Power saving ideas implemented practically

ENERGY CONSERVATION INITIATIVES (TEAM Unit– Shree Gopal)

ENERGY CONSERVATION INITIATIVES IMPLEMENTED

ENERGY SAVING IDEAS IMPLEMENTED

SAVINGS THROUGH VFD’s

S. No. Description Gain Photo

1. Installation of VFD at 37 KW Hydra treated pump PM-5,7. Power reduced from 33 to 22 KW.

Power saving of 11 KW

2. Installation of VFD at 67KW water supply pump to PM-5,7. Power reduced from 50 to 41 KW.


3. Installation of VFD at 55KW Specialty back water tank pump supplying to pulp mill. Power reduced from 40 to 24 KW.


Sheet Total=36kWh



4. Installed VFD for 55KW Vat Dilution Pump of BSW-1 in pulp Mill and started at 45HZ. Power reduced from 33 to 24 KW.

Power saving = 9 kWh

5. Installed VFD at 45KW Cooling Tower pump of PM-7 and started at 42HZ. Power reduced from 40 to 22 KW.


6. Installation of VFD at 67KW Fan pump PM-7. Power reduced from 33 to 22 KW.


Sheet Total=38kWh



7. Installed VFD at 11KW B/L supply pump. Power reduced from 9 to 6 KW.

Power saving of 3KW

8. Installed VFD at 45KW Couch Pit Pump PM-4 , Average power consumption got reduced from 25KW to 11KW.

Power saving=14 KW

9. Installed VFD at 45KW stock chest pump pulp mill. Power reduced from 30-24=6KW.

Power saving=6KW

10. Provided VFD at 75KW Decker MC pump in pulp mill.Power reduced from 60 to 48 KW.


Sheet Total=35kWh



11. Provided VFD at 30KW 10m3 FRP tank back water pump motor. Power reduced from 21 kWh to 13 kWh.

Power saving of 8KW

12. Provided VFD at 22KW Clear water pump at PM-4. Power reduced from 19kWh to 10kWh.


13. Provided VFD at 15KW Cloudy water pump at PM-4. Power reduced from 10kWh to 5kWh.

Power saving of 5KW

Sheet Total=22 kWh



14. Provided VFD at 75KW B-6 effect pump soda recovery evaporator house. Power reduced from 52kWh to 40kWh.

Power saving of 12KW

Sheet Total=12 kWh


TOTAL SAVING THRO’ VFD’s143 KW


SAVINGS THROUGH COMPRESSORS & CHILLING PLANT


1. Two 1000CFM & one 500CFM compressors were running for PM-5, 7&Pulp mill. Over hauled these compressor, replaced air header PM-7, plugged air leakages at various locations in plant. With this one extra running 500 CFM compressor has been stopped. Power reduced from 367 to 295KW.

Power saving of 72 kWh

2. Over hauled all three 500CFM compressor of Soda recovery. Plugged air leakages at various locations in plant. With this one 500 CFM 90KW compressor has been stopped. Power reduced from 142 KW to 92 KW.

Power saving of 50 kWh

Sheet Total=122kWh


S.

No.Description Gain Photo

3. Installed Elgi compressor 5 HP for sludge filter soda recovery separately. Where 5Kg pressure was required, where as for other areas of soda recovery 3Kg pressure was required. This has reduced working pressure of one compressors of 90KW. Power reduced from 92 to 74 KW.

Power saving of 18kWh

4. Old inefficient chilling unit replaced with energy efficient chilling unit at PM-7 and by changing its location just below machine calendars for reducing losses in line bends and line length. Power reduced from 34 to 16 KW


Sheet Total= 36 kWh


TOTAL SAVING THRO’ COMPRESSORS & CHILLING PLANT

158 KW


SAVINGS BY REPLACING DYNO DRIVES MOTORS WITH

INDUCTION MOTORS & SPEED CONTROL WITH VFD’s.

