Energy Conservation in Industries

K.SIVAKUMAR Larsen & Toubro Limited

Introduction
Energy ..

an important input for development very precious resource without which life cannot be imagined has become an essential part of our life as we are developing new gadgets, the consumption of electricity is going up day by day so, demand for electrical energy increasing by 6 to 8 percent every year due to rapid industrial growth, improvement in the standard of living of people and due to population growth. but, generation not increasing in the same proportion hence, huge demand supply gap

Energy Scenario

Peak shortage of power (In Maharashtra & Gujarat)

14.6% (26.6%) 9.9%

Base shortage

(Source: CEA)

Energy Scenario

Generation capacity increased from 1,400 MW in 1947 to over 1,35,782 MW as on 30-09-2007 Still, per capita energy consumption is one of the lowest in the world @ 594 kWh per annum Percentage of population with access to electricity is only 43%, as against 98.6% in China and 52.9% in . Pakistan Very low optimum utilisation of existing generating capacity Plant Load Factor only 76.2%
(Source: CEA)

Energy Scenario
Total Generation Installed Capacity:
Thermal Hydel Nuclear Non-Conventional 87226 MW 34261 MW 4120 MW 10175 MW

Total

135782 MW

Energy Scenario

T & D Losses very high at 35% (both Technical & Commercial), as against international average of 8% Add to this, the inefficient utilisation of electric energy by the end customers As per a 2004 Planning Commission Estimate, over 25000MW equivalent capacity addition could be achieved, through efficient utilisation of electric energy by the end users

Energy Scenario

HOW TO BRIDGE THE DEMAND-SUPPLY GAP?

Energy Management - Two approaches

Supply side management Capacity expansion

Demand side management(DSM)

Energy Management - Two approaches

Supply side management Capacity expansion Unrealistic Capacity addition in the first seven months of the financial year 2007-2008 only 2765 MW Just 32% of the target. Expected capacity addition in the current year scaled down from 17000 MW to 12000 MW only. Capacity addition unable to keep pace with demand due to lack of equipment and manpower.

Supply side management

Economic impact - Very capital intensive

India needs a further capacity addition of 1,00,000 MW by 2012 Capital needed - Approx Rs 8 Cr. per MW (incl. T&D) Scarcity of capital, High Interest Costs

Adverse impact on Environment

Supply side management

We have almost depleted the low cost hydro sources; so only course available is Thermal or Nuclear.
Apart from huge capital cost requirements, installation of new plants involve long gestation periods; also, scarce availability of natural resources is a problem.

Supply side management

Development of non-conventional energy sources such as wind farms, solar cells are also costlier and could not be taken as a permanent substitute since they cannot be taken as dependable to meet the basic loads. Increasing the generation of electricity without looking into the aspect of energy conservation is like filling up more and more water into a leaking bucket, without arresting the leakage.

Demand Side Management

- By Energy Conservation

What is Energy Conservation?

Energy Conservation means reduction in energy consumption without making any sacrifice of quantity or quality

How to achieve energy conservation?

It is not very difficult to save energy Only a little awareness and some efforts are required Energy saving must be a part of our routine life Think over adequate rating of equipments

How to achieve energy conservation?

Elimination of excessive use of equipments

Using high efficiency items

Change of habits that were leading to enormous wastage of energy

Potential for Energy Conservation in industry

50% of Power Generated in the Nation is consumed by Industry 72% of Power Consumption in Industry is by Induction Motors

How to achieve energy conservation? Energy Audit

To determine the pattern of energy consumption and to identify the areas of possible energy saving, an exercise is required, called Energy Audit. Its implementation can improve plant efficiency, thereby reducing energy wastages.

How to achieve energy conservation? Energy Audit

This is done by obtaining necessary data, analyse the same to identify the areas where wastage or losses occur and suggest methods to avoid wastage or loss and also other energy conservation measures to ensure efficient use of energy.

How to achieve energy conservation? Energy Audit

There are two types of Energy Audit (viz.) Preliminary Audit & Detailed Audit

How to achieve energy conservation? Energy Audit

Preliminary Audit: o Scope is to highlight the energy costs and to identify wastages in major equipment processes o Carried out in a limited span of time, say, a week o Focuses on major energy supplies and demands of the industry o Accounts for about 70% of total energy requirements o Sets priorities for optimising energy consumption

How to achieve energy conservation? Energy Audit

Detailed Audit: Goes beyond the Preliminary Audit Accounts for about 95% of energy utilised in the industry Involves detailed engineering study to reduce consumption as well as cost

How to achieve energy conservation? Energy Audit

Major Points to be covered under detailed Audit: Detailed analysis of past and present trends of energy consumption Review of existing energy recording system Consider sub-metering Check the meter readings against records Compare consumption with other locations or with that of other similar industries Check records against invoices Check capacities and efficiencies of equipments

How to achieve energy conservation? Energy Audit

Major Points to be covered under detailed Audit: Review maintenance record from shift-engineers Review lighting requirement Examine need for automatic control Examine need for improved instrumentation Examine need for training to energy management staff on energy conservation Examine and monitor new energy saving techniques

Areas of Energy Conservation

Motors- Motor drive

Lighting HVAC

Reactive power management

Power Quality

Scope of Energy Conservation in Industries

Selection of Motor: Size of motor should be selected in such a way that it fulfils the load demand properly. It should not be overrated. The over-sized motor can cause more energy losses, thus reducing efficiency, resulting in higher power consumption, poor power factor and increased maximum demand, etc.

