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D.S. MALLICK
BACKGROUND.
1972 Acknowledgement of energy efficiency in Fuel Policy Committee Report.
1975 -
Background [contd.]
198090 Agreement with : International Development (UK) German Federal Ministry USAID to assist energy efficiency programme Indian Institutions to offer similar programme: TERI CII ICICI ..
Background [contd.]
1984
Energy Management Centre created in the Power Ministry, now converted to Bureau of Energy Efficiency.
ENERGY MANAGEMENT
OBJECTIVES:
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Conservation of scarce & finite resources by enhancing efficiency of energy conversion and end use
RESULT
Improve profitability Reduce GHG emission Reduce solid waste and thermal pollution
15%
20%
Good house keeping Regulation/Standards Industrial Co-generation Fuel switching Fiscal policies like tax rebates/subsidies Benchmarking Energy audit Information dissemination &demonstration R&D
Energy Consumption & Scope for Energy Conservation in Energy Intensive Industries
Industry Energy cost as Scope for % of Mfg. cost energy consumption 40% 13% 35% 7% 60% 25% 20% 25% 15% 15% 10% 20% .....
Energy Consumption & Scope for Energy Conservation in Energy Intensive Industries [Contd..]
Industry Energy cost as Scope for % of Mfg. cost energy consumption 40% 30% 30% 10% 15% 15%
AGRICULTURE
Around 18 million pump sets 60% driven by electric motors, rest by diesel engines. About 0.6 million pump sets being added each year
Conversion of diesel pump to electric pump Community Scheme Energy efficient tilting Development of Fertilizer Development of Bio-technology
Commercial Sector
Lighting HVAC
Domestic Sector
Household sector consumes 20% of total electricity Scope of energy conservation - 15-20%
TRANSPORT
consumes 112 million te per year of oil in transportation out of 114 MT consumption. 75% imported at 1,20,000 crores. As per PCRA, 20% saving in oil can be achieved by following simple habits. * good driving * check tyre pressure * avoiding spillage * check fuel filters * keep the engine well-tuned -- so on - -
It serves the purpose of identifying where energy conservation opportunities can be effected in a plant/building
Excellent companies have tapped all three opportunities Separate teams with common objective
To concentrate on avoidable losses Quantify the losses Identify ways & means for reduction Implementation
PUMPS
TYPES OF PUMPS
Centrifugal Moderate pressure (upto 6000 m wc) Moderate Capacity (upto 10,000 m3/hr) - Upto 30,000 m3/hr in
Energy Parameters
Efficiency
Pump (%) = Pump output Input to pump[BHP(O)] Pump (%) = Flow (lps) x Head (m) x Sp.Gr. 102 x (motor) x kw (I)
Actual Efficiencies
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Normal = 60-75% Best = 78-80% (upto 85% efficiency in case of horizontal split casing pumps) Worst = 30-60%
Pumps Formulae..
Pumps Formulae
If the RPM is reduced by say 10%, what will Happen to the
Wrong selection Over design Improper layout Old inefficient pumps Multiple smaller size pumps Ad-hoc decisions
Install Flow & Energy meters for all major pumps Observe Flow & Power consumption pattern - Hourly, Shift & daily basis Identify pumps having major power consumption Explore Energy saving possibilities - Apply 80-20 rule
Major problem is over-sizing of pumps Indicated by valve control or recirculation Scan all pumps for valve control
Concentrate on pumps with less than 40% valve opening Cross check design with actual requirements Look for alternatives - Impeller reduction - Correct size pump
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Ef f ec t of V ar i ou s Capa c it y Cont r ol s
k w in %
V FD
I d eal
Q in %
U s e Gr a v i t y Fl o w a s M u c h a s Po s s i b l e
U s e Gr a v i t y Fl o w a s M u c h a s Po s s i b l e
U s e Gr a v i t y Fl o w a s M u c h a s Po s s i b l e
Optimum Margins
Excessive margins due to uncertainty Optimum margins required
Head
- 10%
Simple Definition * Machines to move gases (or) gases mixed with small solid particles Operation of fans similar to pumps Broad Classification * Centrifugal * Axial
Capacity : Head :
(RPM) (RPM)2
Ef f ec t of V ar i ou s Capa c it y Cont r ol s
