PROBLEM UNDERSTANDING

Average electricity consumption in lakh kwh

Date Oct - Nov Dec Jan - Feb - Mar April May June July- Aug Sept Oct-
14 -14 -14 15 15 ch- -15 -15 -15 15 ust- -15 15
15 15

9.47 9.77 8.95 8.63 8.30 9.39 9.56 10.6 10.9 11.2 10.0 10.2 9.22
9 7 3 9 9

Per unit consumption cost reduction by 1 Rupee results

to saving ranging from 8.3 to 11.2 lac per month
SOLUTION??
 SOLUTION.
Global Energy Pvt. Ltd. Supplies electricity at
the rate of Rs.5.79/Kwh.
Minimum cost saving
=Rs.(7.21-5.79) X 8.5 lacs
=Rs. 12.07 lacs/month
=Rs. 1.45 crore/yr
 PROBLEMS
Unreliability
No power provided during holidays
Billing procedure of MSEB.
 Billing method of MSEB
Total Contract Demand
=(Sanctioned demand- third party demand)
=(2700-third party demand)
Total cost= (220 X Billed demand)+ (units
consumed X 7.21) + (Bill for open excess)
 Billing method of MSEB
Bill for open access includes
Cross subsidy sub charge
Wheeling charges
Transmission charges
Operating charges
Extra energy charges at Rs.12.50/Kwh
Monthly Billing Demand will be the maximum value
Actual Maximum demand from 6 am to 10 pm
75% of highest billing Demand
50% of the Contract Demand
 Improvised Solution
The best solution will be the
Maximum usage of cheaper electricity
Limiting the usage of MSEB current below the
maximum contract demand.
Graphical optimization method

Problems in word In form of Equation

We have to take current from MSEB X2 0

We want to take current from Global X1 0

power
Addition of both should meet the X1 + X2 2700
highest consumption
Power provided by Global and half the X1 + 0.5 X2 Minimum consumption
power demand of MSEB has to be
consumed
Consumption in holidays are to be X2 Maximum power consumption in
taken from MSEB without violating the holidays
limit
Maximum power consumption
1200000

1000000

800000

Year (May to Dec) (KWH)

600000 Maximum consumption (KWH)

Average (KWH)
Minimum Consumption (KWH)

400000

200000

0
1 2 3 4
 Maximum power consumption
Maximum power consumption was in July 2015
Assuming the average consumption
increase by 12% for the next 3 years
Maximum consumption in holidays
Max. consumption in the month of July 2015
Assuming the increase by 12% in next 3 years
Maximum consumption
=1.12 X 1050
=1176 KWH
Graphical solution (future scenario)
Graphical solution (present scenario)
 Conclusion and Results
Started to take power from Global Energy at
1.2 MW/hr from 6 am to 10 pm and 1 MW/hr
during 10 pm to 6 am.
 Conclusion and Results
Saving of more than 10 lacs in the month of
October 2015.
Boiler Efficiency calculation

Boiler
Theoretical Calculation
Efficiency calculation
Working principle Costing Calculation
Construction Losses Calculation
Maintenance Monitoring suggestion
Documentation Actual Capacity Calculation
 Theoretical Study
Working principle
Construction
Feed water system
Steam system
Air system
Fuel Handling system
Ash handling system
Maintenance
Documentation
Usage in plant
 Calculation
Direct efficiency
Indirect Efficiency
Major Assumptions
1. Feed water temp is 20 degee celcius.
2. Calorific value of fuel is 12,953 KJ/kg
3. Steam is dry and saturated
4. About 2% of feed water is drained while blow down
5. 3% of energy available is lost as unburnt fuel.
6. Average of 4 % energy is lost as the heat carried away
by ashes.
7. 3% of heat is lost in heat transfer to surrounding
 Calculation
Heat load calculation for evaporator and
Economizer
Direct Method

Indirect Method
 Steam vs briquettes consumption
Steam consumption during Jan 2015 Briquettes (kg)
6000
20000

18000
5000
16000

14000 4000
Steam consumption in kg

12000
3000
Briquettes (kg)
10000
Series1
8000 2000

6000
1000
4000

2000
0
27/12/14 06/01/15 16/01/15 26/01/15 05/02/15
0
27/12/14 06/01/15 16/01/15 26/01/15 05/02/15
Date
 Steam vs briquettes consumption
Observations
Upon relatively constant steam load from date 5 Jan to 12 Jan,
steam fuel ratio of 4.07 was required.
Upon the varying load from 17th to 28 Jan, the ratio lowered
to 3.2.
Upon constant loading of boiler above 15000 kg gives very
good steam fuel ratio.
The average cost for 1 kg steam production is
 Chilled water system

Chilled water system

Theoretical Calculation
Working principle Actual TR Calculation
Construction COP calculation
Maintenance Cost of production
Documentation Heat exchanger efficiency
 PERFORMANCE CALCULATION
REFRIGERATION EFFECT (TR) =
( )
3960

60
=
12000

= 3
= 0.01 + 0.42 + 0.45 + 0.12
A,B,C,D are the COP of the system at 100,75,50 and 25 % load.
 Performance Results
350
5

300 4.5

4
250
3.5

3 COP
200
Actual TR of the
chiller 2.5
Power input (KW) Cost involved in
150
2 chilled water per kg
(Rs./Litre)
1.5
100

50
0.5

0
0 0 2 4 6
50% 67% 75% 94%
 Conclusion
It is appropriate to work the compresser at
the load of 67% for efficient and economic
result.
The Energy Efficiency Ratio (EER) of the chiller
is 3.85.