Truevacuum ACC Solutions

[Audio] TRUEVACUUM Truevacuum ACC Solutions Our services: –Performance enhancement of old ACCs –Troubleshooting in old ACCs – Thermal Hydraulic Design of ACCs.

[Audio] Problems in an ACC ! ❿No problems at all ! ❷Problem is with fans! ❶Problem is with design. Can I Integrate all problems? ❹Problem is with Steam Jet Ejector performance! ❸Problem is due to tube puncture or air ingress! ʃ problems = ACC Capability (%) (simple calculations as per ASME Code) ❻Problem is with bundles (loose bonding between tube & Fins) ❺Problem is due high to cross winds! For example: ❼Problem is due FAC (Flow accelerated corrosion). ❽Problem is due to Cement dust deposition! ACC Capability = 98% Almost no problem. ❾Problem is due to high vibrations! ACC Capability = 90% Minor problems. ACC Capability = 80% Major problems. On Ventilator. ACC Capability = 70%.

[Audio] Understanding Losses in Air-Cooled Condensers (ACC) Operation Practices ACC Equipment Underperformance Factors Beyond Human Control ● Bundles ● Fans, motors , Gear boxes ● SJE ● Ducting , piping ● Pumps, Valves, tanks, etc. (20% losses) (70% losses) (10% losses) Key problems include: Key problems include: Key problems include: Inherent design-related issues within the ACC system. Undersized equipment selection due to a lack of comprehensive understanding of site-specific conditions, such as obstructions in airflow paths and the prevailing crosswind effect. Reliance on fixed vacuum settings in the Distributed Control System (DCS), which may not adapt to fan assembly related inefficiencies. Steam flow distribution and air flow distribution at low load & low ambient temperature are difficult to predict. Periods of high ambient temperatures and strong winds, which inherently challenge the cooling capacity of the ACC. Ingress of cement dust into the ACC through fan openings, leading to fouling and reduced heat exchange efficiency. Solutions: Solutions: Solutions: Engaging independent third-party experts or consultants for thorough design validation. This proactive step can resolve up to 40% of equipment-related problems. Empowering end-users, like UTCL, to independently select and procure fans based on a deeper understanding of their operational needs. This can address an additional 60% of the equipment-related issues. Implementing dynamic changes in interlock settings based on real-time site conditions. This alone can resolve up to 80% of operation-related problems. Providing comprehensive training to both operation and maintenance teams, focusing on advanced ACC processes and their interaction with various ambient and load conditions. Developing customized solutions specifically designed to counteract the adverse effects of high temperatures and strong winds, tailored to each site's unique environmental profile. Developing customized solutions for cement dust capture..

[Audio] Who Understands Your ACC Problems Best? Consider the analogy: You own a car, and you drive it daily to the office. Consequently, you know your car's problems better than anyone else. The same principle applies directly to your ACC. The end-user, specifically the operation and maintenance team, holds the most critical understanding of their ACC's ongoing performance, challenges and problems. While some problems can be easily identified and rectified by the site team independently, others require a deeper dive. These more complex issues often necessitate thorough investigation and root cause analysis to uncover underlying systemic problems. Our role is to empower your team with the tools and expertise to identify, quantify, and resolve these issues, ensuring your ACC operates at its peak potential..

[Audio] Quantifying Losses: The AMSE PTC 30.1 Code By using ASME PTC 30.1 code, we can accurately translate operational problems into quantifiable percentages, providing a clear picture of the extent of performance degradation and the potential for improvement. Current ACC Capability = 79.61% Treat this as a MINI PG test of ACC Key features of the test: This test can be carried out any day/any time (except while it is raining). Only DCS data is required and output (ACC Capability in % ) can be known in 15 minutes. Advantage of the test: Helps in problem identification. Energy saving potential can be seen and harnessed. Regular monitoring of ACC performance (preventive maintenance). Consider the analogy: You visit a doctor or hospital as a patient. The very first thing they do is measuring your blood pressure. Why ? →Blood pressure is a key indicator of a patient's overall health status..

[Audio] Translating Losses into Monetary Terms UTCL Captive Thermal Power Plants (TPP) 1189 MW UTCL Waste Heat Recovery Systems (WHRS) 278 MW UTCL Combined Capacity ~1467 MW Assuming ACCs are installed at 1000 MW combined capacity of power plants at UTCL Hourly losses for the group shall be: ACC capability - 90% = 8 x 1,000 x 5Rs/kWh = INR 40,000 per hour → 8 MW loss out of 1000MW ( ~ less than 1%) ACC capability - 80% → 40 MW loss out of 1000MW (4%) = 40 x 1,000 x 5Rs/kWh = INR 2,00,000 per hour →100 MW loss out of 1000MW (10%) ACC capability - 70% = 100 x 1,000 x 5Rs/kWh = INR 5,00,000 per hour Assuming all UTCL ACCs running at 80% ACC Capability , yearly losses (8000 hours) or saving potential can be estimated as INR 160 Crores (for PLF 100%) Improvement from 80% to 90% ACC Capabilities means savings of INR 128 Crores (for PLF 100%) 80% of losses can be recovered by improving ACC capability by 10%.

[Audio] Performance monitoring on continual basis Non performing assets can be revived/replaced at right time..

[Audio] Case Study - 1: UTCL – Birla White (Kharia Khangar) TPP.

[Audio] UTCL TPP Case Studies: Conclusion: Monitoring ACC capability is not just good practice; it's an indispensable tool that helps in taking the correct action at the correct time, ensuring sustained profitability and operational excellence..

[Audio] Beyond Bundle Replacement: Unpacking the Diverse Causes of Low ACC Capability Case Study - 2: UTCL – Awarpur TPP (~25MW Unit) ACC Capability (year 2025) = 76% Reasons for low capability:.

[Audio] Reducing ACC Losses Through Smart Operation A new approach in your operation philosophy!.

[Audio] Conclusion (Quick Recap) ● Know your ACC CAPABILITY (as per ASME Code) ● ACC CAPABILITY = 80% means = 4% Generation loss ● ACC CAPABILITY = 70% means = 10% Generation loss ● Smart operation methods can improve performance of existing ACCs. ● Fan assembly play critical role in ACC performance. ● Fan selection parameters should be fixed based on site condition (should not OEM choice). ● Truevacuum ACC Solution Pvt. Ltd helps our clients with ACC Capability measurements. ● Truevacuum ACC Solution Pvt. Ltd can provide customised solution to improve performance of their old ACCs..

[Audio] Q&A / Contact Info QUESTIONS PLEASE. Please contact us at: [email protected] [email protected] Tel: +91 9818848693 www.truevacuum.co.in THANK YOU!.