EXECUTIVE SUMMARY

1
EXECUTIVE SUMMARY
Capacity of Plant Ammonia - 1.003 million TPAUrea - 1.730 million TPA
Total electricity generated by plant 206,600,000 kWh/year
Total electricity consumption 212,296,1000 kWh/year
Electrical energy Imported from SEB 5,732,000 kWh/year
Total steam generated 832.6 TPH
Total steam consumption 832.6 TPH
Contract demand 5000 kVA
Maximum electrical energy consumed in any month from SEB 650,400 kWh in June 2006
Minimum electrical energy consumed in any month from SEB 382,000 kWh in November 2005
Specific energy consumption of complex (yearly basis) 7.7051Gcal/Ton for Ammonia (2006-07)
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Break up of Electricity Consumption
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Scope of Study Electrical System Network

• Electrical System Network
• Review of electricity bills, contract demand and
  Power Factor for last one year, in which
  possibility will be explored for scope of further
  reduction of Contract Demand and improvement of
  Power Factor.

4
Scope of Study - Transformers

• Transformers of various capacities / rating
• This would involve analysis of the loading
  patterns and estimation of the losses to evaluate
  the possibility of load rationalization

5
Scope of Study Motive Load

• HT equipments including motors / pumps, ID / FD
  Fans.
• LT motors/Pumps/ Fans/ Borewell motors and
  Blowers above 25 KW.
• Study the loading pattern flow etc. in case of
  pumps/ fan so as to evaluate the operating
  efficiency and possibility of reducing the energy
  consumption. Also the feasibility of using
  electronic drives would be worked out

6
Scope of Study Motive Load

• Belt conveyor motors / Dust extraction fan / Main
  chain motors above 25 KW.
• Study of the mechanical power transmission
  systems and assess the feasibility of using more
  efficient power transmission systems.

7
Scope of Study Compressors (Air/Ammonia)

• Air compressors
• Ammonia compressors 2 Nos. in the Ammonia Storage
  Plant.
• Evaluate the Specific Power Consumption, free air
  delivery capacity, operational scheduling and
  other parameters so as to work out the cost of
  compressed air and feasibility for further
  optimisation. Also the leakages (if any) in the
  distribution system would be identified using
  ultrasonic leak detection equipments

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Scope of Study Air Conditioning

• Air Conditioning Plant (above 80 TR each).
• CO2 Compressors in Urea I and Urea II.
• Compressors in AC Ammonia Control Room and AC
  Ammonia Compressor House.
• The audit would involve analysis of various
  parameters like co-efficient of performance,
  Tonnage Delivered, Effectiveness of the Ducting
  and allied systems

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Scope of Study Cooling Tower Pumps / Fans

• Cooling Tower Pumps/ CT Fans above 25 KW.
• This would include detailed study of the
  operational performance of the Cooling towers
  through measurements of temperature differential,
  air / water flow rate to enable evaluate specific
  performance parameters like approach, efficiency
  etc.

10
Scope of Study GTG

• GTGs (2 Nos. in the Power Plant)
• Study of the operational scheduling, cost of
  power generation, effectiveness of the heat
  recovery systems etc. and feasibility of energy
  savings would be worked out

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Scope of Study Illumination

• Lighting and allied systems.
• A comprehensive study of the entire Lighting
  systems covering the Light Source (Lamps),
  Luminaries (Reflectors etc), and the Gears
  (Ballasts) would be taken up. Besides this the
  illumination levels required vis-à-vis available
  would also be studied

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Scope of Study Boilers

• Power Plant Service Boiler (150 MT/ hr).
• Waste heat Boilers (3 Nos. in Ammonia I and 3
  Nos. in Ammonia II).
• Detailed study of the boiler operations to
  evaluate the combustion performance - both by
  direct and indirect method. In the direct
  Efficiency method measurements of fuel
  consumption vis-à-vis steam generation would be
  done continuously for 24 hours - provision for
  measuring the fuel/ water flow during the test
  period has to be provided by the plant. Energy
  balance would be worked out giving different
  losses prevalent in the boilers. Also, the study
  of steam generation and distribution system /
  network would be carried out