k w in %
V FD
I d eal
Q in %
Throttling of a Fan
Control by Varying Speed Damper 100% Open Power with damper = 53 kw Power with VFD = 29 kw Savings = 24 kw Annual Savings Rs.7.76 Lakhs Investment Rs.6.85 Lakhs Payback period 11 Months
o o
High efficiency of 85% Lower weight Lower starting torque requirements for the motor Lesser foundation requirements Nearly same efficiency for a wide range of operation part load & full load efficiencies are almost same
Replace Centrifugal Fans with Axial Fans Parameters Centrifugal Axial Capacity (m3/h) Pressure (WG) Power (KW) 181880 0.98 22 120000 1 12 80%
Efficiency () 41% Annual savings : Rs.2.9 Lakhs Investment : Rs.1.5 Lakhs Payback : 6 months
MOTORS
Watts Losses
Stator & Rotor Losses I2R Iron Loss Friction & Windage Losses Stray Load Losses
Mot or
Load
Typic al range
Use of less efficient motors Oversized/under loaded motors Improper supply voltage Voltage fluctuations Poor power factor Less efficient-driven equipment Idle running
Voltage Optimisation
Impact on motor operating parameters
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q q q q q
Reduction in voltage dependent lossesDrop in Magnetization current Capacity reduces PF improves Load current drops Load factor improves Efficiency improves
Delta to permanent star Steady load applications Automatic star-delta-star converters for shock loads Soft starter cum energy savers high starting starting torque applications Down sizing Overall voltage optimization
Option based on
Motor and power factor varies with % loading For lightly loaded motors (38%) v Voltage related losses high v Power factor is very low v More copper losses v Motor operates in less efficiency range
Reduction in voltage related loses Operates with improved P.F. Reduction copper losses Motor efficiency improves
Delta mode = 10.5 kw Star mode = 8.0 kw % Load = 35% Savings in kw = 2.5 kw Annual Saving = Rs.3.0 Lakhs
Automatic Star-delta-star
Application motors with shock loads Automatic star-delta-star converter has load sensor & Timer Capacity V2 Principle of voltage optimisation
CASE STUDY Install Automatic Star Delta Star Starter for Coal Crushers
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CASE STUDY Install Soft Starter Cum Energy Saver For Identified Simplex Machines
Rated kw of the motor Actual load = Loading = Type of load = Total no. of machines in operation =
Annual Saving = Rs.5.50 Lakhs Investment = Rs.5.00 Lakhs Payback period = 11 months
Plant operating voltage plays a critical role in energy conservation Suggested to have on line voltage optimising devices to regulate the operating voltage as required Magnetization losses vary exponentially with the voltage
Capacity V2 Torque V2 Voltage optimisation will vary the capacity of the motor Implemented after analysing the loading pattern of all motors
Engineering industry operated with OLTC Transformer Majority of the motors are loaded less than 50% Voltage before optimisation = 425v Kw load at 425v = 2800 kw Optimised voltage = 400v Kw reduction at 400v = 45kw Annual Savings = Rs.13.80 Lakhs
Pumps, fans & compressors are major loads 50 60% power consumption Majority of loads are centrifugal in nature Power cons. Rpm3 10 20% over design is common Excess head & capacity controlled
Controlled using valves/dampers/recirculation Energy inefficient methods of control Variable frequency drives are ideal choice Majority of case low frequency is helpful reduce energy cons.
Operate captive power plant (DG set & TG set) at lesser frequency incase of process industry Speed correction (pulley size adjustment) in case of textile & engineering industry Optimise system voltage based on frequency
More Cu wire in stator and rotor to cut resistance losses Longer stator and rotor cores to reduce magnetic losses Precision air gaps to reduce current requirements Improved windings and lamination designs to maximise energy consumption Special steel processing in stator to minimise core losses
It has been implemented in many industries Case study is from one of the textiles industry Ring frames are vital and continuously operating equipment in textile industry Total number of RF machines 30 Nos.
