YANTRA AUTOMATION PRIVATE

LIMITED

ENERGY SAVING CALCULATION

Client : HINDALCO INDUSTRIES LTD BIRLA COPPER

PLANT : CAPTIVE POWER PLANT CPP3
Application : ID FAN 1&2

Design Data Collected:

Total Fans : 02
Motor Rating : 675KW, 3300V, 50Hz, 988RPM, 153 Amp
Flow Control : Inlet Guide Vane
Rated Flow : 83 m^3/s
Medium : Flue Gas
Pressure Rise : 6362 pa
Fan rpm : 921
Plant Operation : 24 Hours, 333 days/Year = 8000Hrs/Yr
Generation Cost : Rs.5.50 / KWHr
Plant Capacity : 60MW

Present Running Condition Data

Present Running current : 122 Amp.

IGV Position : 48.36% open
No output flow measurement. But from the performance curve Doc. No. KNL
273094, ID fan flow requirement is 66.3 m^3/s when generation is 60MW. At
lower generation, output flow will be further less.

Running Condition

Supply Voltage = 3300V

Motor Current = 122 Amp
Power Factor = 0.79 measured by Birla copper
Power Consumed by Motor
Power consumed during present DOL operation = 3 x 3.3 x 122 x 0.79
= 544 KW
Power consumed in a year with DOL operation = 544 KW x 8000 Hrs
= 4352000 KWHr
Power consumed in a month with DOL operation = 362666 KWHr

Power Consumption using Medium Voltage Drive.

 YANTRA AUTOMATION PRIVATE
LIMITED

As per the data, design pressure & flow is higher than required ( present )
pressure & flow. As per the formula of affinity laws, required speed is calculated.
Require pressure is 30% less than design pressure and require flow is 21% less
than design flow. We can achieve the same amount of flow & pressure by
reducing the motor speed to 85%, running the motor at 840 rpm and keeping
IGV 100% open.

Power consumption using MV drive

= ( 0.85 )^3 x 544KW + 50KW ( losses at low speed )
= 384 KW

Power consumed using MV drive in a year = 384 KW x 8000 Hrs

= 3072000 KWHr / year
Power consumed using MV drive in a month = 256000 KWHr / month

Energy Saving using MV drive per month = 362666 KWH - 256000 KWHr
= 106666 KWHr / month
Rupees saved per month using MV drive = 106666KWHr x 5.50 Rs.
= Rs.5,86,663

Landed cost of 675KW / 3300VAC, Harvest make Medium Voltage drive to M/s
Hindalco Industries Birla Copper is as follows

Rs.90,00,000 ( this price is inclusive of VAT, excise & all taxes. M/s Hindalco will
get excise Modvat benefit )

Above price is of Medium Voltage AC drive of 675KW / 3300V rating with power
cell bypass facility and with complete manual bypass panel

Hence payback period is = Rs. 90,00,000 / Rs.5,86,663

= 16 months

Note:

Above calculation is done based on data collected from M/s Hindalco Industries
with certain assumption. Actual savings may varies based on process
requirement, variation in flow requirement, pressure requirement, variation in
production capacity and hours of operations per years & tariff rate.
 YANTRA AUTOMATION PRIVATE
LIMITED

IMPORTANT

Apart from energy saving M/s Hindalco Industries Ltd Birla Copper will get
following benefits using Medium Voltage AC drive.

Smooth start & stop of the motor which will reduce mechanical
wear & tear on motor part, enhance motor life.
Precise flow control using Variable Frequency Drive.
All protection like Over current, Under voltage, Over Voltage, Short
Circuit, Phase to phase, phase to ground short, Over temperature
etc. to motor electronically from drive which enhance motor life.
Being an energy saving device, M/s Hindalco Industries Ltd Birla
Copper can claim 80% depreciation at very first year under income
tax act 32.
Improved power factor, better than 0.95 all the time irrespective of
load variation, saves reactive power.
Can take CDM benefit