibration of flow and pressure Tx in mill air system to be ensured .

GAP ANALYSIS IN PRIMARY

AIR FAN

REASONS OF VARIANCE IN
PRIMARY AIR FAN
TARGET-Reduction in PA FAN loading by 30 amps.
REASONS OF VARIANCE
1. Higher ash content in coal.
2. Seal leakages in APH.
3. High primary air flow in mill due to
measurement inaccuracy.
4. High primary air DP across APH.
5. High MILL DP .
6. Shifting of operating point of fan.
7. High pressure drop across duct.

IMPROVEMENT SCOPE
1.
2.
3.
4.
5.
6.
7.

Higher ash content in coal.-- Proper blending of coal

Seal leakages in APH.-- Seal clearance to be inspected
and to be adjusted accordingly. High primary air flow in
mill due to measurement inaccuracy.
High primary air DP across APH.-- Cleanliness of basket to
be checked & proper DP measurement across APH to be
done
High MILL DP . Condition mill internals to be checked
properly at regular interval , classifier setting to be done
appropriately
Shifting of operating point of fan. Due to detoration of
fan performance or change in system resistance.
High pressure drop across duct.-- change in system
resistance may be due to accumulation of ash in PA DUCT
or change in duct design.
Three mill operation for 100% TMCR(As 99.1 tph coal is
required for 100% TMCR at designed GCV & MILL capacity
is 37tph) by proper blending of the coal.

GAP ANALYSIS IN COOLING WATER

SYSTEM

REASONS OF VARIANCE IN
COOLING WATER SYSTEM
TARGET- Single CW Pump operation.
REASONS OF VARIANCE
1. Lower vacuum in condenser.
2. Poor pump efficiency
3. Chocking in CW line either in condenser
or in nozzle at Cooling Tower.
4. High DP across Condenser.
5. High DP across Debris Filter.

IMPROVEMENT SCOPE
1.

Flow Measurement of CW pump to be carried out, for

Calculation of Heat and mass Balance of Condenser.

2.

Air leakage into the condenser are needs to be indentified

by using Helium Leak detection test or some other
Methods to rectify them.

3.

COLTCS to be operated properly at regular interval.

4.

Debris filter Cleaning to be done properly at regular

interval.

5.

ACF operation to be done properly at regular interval.

6.

Regular inspection and cleaning of cooling tower Nozzle

and fills.

7.

Single CW pump operation to be implemented after

GAP ANALYSIS IN COMPRESSED AIR

SYSTEM

REASONS OF VARIANCE IN
COMPRESSED AIR SYSTEM
TARGET- Single COMPRESSURE
operation.
REASONS OF VARIANCE.
Leakages in compressed air line.
Low Compressor efficiency.

IMPROVEMENT SCOPE
1. Remote Operation for Compressor to be implemented.
2. Clean air-inlet filters regularly. Compressor efficiency will be
reduced by 2 percent for every 250 mm WC pressure drop across
the filter.
3. Keep compressor valves in good condition by removing and
inspecting once every six months. Worn-out Bypass valves can
reduce compressor efficiency by as much as 50 percent.
4. Minimize low-load compressor operation; if air demand is less
than 50 percent of compressor capacity, consider change over to
a smaller compressor or reduce compressor speed appropriately.
5. A smaller dedicated compressor can be installed for ignitor
Cooling at Boiler, instead of supplying air through lengthy
pipelines. And SA to Boiler May be Cut off. And HFO guns may
be kept in Healthy conditions.

.IMPROVEMENT SCOPE
1. Compressor free air delivery test (FAD) must be done
periodically to check the present operating capacity against
its design capacity..
2. Reduce compressor delivery pressure, from 6.8 to
6.2kg/cm2, to save energy.
3. Keep the minimum possible range between load and unload
pressure settings.
4. A smaller dedicated compressor can be installed for ignitor
Cooling at Boiler, instead of supplying air through lengthy
pipelines. And SA to Boiler May be Cut off. And HFO guns
may be kept in Healthy conditions.
5. On account of high pressure drop, ball or plug or gate valves
are preferable over globe valves in compressed air lines

THANK YOU
SIBASIS DAS
Sibasis.das@adityabirla.com
8018043669