Replace Conventional Old Motors With Energy Efficient Motors Continuous operation Results: Motors Old motor Energy efficient motor Difference in consumption Annual Savings Investment Pay back period Rated kw 15.0 15.0 No Load kw 23.2 1.56 0.76 : Rs.23.0 lakhs : Rs.12.0 lakhs : 7 months Load kw 9.92 7.36 2.56
Rewound Motors
Motor Burning
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Quality of insulation between stampings deteriorated Eddy current losses increase Magnetic property deteriorated Magnetic losses increase Causes drop in efficiency
Rewound Motors
Bearing failure
Rotor scratches stator Air gap becomes uneven Torque induced not uniform Net torque developed is low Causes drop in efficiency
Motors replacement should be analysed case to case basis Maximum 3 times motor can undergo rewinding normal failure
In a large complex distribution system, voltage drops are very common Acceptable limit in a 3Ph. System is 4-5v/phase
Measuring instruments should be calibrated Simultaneous measurement of voltage in the feeding and receiving end of the feeder Measure P.F. & current Note the capacity of the power cable used
Poor power factor Inadequate cable size laid Poor contact surface at
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Voltage at sub station = 415V Voltage at LT panel = 398V Load current = 180-200A Power factor = 0.4 Lag Cable size = 1R x 3C x 300Sq.mm
Relocate 90KVAR Capacitor bank from SS to LT panel Reduced 50% of energy loss (Approx. 1Kw/Ph.)
TRANSFORMERS
Losses in Transformer
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Alloying steel with silicon Hot rolled grain oriented silicon steel Cold rolled grain oriented silicon steel Latest - amorphous
Transformers
Transformer efficiency = 98 - 99% Optimum efficiency occurs, where Iron losses = Copper losses
Normal Efficiency - 98% to 99% Iron losses is 10% to 15% of full load copper losses Optimum efficiency occurs between 40% to 60% of loading
Normal efficiency - 99% to 99.5% Iron losses is 20% to 25% of full load copper losses Optimum efficiency occurs between 60% to 80% of loading
POWER CAPACITORS
How poor operating power factor cost money?
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Maximum demand increases for the same load Draws more current for the same load More distribution voltage drop i.e. loss in the distribution cable increase Copper loss in the transformer increase
POWER CAPACITORS
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Capacitor banks install to improve power factor Allowable power loss = 3-5 w/Kvar
Ageing Input voltage and frequency fluctuation Harmonics present in the system Temperature around the bank Poor quality capacitors use in the construction
Indication:
Power consumption above the permissible level Temperature on the body is above ambient temperature
LIGHTING SYSTEM
Lighting
Terminologies
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Flux emitted by lamp lumens Luminous Efficacy Lumens / watt Illuminance = Lumens / sq. meter (Lux) Colour Rendering Index Colours of surfaces illuminated by a given light source
Types Of Lamps
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Fluorescent Lamps (FTL) Compact Fluorescent Lamps Mercury Vapour Lamps Sodium Vapour Lamps Metal Halide Lamps
LED Lamps
High efficiency lamp Low Wattage Less heat dissipation Excellent colour rendering Long life 8000-10000 glowing hours Highly suitable living rooms, lounges, corridors, hotels and canteens
Corridors & Canteen 100 Nos. of 60 watts GLS lamps Replaced with 15 watts CFL Annual Savings : Rs.0.56 lakhs Investment : Rs.0.40 lakhs Payback period : 9 months
Tri-phosphor fluorescent powder technology High colour rendering Ra-85 (conventional FL Ra-65) High luminuous efficacy Conventional : 68 lumens/w Energy efficient : 90 lumens/w
40% more lumens Ideal choice new projects and Places where existing lighting is poor Paint shops, assembly bays, printing press, Inspection areas
HPSV Lamps
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High efficiency - 108 Lumens/watt Colour rendering Fair Godowns, storage yards, ware house, highways, flood lighting and street lighting Comparison of HPMV & HPSV HPMV Watts Lumens HPSV Watts Lumens 80 3500 70 5800 125 6250 150 13500 250 13500 250 27000 400 23000 400 47500
Case Study Replace HPMV Lamps with HPSV Lams Cement Plant
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Street lighting, yard lighting and some plant area . 120 Nos. 250 watts HPMV Replaced by 120 Nos. 150 watts HPSV Power Savings : 12 KW Annual Savings : Rs.1.60 lakhs Investment : Rs.2.00 laksh Payback period : 15 months
Gas discharge lamps iodide additives Excellent colour rendering (Ra-69) Highlight output Suitable for colour critical areas Uses HPMV ballast additional igniter
LED Lamps
More suitable for panel indication Power consumption of the filament panel indication lamps = 14-15 w/lamp Power consumption of the LED panel indication lamps = 0.5 1.0 w/lamp Power savings = 14 W/lamp
LED Lamps..
