What is Electrical Power...?

Electric power is the rate at which electric energy is transferred by an electric circuit. The SI unit of power is WATT(W) or (Joule per Second.) Electrical Energy is the Power consumed over unit time. We express Electrical Energy in the unit kilowatt hour, (kWh) which is equal to 1000 watt hours. For constant power, energy in watt hours is the product of power in watts and time in hours.

How much energy we at HNL consume in one day ????

Around 500000 kWh (including colony)
500000 kWh is a huge amount of energy ..... So from where we get this power.?????

Source of electrical power for HNL

Kerala State Electricity Board (KSEB)
24 MVA contract demand

Self generation
22 MW Steam based captive power generation 2.5MW Diesel generator for emergency power

How do we receive power from KSEB...???

DOUBLE CIRCUIT

110 KV LINE

LINE 1 : FROM KANDANADU 110KV SUBSTATION LINE 2 : FROM BRAHMAPURAM 220KV S/S HNL is an EHT CONSUMER AT 110 KV (EHT is acronym for Extra high tension)

Why in world Power is transmitted at Higher voltages cant they do it at 415 V???
For minimizing transmission losses. Power = Volt * Current Losses = Current2 *Resistance So, if we increase Voltage and reduce Current, we can transmit the same power with minimum losses

Our Captive Generation

15 MW TG ( EXTRACTION AND CONDENSATION TYPE )
CRITICAL LOADS RUNS IN SOLO MODE

7 MW TG
2.5MW

( FULLY CONDENSATION TYPE )

PARALLEL WITH KSEB NOT CONTINOUS DIESEL GENERATOR (For emergency supply )

Both TG & DG produce power at 11 KV

KSEB transmit power @ 110 KV and we generate @ 11KV . How do we link both together ???
Step down KSEB power from 110 KV to 11 KV with help of step down transformer at our 11 KV substation . Connect all part of our mill with 11KV bus. Our load (motors, fan, lighting ......)will be at lower voltage ratting. So again we step down to required voltage level.

Our 11KV Electrical Distribution looks like .....

11KV Electrical Bus in HNL

Total 6 buses A B C D E F of which Two are Connected to our TG
A bus to 15 MW TG F bus to 7 MW TG

Three Connected to KSEB

B bus C bus D bus

One Connected to our 2.5 MW DG

E bus

Buses are interconnected by using Bus Coupler

How power is transferred from 11 KV bus to load ????

11 KV bus Step down transformer (if needed)

Transformer secondary is connected with PCC (Power control Centre)

Load(eg motor) MCC (Motor control Centre)

What are different types of motors used in HNL?

DC motor AC motor
Induction motor Slip Ring motor Synchronous motor

DC Motor
Used where speed control is required. In 1980s AC drive (VFD) technology was not there. So for speed control, DC motor are used in HNL.

Used in Paper Machine Drive motor, Winder Drive motor.

Maintenance of DC motor is much more costly than AC motor. Now a days DC motors are seldom used.

Induction motor
Most common type of motor used in HNL Generally runs on constant speed, speed of motor will vary with load (not much though). With modern AC drive (VFD), Speed control of induction motor is possible. In HNL, generally motors above 200 KW will be running at

3.3KV voltage or above (so called as HT motor)

Slip Ring Induction motor

It is used where high starting torque is
required.

Used in Wood Chipper, Disperger (in DIP),

Crane motors.

Synchronous

motor

Used where motor has to run at constant speed (generally low speed) and deliver high torque. Used in Raffinators (in CMP) and in Vacuum pump (in paper machine)

ELECTRICAL DEPARTMENTS

UTILITY

PAPER MACHINE

PULP MILL

ELECTRICAL WORKSHOP

PLANTS UNDER UTILITY

Power House 110 KV Substation Chipper House Pump House Recovery Plant Evaporator Plant ( Old And New )

Lime Kiln
Filtration Plant

Power House
Main electrical equipments of power house are
Turbo Generator 15 MW Turbo Generator 7 MW ELECTROSTATIC PRECIPITATOR (ESP) A and F bus is located in power house

ELECTROSTATIC PRECIPITATOR
ESP is a particulate collection device that removes particles from a flowing gas using the force of an induced electrostatic charge. Collects fly ash from boiler. ESP unit consists of 3 field units. RATED I/P: 415 V 50 HZ RATED O/P: 88 KV DC

84 A 400 mA

110 KV SUBSTATION
2nos. of 110 KV line come from KSEB 3 nos. Step down Transformers 110/11 KV convert 110 KV to 11 KV. Each transformer are of 20 MVA capacity (TRF 1 , 2 & 3) and all have on-load tap changer facility. This 11 KV is fed to CMP load dispatch centre and utility for synchronization with TG Breakers used are SF6 and MOCB

CHIPPER HOUSE
Main Electrical Equipments : Two nos. 11/3.3 KV transformer of 5 MVA & 1.6 MVA capacity 2 nos. of Wood Chipper - slip ring induction motor of 3.3KV 970 KW 987 RPM
(This is largest slip ring induction motor in HNL) Reed and Bamboo chipper-squirrel cage induction motor 3.3KV 400 KW 960 RPM

PUMP HOUSE
Main Electrical Equipments : Two nos. 11/3.3 KV & 11KV/ 415V transformer of 3 MVA & 1.6 MVA capacity respectively.