13
Scope of Study Steam Distribution Network

• Steam Distribution system in Ammonia I II,
  Urea I and II, Power Plant.
• Condensate recovery / Handling system.
• Steam Traps (approx. 1000 Nos.) (sample 25 will
  be checked).
• This would include study of the steam and
  condensate distribution networks to evaluate the
  appropriateness of the pipe size, insulation
  levels, steam trap performance, feasibility of
  flash steam recovery etc

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Scope of Study Furnaces

• Heat Recovery Steam Generators (HRSGs) 2 Nos.
  of 80 MT/hr each in the Power plant and 1 No. HRU
  of 120 MT/hr in Ammonia II.
• Operational performance evaluation and suggest
  measure for improvements

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Summary of recommendations
S. no. Equipment/ System Equipment/ System Exist ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Payback period
 ENERGY CONSERVATION  ENERGY CONSERVATION  ENERGY CONSERVATION Kwh Rs. Rs.
1. NG Pressure reducing stations NG pressure is reduced from about 40 bar to 5 bar in control valves. This is done for NG which is used for combustion in boilers, HRSGs and GTs. NG pressure is reduced from about 40 bar to 5 bar in control valves. This is done for NG which is used for combustion in boilers, HRSGs and GTs. Install turbo expander to reduce the NG pressure from 40 bar to 5 bar for fuel requirements to generate 1000 kW power and 100 TR refrigeration effect for air conditioning 86,19,000 kWh from GT or grid can be displaced 1.81 crores 10.5 crores 6 years
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Summary of recommendations
S. no. Equipment/ System Exist ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Pay back period
 ENERGY CONSERVATION  ENERGY CONSERVATION Kwh Rs. Rs.
2. Boiler Feed Pump of Power Plant Operating pressure (observed during energy audit for few days) was 150 kg/cm2g while the drum pressure is 120 kg/cm2g Reduce the discharge pressure to 135 kg/cm2g after replacing oversized control valves of desuperheater feed, if necessary. 79,20,000 kWh 34.85 lakhs 60 lakhs 21 months
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Summary of recommendations
S. no. Equipment/ System Equipment/ System Exist- ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Payback period
 ENERGY CONSERVATION  ENERGY CONSERVATION  ENERGY CONSERVATION Steam Rs. Rs.
3. Boiler FD fan System efficiency (including fan damper losses) is only 14.3 System efficiency (including fan damper losses) is only 14.3 Reduce steam turbine speed and increase damper opening automate control to move damper to preset position in case of changeover to electric motor drive 1,584 tons HP steam 69.7 lakhs Minor Immediate
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Summary of recommendations
S. no. Equipment/ System Equipment/ System Exist- ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Payback period
 ENERGY CONSERVATION  ENERGY CONSERVATION  ENERGY CONSERVATION NG Rs. Rs.
4. Service Boiler CBD is cooled in heat exchanger with cooling water CBD is cooled in heat exchanger with cooling water Use CBD from flash tank for preheating NG for Service Boiler 90000 Sm3 NG 5.1 lakhs 7 lakhs 15 months
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Summary of recommendations
S. no. Equipment/ System Equipment/ System Exist ing status Recommendation for energy saving Saving potential per year Energy Saving potential per year Energy Investment  Payback period
 ENERGY CONSERVATION  ENERGY CONSERVATION  ENERGY CONSERVATION kWh Rs. Rs.
5. DM water supply pumps (Raw Water Pump House) Pumps are inefficient and valves throttled Pumps are inefficient and valves throttled (a) Install efficient pumps (b) Install efficient pumps and also VFDs 248750 kWh 4,00,300 kWh 5.22 lakhs 8.4 lakhs 2.4 lakhs   12.9 lakhs 6 months   19 months
4.2.1
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Summary of recommendations