S. No.

Description Gain Photo

1. Replaced 20 Nos. variable speed inefficient dyno drive motors with energy efficient normal induction motors by controlling its speed with VFD at following locations:-(a) 6 No Silo Screw extractors of chipper

house 7.5KW each power saving 12KW(b) 5 No. Wire shaker motors of 3.7KW of all

5 paper machines Power saving 7.5 KW (c) 6 No. Rectifier rolls motors 2.2KW each of

PM-4, 5 & 7 power saving 3 KW (d) 3 No Maloney filters motors 11KW each

of Soda recovery, PM-4 & PM-5 power saving 7.5 KW

Power saving=30 KW


TOTAL SAVING BY REPLACING DYNO DRIVE MOTORS

30 KW


SAVINGS THROUGH ENERGY EFFICIENT MOTORS

No. Description Gain Photo

1 Replaced A class open type inefficient motors with F class energy efficient motors at 17 locations mill wide after reconsidering their actual power requirement of equipment.


2. Replaced Broke Refiner open type A class motor 65KW 1000 RPM with F class 37 KW 750RPM after taking trial with VFD of PM 4. Power reduced from 42kWh to 22kWh.


Sheet Total= 46 kWh


TOTAL SAVING THRO’ ENERGY EFFICIENT MOTORS46 KW


No. EQUIPMENT NAME RATING SAVING NO. EQUIPMENT NAME RATING SAVING

1 THICK BLACK LIQ TANK AGIT S/R 22 1.2

10 CAUSTIC PUMP OLD EVAP.HOUSE7.5

0.7

2 BLEACHED STOCK CHEST PUMP 11 0.8

11 PULP TRANSFER PUMP PM-455 2.5

3 STOCK CHEST-5 AGIT PM-422 1

12 MIXING CHEST -1 AGITATOR PM-4. 22 1.2

4 STUFF PUMP-1 PM-215 0.6

13 SMALL W.L.PUMP-1 DOOR PLANT7.5 0.5

5 SERVICE PUMP NO.2 PUMP HOUSE 75 3.5

14 LIME TANK-1 AGIT. CHEMICAL HOUSE 7.5 0.75

6 B.W.PUMP-2 PM-122 1

15 LIME TANK-2 AGIT.CHEMICAL HOUSE 7.5 0.75

7 STUFF PUMP PM-118.5 1

16 REFINER PM-263.75 3.5

8 PULPER NO.1 PM-237 1.5

17 COMPRESSOR SODA RECOVERY90 4

9 PULPER NO.2 PM-237 1.5

TOTAL 26

LIST OF MOTORS REPLACED WITH NEW ENERGY EFFICIENT MOTORS IN FY_-2010-11


SAVINGS THROUGH ENERGY EFFICIENT PUMPS

S.

No.Description Gain Photo

1. Replaced inefficient 67KW pump of water supply to PM-5,7 with energy efficient pump & with new lines. Also started VFD in close loop by providing pressure control switch with setting of 2.1Kg pressure. Power reduced from 50 to 32KW


2. Replaced inefficient 75KW water supply pump of PM-1,2 with energy efficient pump and started in close loop with pressure of 1.5Kg. Power reduced from 50 to 41KW

Power saving=9KW

3. Replaced inefficient pump of 110KW Blow tank stock pump pulp mill with new efficient one Power reduced from 80 to 70 KW.


Sheet Total= 37 kWh



4. Replaced inefficient 55KW pump of Bleached stock chest PM-4 with energy efficient pump. Average power consumption got reduced from 34KW to 24KW.


5. Replaced inefficient 30KW pump of back water PM-4 with energy efficient pump. Power reduced from 22 to 17KW.


Sheet Total= 15 kWh


TOTAL SAVING THRO’ ENERGY EFFICIENT PUMPS52 KW


SAVINGS THROUGH TUBE WELL RUN HRS & REPLACING INEFFICIENT WATER PUMPS


1. Unit SGU was meeting its water demand thro’ installed 19 No. bore wells (130M3/Ton of Paper) by running 16 bore wells continuously. Through various actions on water conservation & by replacing inefficient vertical 45KW bore wells with 37KW submersible water pumps at new locations with increased water flow, we are now meeting our water demand by running 13 bore wells only. 1) Water conservation actions. 2) Waste water management. 3) Utilization of treated effluent