PAPER MACHINE
Paper Machine requires enormous electrical energy and it should be uninterrupted. 4 buses are connected to paper machine(A3, A4,A5,A6) A3 feeds stock preparation through 5 MVA and two 1.6 MVA transformers A4 feeds Paper M/C auxiliaries through 5 MVA AND two 1.6 MVA transformer. A5 feeds P M/C drives through 1.6 MVA and

two 2 MVA transformer.

A6 feeds finishing part through two 1.6 MVA

PULP MILL
THREE PULP PLANTS IN HNL: CHEMICAL PULP (CP) MILL Three 1.6 MVA transformer feeds CP mill DE-INKING PLANT Two 2.5 MVA transformer feeds DIP DISPERGER 500kw 3.3kv slip ring motors

CHEMICAL MECHANICAL PULP (CMP) MILL

Raffinators of CMP are driven by 6.5 MW SYNCHRONOUS MOTOR (BHEL MAKE) (largest motor of HNL)

Two 1.6 MVA transformer feeds CMP auxiliaries

B, C, D, E bus are located in CMP

ELECTRICAL WORKSHOP
An incorporated facility for rewinding of motors and transformers etc.

How much power we consume (Plant wise) ???

CMP Plant: CP Plant Deinking CMP plant Auxiliaries Raffinators Drives: KWh KWh KWh KWh KWh Paper Machine Recovery Plant: Chipper KWh

Stock Finishing Recovery preparation Auxiliaries House Boiler Causticising Evaporator II Lime Kiln
KWh KWh KWh KWh KWh KWh KWh

4496

16675 134317 150992

15673

29952

32342

111915 39387 198927

15283

9219

1212 17550

4990

2129

Power House :

Steam Water Effluent TG Aux.15 TG Aux.7 Plant Generation Treatment Treatment MW MW Air supply Workshops Lighting
KWh KWh KWh KWh KWh KWh KWh KWh

Distributi Colony on Losses Total

KWh KWh KWh

2129

39111

8336

37 73570

12309

13777

336

6229

4917

4229

417590

This was HNLs power consumption as on 30 April 2013

How do we monitor HNLs power consumption...???

HNL has Schneider Enercon Energy monitoring system. It has 116 Enercon meters installed at various areas of the plant. These meters collect energy data and send to a server which is located in the power house. Power consumption of all plants in HNL can be monitored in real time using this facility.

How KSEB Billing is Done...????

A
DESCRIPTIO N UNIT RATE CONTRACT DEMAND KVA 24000

B
DEMAND CHRGE MINIMUM PAYABLE KVA

E
OFF PEAK TIME hrs.

F
DEMAND CHARGE ` 290/KVA

G
ENERGY CHARGE ` 4.30/kWH

PEAK TIME NORMAL TIME hrs. hrs.

MD CHARGE- TOTAL MD NORMAL CHARGE ` 290/KVA `

REMARKS

18000 75% OF CONTRAC 06:00 TO T DEMAND 18:00 (CD)

18:00 TO 22:00

22:00 TO 06:00

NRD *290

NRD *290

L NORMAL ENERGY CHARGE `

M
PEAK ENERGY CHARGE `

N
OFF PEAK Energy Charge `

O TOTAL ENERGY CHARGE `

P
COLONY LIGHTING `

Q
ELECTRICTY DUTY `

SELF TOTAL FUEL GENERATION AMOUNT SURCHARGE SURCHARGE DUTY PAYABLE ` Rs ` `

4.30/kWH 6.02/kWH 3.225/kWH PEAK ENERGY CONSUMTI Energy*4.3 Energy*.8* ON L+M+N 0 4.30 (Energy *1.4*4.30) =(6.02)

0.07/KWH 0.10/KWH 0.025/KWH 0.0/ KWH 0.012/KWH

Sam e as Existing

Sam e as Existing

Sam e as Existing

Nill for m arch april m ay

Sam e as Existing

K+O+P+Q+ R+T-Pf incentive

How much we have to pay for Electricity Bill???

KSEB bill comes around Rs 5.2 per unit.
Cost of generating power in 15 MW TG is around Rs 5.1 per unit 7 MW TG is around Rs 7 per unit

What is Specific Energy Consumption..?

Specific Energy consumption : Energy consumed in producing unit quantity of a product. In a Paper Industry, it is the Energy consumed to produce 1 MT of Finished Paper.

PRODUCTION Vs SPECIFIC ENRGY CONSUMPTION

Specific Electricity Consumption Norms

Specific Electricity Consumption Norms Overall 1600 KWh/MT

P M/c CMP CP DIP Steam Lime WL

620 1060 390 270 14.5 80 585

KWh/MT KWh/MT KWh/MT KWh/MT KWh/MT KWh/MT KWh/MT