S. no. Equipment/ System Exist ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Payback period
 ENERGY CONSERVATION  ENERGY CONSERVATION kWh Rs. Rs.
6. Service water pumps (Raw Water Pump house) Two dissimilar pumps (one high and one low flow with identical rated heads) are operating in parallel The smaller pump can be stopped as it is not delivering any flow against the head of the larger pump 1,38,000 kWh 2.9 lakhs Nil (already implemented) Immediate
4.2.2
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Summary of recommendations
S. no. Equipment/ System Equipment/ System Exist -ing status Recommendation for energy saving Saving potential per year Energy Saving potential per year Energy Investment  Payback period
 ENERGY CONSERVATION  ENERGY CONSERVATION  ENERGY CONSERVATION kWh Rs. Rs.
7. Service water pumps (Raw Water Pump house) Pumps are operated with throttling of valves for flow control Pumps are operated with throttling of valves for flow control Install VFD on existing pumps to vary speed of larger pump instead of throttling valves 1,05,000 kWh 2.21 lakhs 3.5 lakhs (for 1 no. pump) 19 months
4.2.2
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Summary of recommendations
S. no. Equipment/ System Exist -ing status Recommendation for energy saving Saving potential per year Energy Saving potential per year Energy Investment  Payback period
 ENERGY CONSERVATION  ENERGY CONSERVATION kWh Rs. Rs.
8. Cooling water supply pumps (Raw Water Pump House) Pumps are operated with throttl-ing of valves for flow control Install VFD on existing pumps to vary speed of larger pump instead of throttling valves 5,52,000 kWh 11.6 lakhs 20 lakhs 21 months
4.2.3
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Summary of recommendations
S. no. Equipment/ System Exist -ing status Recommendation for energy saving Saving potential per year Energy Saving potential per year Energy Investment  Payback period
 ENERGY CONSERVATION  ENERGY CONSERVATION kWh Rs. Rs.
9. Drinking water pumps (Raw Water Pump House) Pumps are operated with throttling of valves for flow control Install VFD on existing pumps to vary speed of larger pump instead of throttling valves 36,900 kWh 77,500 4.5 lakhs (for 3 nos. pumps) 6 years
4.2.4
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Summary of recommendations
S. no. Equipment / System Exist ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Pay back period
 ENERGY CONSERVATION  ENERGY CONSERVATION Steam NG Rs. Rs.
10. Compressed Air Normal instrumentation air consumption is about 182.1 Nm3/min at 8 bar pressure about 26.7 Nm3/min is extracted from at 14 kg/cm2g from steam turbine driven process air compressor in Ammonia-1 and 45 Nm3/min from gas turbine driven process air compressor in Ammonia-II and about 110.7 Nm3/min is delivered by the offsite electric motor driven air compressor in Ammonia II Install a 100 Nm3/min electric motor driven air compressor and stop extraction from process air compressors. We understand that the process demand for air is also increasing and this suggestion may be in consonance with other process improvements planned. Hence this recommendation need not be justified merely on the basis of energy saving potential Both steam and NG are saved 39.4 lakhs (including steam NG cost) 1.3 crores 3 years
4.5.3
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Summary of recommendations
S. no. Equipment / System Exist ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Pay back period
 ENERGY CONSERVATION  ENERGY CONSERVATION Kwh Rs.
11 Air Conditioning Existing specific power consumption at compressors shafts of process control rooms air conditioning systems is in the range of 1.07 to 1.61 kW/TR even during favourable winter conditions The specific power consumption has to be brought down to about 0.7 kW/TR by attending to specific routine maintenance issues that are detailed in the report 6,28,000 13.2 lakhs No additional expenditure, part of routine maintenance budget Immediate