Advantages
More life 10000 hrs. Withstand for +/- 25% voltage fluctuation Energy efficient Cannot be used for illumination purpose
LED Lamps..
Applications Panel indication Tower lighting Textile machines post lamps Signature Board display lighting
LED Lamps..
Case study from textile unit
No. of filament lamps installed = 4000 nos. No. of lamps glowing = 2000 nos. Total power savings achieved = 28 KW Annual Savings = Rs.8.0 lakhs Investment = Rs.8.0 lakhs Payback period = 12 months
Lighting Control
Voltage Reduction Discharge Lighting Optimum voltage for discharge lighting 205 210 volts Reduction in voltage by 15%
Proportional drop in power consumption 15% Insignificant drop in illumination level Only digital lux meters measure the drop (1-2%)
Total power savings achieved = 25 kw Annual Savings = Rs.6.7 lakhs Investment = Rs.7.2 lakhs Payback period = 13 months
Summary Recommendations
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Maximum utilisation of natural light Select energy efficient lamps Installation of mirror-optic luminaries Fixing lights at optimum height Optimum voltage for lighting system Use energy efficient HF Ballast ....
Use timer control switches for outside lighting system Use movement sensor and dimmer control system, wherever required. Proper grouping of lights and proper control system
High specific heat capacity High latent heat Cheap and easily available Non toxic and inert High heat transfer coefficient
Steam System
Considerable savings can be achieved by systematic steam system audit. Audit should cover:
Steam Balance Steam turbine performance Condensate recovery Steam traps Co-generation Recycling waste heat
CO-GENERATION
WHAT IS COGENERATION?
WHY IT IS ECONOMIC ?
1. The conventional method of power generation in a fossil fired power station has to reject about 60 - 70% of input energy. This is law of nature and can never be reversed.
2.Co-generation
scheme uses this reject energy as process heat input and hence, efficiency can reach 100%.
COGEN ROUTES
1. High pressure steam - back pressure or condensing-cum -extraction turbine extraction steam to process. 2. Gas turbine - exhaust heat - waste heat recovery boiler - process steam
INPUT : 100% TURBINE OUTPUT : 35% CONDENSER LOSS : 55% STACK LOSS : 9% MISC. LOSS : 1%
STEAM TURBINE CO-GEN PLANT WITH BACK PRESSURE TURBINE A TYPICAL ENGERY DISTRIBUTION SCENARIO
FUEL INPUT : 100% STEAM TURBINE OUTPUT : 10% PROCESS STEAM : 74% STACK LOSS : 15% MISC. LOSS : 1%
FUEL INPUT : 100% STEAM TURBINE OUTPUT : 20% PROCESS STEAM : 25% CONDENSER LOSS : 39% STACK LOSS : 15% MISC. LOSS : 1%
GAS TURBINE WITH WASTE HEAT RECOVERY A TYPICAL ENGERY DISTRIBUTION SCENARIO
FUEL INPUT : 100% GAS TURBINE POWER : 30% PROCESS STEAM : 44% STACK LOSS : 25% MISC. LOSS : 1%
To study the process and energy fluctuation Review the impact of process fluctuation Select design power : steam ratio Select the optimum cycle configuration - energywise Study and work out the cost effectiveness of the selected option Sometimes, the most energy efficient option is not the most cost effective one
Alternate 1
Boiler
Alternate 2
TG
Steam
Power : Steam Ratio The most important criterion to select the most cost-effective configuration
THANKS