Power saving 93 KW BEFORE

Sheet Total=93kWh


AFTER


1 Re-use of pope reel & compressor cooling water.

6 Re-use of vacuum pump water by passing thro’ cooling tower.

11 Push button type taps provided in bath rooms & toilets of mills.

2 Re-use of barometric condenser water Clo2 in pulp mill.

7 Re-use of machine back water for pulp dilution.

12 Re-use of treated effluent in jet condenser chemical house.

3 Use of disc save all clear water on wire showers PM-4.

8 Wood log washing with treated effluent water.

13 Installed level controllers in pumps to avoid overflow.

4 Re-use of treated effluent for gardening in mills & colony.

9 Ash quenching with treated effluent water.

14 Thickener shower of PM-1,2 replaced with new showers.

5 Re-use of D1 filtrate on E/O screw conveyor for pulp dilution.

10 Use of Macstar packing in pump glands for reduction in water consumption.

TOTAL POWER SAVING = 93kWhWATER CONS.100M3/TON PAPER

TOTAL SAVING THRO’ TUBE WELL RUN HRS & REPLACING INEFFICIENT WATER PUMPS

93 KW

FOLLOWING INITIATIVES WERE TAKEN FOR WATER CONSERVATION MILL WIDE


SAVINGS THROUGH OPTIMIZATION OF EQUIPMENTS


1. Filtrate tank pump made shut at PM-1,2 by transferring back water by gravity with modification in pipe line.

Power saving 5 KW

2. Speed reduction of Pressure Screen PM-4 by changing motor pulley.

Power saving 19KW

3. Started KVM-600 Vacuum pump PM-4 and stopped KVM-900 Vacuum pump. Consumption reduced from 110kWh to 74kWh.

Power saving 36KW

4. Decreased run time of two Foam breakers in NPM of running 6KW each. These were running for 30 min and shut for 30min. Now these are running for 30min & shut for 1 Hr. Saving 4 HrsX6X2KW

Power saving 2 KW

Sheet Total = 62 kWh



5. Replaced suction fan of secondary conveyor of Sheeter no.2 BCP from 2.2KW to 0.55KW and has saved 1KW.

Power saving=1KW

6. Optimized speed of white liquor supply pump after taking trial with VFD & replaced pulley of motor accordingly.


Sheet Total=6 kWh


NEWOLD

TOTAL POWER SAVING BY OPTIMIZING EQUIPMENTS

68 KW


SAVINGS THROUGH STOPPING EQUIPMENT AFTER

OPTIMIZATION OF OTHERS RUNNING


1. Connected water lines of high pressure pump PM-7 with PM-5 high pressure pump & stopped PM-7 H.P.Pump .PM-5 H.P.Pump running for PM-5 only= 25 KWPM-7 H.P.Pump= 22 KWPM-5 H.P.Pump running for PM-5 & 7 M/C = 26 KW


2. Installed new 132 KW KVM 900 Vacuum pump at PM-7 resulted to shut of two inefficient 90 KW vacuum pumps consuming 65KW each. Power saved 15 KW.


3. Shut one1000KVA transformer of finishing house running at 30% load by shifting its load to other under loaded transformer at PM-4. Power saving 4 KW.


Sheet Total=40kWh



4. Stopped one paper rewinder no.1 of PM-4 which was consuming average 25KW power by optimizing production at other three rewinders.


5. Stopped trim nozzle pump at PM-2 by connecting line with H. P. Oscillating shower PM-1. With this common operation saved 4 KW.

Power saving of 4KW

6. Three 250KW refiners were running for common operation of PM-1, 2 (178KW + 190 KW + 200 KW). Stopped DDR 2 (20”) 250KW refiner permanently which was consuming 190 KW power, by optimizing refining on other two 250KW refiners. Net power saving 148KW.


Sheet Total=177 kWh



7. Two refiners 250 & 110KW were running for PM-7 (158KW + 90 KW). Stopped 110KW refiner permanently by increasing refining on 250KW refiner. Net power saving achieved = 40KW.