4.6.2
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Summary of recommendations
S. no. Equipment / System Exist ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Pay back period
 ENERGY CONSERVATION  ENERGY CONSERVATION KWh Rs. Rs.
12 Effluent Treatment (Disc oil pit) In Ammonia-1, effluent is pumped from disc oil pit to another ETP pit and then pumped again to offsite ETP Double pumping can be avoided and the effluent can be sent directly to from disc oil pit to ETP, bypassing the intermediate ETP pit 39,600 83,000 Minor investment for bypass piping Immediate
5.6.1
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Summary of recommendations
S. no. Equipment / System Exist ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Pay back period
 ENERGY CONSERVATION  ENERGY CONSERVATION Steam Rs. Rs.
13 Waste heat recovery CBD flash tank outlet water is presently cooled in cooling water cooled heat exchanger The heat can be used for heat the off gases from PGRLP washing 28 TPH LP steam 14.0 lakhs Rs 11.0 lakhs 9 months
5.6.2
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Summary of recommendations
S. no. Equipment / System Exist ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Pay back period
 ENERGY CONSERVATION  ENERGY CONSERVATION NG Rs. Rs.
14 Recovery of vent gases About 20 sm3/hr of vent gases, containing 75 H2 25 N2, from LP sour oil trap are vented in both Ammonia-I II These vent gases can be recovered and used as primary reformer fuel connection can be given to the NG fuel header 10 Nm3/h of NG total 3.0 lakhs Rs 20.0 lakhs 7 years
5.6.3
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Summary of recommendations
S. no. Equipment / System Exist ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Pay back period
 ENERGY CONSERVATION  ENERGY CONSERVATION KWh Rs Rs
15 DM Water Pumping DM water from DM Water Plant is sent to tanks in Ammonia-1 II and then pumped fron the tank to deaerators by separate pumps DM water can be sent directly from DM water header to deaerators through control valve a pump bypass line already exists as per orginal design (this arrangement is already operational in Power Plant) A booster pump may be required if pressure is not sufficient 11.88 lakh kWh 24.9 lakhs Rs 2.0 lakhs 1 month
5.6.4
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Summary of recommendations
S. no. Equipment / System Exist ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Pay back period
 ENERGY CONSERVATION  ENERGY CONSERVATION kWh Rs Rs
16 Naptha feed pump In Ammonia-II, the naptha pump flow is control by both throttling control (at inlet to vaporizer) with recirculation (pump discharge bypass). Use of VFD to reduce the speed and continuously match the end-use pressure requirement can avoid throttling losses and wasteful discharge bypass 2,00,000 kWh 4.2 lakhs 5 lakhs 15 months
6.2.1
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Summary of recommendations
S. no. Equipment / System Exist ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Pay back period
 ENERGY CONSERVATION  ENERGY CONSERVATION kWh Rs Rs
17 Lighting The illuminance in the control rooms of Ammonia-I and Ammonia-II/Urea-II are in the range of 400 to 450 lux, which is very high About 595 of the lamps may be removed to reduce the illuminance to 150 to 200 lux. This should be done in consultations with occupants for comfortable working environment 60,000 kWh 1.26 lakhs Nil Immediate
9.3.2
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Summary of recommendations
S. no. Equipment / System Exist ing status Recommendation for energy saving Saving potential per year Saving potential per year Investment  Pay back period
 ENERGY CONSERVATION  ENERGY CONSERVATION Kwh Rs Rs
18 Lighting Existing fluorescent tube lights have electromagnetic ballasts Replace electromagnetic ballasts with electronic ballasts 84,000 1.77 lakhs 8.6 lakhs 5 years
9.3.3
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• Other points