Power saving=40KW

Sheet Total=40kWh


TOTAL POWER SAVING BY STOPPING EQUIPMENT AFTER OPTIMIZATION OF

OTHERS RUNNING 257 KW


SAVINGS THROUGH AUTO CONTROL OF

EQUIPMENTS INSTEAD OF MANUAL CONTROLS

S. No.

Description Gain Photo

1. CD tower launder dilution pump pulp mill 30KW.Saving= 26.3-25 = 1.3KW

Power saving of 1.3 KW

2. EO tower dilution pump pulp mill 37KW.Saving=26-24.3= 1.7KW.


3. EO tower stock pump pulp mill 37KW.Saving=15-13.7=1.3KW


4. EO washer Vat dilution pump pulp mill. Saving=25-22.3= 2.7KW


5. D2 tower launder dilution pump pulp mill. Saving=27-22= 5.0KW.


6. P4 warm water BHR area pulp mill 30KW. Saving=16-14.3= 1.7KW.


7. D1 launder dilution pump P.Mill 45KW. Saving=30.7-29.4= 1.3KW.


Sheet Total=15kWh


FOLLOWING VFD’s OF PULP MILL HAS BEEN STARTED IN CLOSE LOOP IN DCS TO SAVE POWER


8. Started VFD of P.Mill fresh water supply pump in close loop of pressure. Saving=62-56= 6KW.


9. Provided emergency stop for stopping cooling fan PM-7 rewinder DC motor when not in use. Saving=2-0= 2 KW.


10. Modified control circuit of warm water pump P.Mill & hooked up with level from DCS. Saving = 18-12=6 KW.

Power saving=6 KW

Sheet Total=14kWh



TOTAL SAVING THRO’ AUTO CONTROL OF EQUIPMENTS INSTEAD OF MANUAL CONTROLS

29 KW


SAVINGS THROUGH VOLTAGE & FREQUENCY OPTIMIZATION

S. No. Description Gain Photo1. Earlier many motors in plant were open type

‘A’ class having voltage rating 425-440V. But now maximum motors are replaced with ‘F’ class rating having voltage level 415V and will give maximum efficiency at 415V. Reduced voltage from 11KV to 10.7KV & 6.6 to 6.4 KV and frequency from 49.9 HZ to 49.3 HZ of both sources 11KV TG & 6.6KV BTH turbines. Also adjusted transformer tap changer switches at few locations as per required voltage. Power saving 90 + 60 = 150 KW.


Sheet Total=150 kWh


TOTAL SAVING THRO’ VOLTAGE & FREQUENCY OPTIMIZATION

150 KW


SAVINGS THROUGH LIGHTING & OTHERS

S. No. Description Gain Photo1. Provided MCB for putting of all

lights of pulp mill, PM-5,7 mech. workshop, drive rooms, electrical centers & transformer rooms. etc. Total 10KW load will be saved for 12 Hrs. Net Saving=5KW


2. Provided MCB in cable gallery & HT switchboard of pulp mill. 2KW will remain shut for 24Hrs.Net saving = 2KW


3. Replaced 120 chokes of fluorescent tubes with electronic chokes. Power saving 2KW


Sheet Total=9 kWh


BEFORE

AFTER


4. Interacted with workmen of various departments mill wide after identification and marking lights to be put off when not required in day time. Power saving = 6 KW for 12 Hrs. Net power saving = 3KW.


5. Restructured street light circuits in mills near canteen PM-1, mechanical workshop pulp mill & chipper house area. Saving = 2KW


6. 1000 Watt Halogen lights for Load Break Switches removed after installation of OCBs at four transformers. Saving = 4 KW.

Power saving=4 KW

Sheet Total = 9 kWh



7. Provide 20 MCBs for main power supply at the doors of offices, halls, So that complete power can be switched off while moving out. Power saving = 1KW

Power saving of 1.0KW

8. Transparent fiber sheets on roof sheds at Pulp godown, New syn. Sheeter area, new dispatch section, stores etc. Power saving 12KW for 12 Hrs. Net power saving = 6KW

Power saving of 6.0KW

Sheet Total=7 kWh


TOTAL SAVING THRO’ LIGHTING & OTHERS

25 KW

TOTAL SAVING WITH ENERGY SAVING IDEAS IMPLEMENTED

SR. NO. SAVING THROUGH

SAVING IN kWh

1. VFD’s 1432. Compressors & Chilling plant. 1583. Replacing Dyno Drive motors with induction motors &

speed control with VFD’s 30

4. Energy efficient motors. 465. Energy efficient pumps. 526. Tube wells run hrs reduced thro’ water saving & by

replacing inefficient water pumps mill wide. 93

7. Optimization of equipments 688. Stopping equipment after optimization of others running. 2579. Auto control of equipments instead of manual controls. 29

10. Voltage & Frequency optimization 15011. Lighting & Others. 25

TOTAL = 1051 kWh

Power saving ideas implemented practically

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