1. Operation of Gas Turbines on naptha is not
recommended due to reduced efficiency and
maintenance issues 2. Operation of HRSG in
auto mode is not recommended 3. Potential for
saving energy by use of variable frequency
drives exists in DM Plant also however, as the
number of pumps are large, some discussion is
required to develop better understanding of the
utilization and operating hours 4. The
operating efficiencies of cooling tower pumps are
estimated to be in the range of 84 to 88,
which reasonably acceptable considering site
variations
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• Other points

5. Compressed air leakage survey was done list
of identified leakage points have been
provided 6. About 100m3/hr process condensate at
100C comes out of process condensate stripper
after transferring heat to incoming condensate
this condensate is cooled in cooling water heat
exchanger before sending to DM water plant. This
hot water can be used for a 300 TR absorption
chiller for supplying cooling to control rooms
or process applications. 7. The efficiencies of
some process pumps in Ammonia I II and Urea
I II have been reviewed 8. On request of plant
managers, cooling water flows at a number of
process heat exchangers were measured in Ammonia
I II and Urea I II
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• Other points

9. The transformer efficiencies of majority of
the operating transformers have been estimated
no changes for efficiency improvement are
envisaged in this area. The possibility of use
of low loss amorphous core transformers for
non-critical loads in future projects. 10. Measure
ments were made on majority of the working
electric motors above 50 hp. The loading levels
are generally good and no specific
recommendations are made for motors.
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WATER CONSERVATION
   Present Scenario  Suggestions for improve - ment  Water saving m3/ annum  Water cost saving Rs  Saving in Chemi-cals, Tons/ year  Saving in chemicals costs Rs  Total saving Rs
Effluent from Ammonia Urea Plants Presently the ammoniacal and non-ammoniacal effluent is mixed. Significant amount of ammoniacal effluent from ammonia-1 from Syngas compressor intercooler mixes with other effluent, resulting in prolonged stripper operation and about 5 to 6 tons per hour of LP steam Stop ammonia mixing in intercooler and provide separate ammoniacal effluent stream from non ammoniacal effluent. Separate ammonical effluent collection pits are planned and intercooler tubes have been replaced to arrest ammoniacal effluent. - - - - 72.6 Lakhs/ year
11.3
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• Other points

1.     Drinking water requirement in the factory
is reported to be around 500 m3 per day which
for the 1200 nos. of employees appear to be very
high. Assuming that there is additional staff of
contractors of about 600 and the company
employees of 1200 (total 1800 persons) using
water for drinking and sanitary purpose the
consumption at any point of time should not
exceed 150 m3 per day, which means there is
scope in this area to reduce the consumption by
about 350 m3 per day i.e. 127750 m3 per annum.
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• Other points

2. The maximum number of people at any point of
time in the town ship (colony) including the
employees and outsiders (contracted workers) is
not likely to exceed 2500. Taking Indian
standard of water consumption at the rate of 100
litres per person/day, the consumption is not
likely to exceed 250 m3/day. As per the
international standard about 150 litres of water
is consumed per person per day. Applying the
mean standard of 120 litres per person per day,
the water consumption should not exceed 300
m3/day. However, from the record made available
to us, it appears that the daily consumption is
in excess of 600 m3/day and this it self offers
scope to reduce the consumption by about 300
m3/day i.e. 109,500 m3/annum.    
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• Concluding Remarks

Energy Cost Savings 1.  The total energy
cost savings with zero or minor investments is
estimated Rs 117 lakhs/year. The payback will be
immediate or less than 6 months in these
cases. 2.  The total energy cost saving for
measures with payback period between 6 months
and 2 years is estimated Rs. 80.5
lakhs/year savings with an investment of 119
lakhs. 3.  The total energy cost saving for
measures with payback period more than 2 years
is Rs 2.39 crores/year with an investment of Rs
12.0 crores. It may be noted that the Investment
for Turbo Expander and Centrifugal compressor
account for about Rs 10.5 crores of the above
projected investment. 4. The total energy saving
potential identified in this report in about
4.36 Crores/annum.
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• Water Cost Saving

1. Total water cost saving potential
identified is Rs 72.6 lakhs/year. 2. The
plant has already invested in change of
intercooler tubes of Syngas
compressor, and has planned
for condensate recovery schemes so that
stripper operation can be minimized.