Scope of Energy Conservation in Industries

Under loaded Motor: If motor consistently operates at less than 60% of rated load it should be considered for replacement Efficiency of Motor: Higher efficiency motors operate at better power factor as compared to other motors, so that considerable energy saving will be there.

Scope of Energy Conservation in Industries

Use of High Efficiency Starter: At the time of starting, the motor draws 6 to 8 times the rated current as starting current. To limit the starting current to a safe limit, high efficiency starters, like soft starters, can be used. Placement of Motor: Motor should be placed near the load so that transmission losses may be minimised or eliminated.

Scope of Energy Conservation in Industries

Using Shunt Capacitors: Adequate rating of shunt capacitors should be connected at motor terminals or at the MCC bus bars to compensate for the reactive power requirement so that power factor can be improved. Alignment: The alignment between motor and load should be accurate and it must be checked periodically.

Scope of Energy Conservation in Industries

Individual Drives: Group drives should be replaced with individual drives, so that at any time, when individual machine is not required to run, it can be switched off individually. Lubrication of motor: It is also necessary to check the lubrication of motor periodically, as per schedule so that its friction losses can be kept within permissible limits.

Scope of Energy Conservation in Industries

Using Variable Speed Drives: For flow control requirements large rating fans, pumps and compressors are used. In past, dampers, valves and other mechanical means were used to achieve the flow control at constant speed. Now, variable frequency based new equipments are available in market for centrifugal devices like fans, pumps and compressors so approximately 30% energy can be saved easily.

Scope of Energy Conservation in Industries

Replacement of worn-out bearing: Any worn-out bearing should be replaced promptly. Switch-off the load when not required: Many non-essential loads like lighting, pumps and smaller loads can be switched off during peak hours when not required. It may also help to accommodate more loads during maximum demand restriction periods.

Scope of Energy Conservation in Industries

Using High Efficiency Light Source: Nowadays, compact fluorescent lamps (CFL) are most efficient energy saving devices as compared to incandescent lamps. Therefore all incandescent lamps must be replaced with CFL Lamps. Optimise use of sunlight: There should be optimum use of sunlight or daylight by using transparent sheet in roofs so that light load can be reduced during day hours.

Scope of Energy Conservation in Industries

Compressed air system: Losses in the compressed air system depend upon leakage of air, number of bends in the pipe and efficiency of compressor and motor. The equipment should be placed near the load so that the losses would be minimum. In addition to it, an automatic pressure check valve should also be provided to measure inside pressure and disconnect the motor from supply automatically as and when full pressure has developed within it. VFDs can be employed for motor drives such that no-load running of the motor during compressor un-load periods can be avoided.

Scope of Energy Conservation in Industries

Thermal System: Heat losses of the furnace can be reduced, by providing adequate insulation, opening of it for minimum period, using proper insulation for the tubes thro which steam flows for process and proper repair of refractory lining.

Electrical Energy Conservation Reactive Power Compensation

Power- Three quantities

Active Power Kilowatts (kW)

Reactive Power Kilovolt amperesReactive (kVAR)

Apparent Power Kilovolt ampere (kVA)

Electric Power
Apparent Power kVA

Methods to reduce energy consumption

Reduce the watts component

Reduce the kVAR component

Reducing Watt Consumption

No investment

Processed air :
Power down compressed air system when not required Do not use compressed air for cleaning purposes

Process Machine
Turn off processing equipment, when product quality will not be affected Exterior lighting is switched off during daytime

Lighting
Turn-off lighting in unoccupied areas, if safety is not compromised

Low investment

Processed air
Locate and repair leaks in compressed air systems

Lighting
De-lamp general overhead lighting & use task lighting Replacelamps with CFL

HVAC
Do scheduled maintenance

Investment with short/long payback

Processed air
repair leaks in difficult areas, lower system pressure VFDs to control air motor speed

Lighting
Install occupancy sensors to turn off lights

HVAC(long payback)
Replace old motors with energy efficient motors

Lighting

Relamping
From To Saving

GLS HPMV HPMV

CFL HPSV MH

77-81% 37.5% 37.5%

T12(40W)
T8

T8(36W)
T5(28W)

10%
33%

Before Relamping..
Understand the lighting need Colour rendering, visual comfort Dont forget the luminaire optics

Co-efficient of utilisation Spacing to mounting ratio Higher the better Better degree of protection prevents dust accumulation

Lighting Control Use of Time Switches

Programmable

Daily, weekly switching Factory, yard lighting, security lighting controls

Losses in HRC Fuses

It would be surprising to note that all knife blade type HRC Fuses continuously consume some watts, due to the welding at the joints of the knife blades. We normally do not realise this as the loss per fuse is very less. But, imagine the total number of fuses in an Industry and the aggregate watt loss in the fuses would be considerable. Standards also recognise this and IS 13703 lists the permissible watt loss for each rating of fuse, as given in the following table:

RATED POWER DISSIPATION

AS PER IS 13703/PART 2 FOR gG FUSE LINK AT 500V

SIZE

In (A)
100/160 160 250 400 630 1000

MAXIMUM PERMISSIBLE POWER DISSIPATION (W)

7.5/12 16 23 34 48 90

00 0 1 2 3 4

HRC Fuses- With Low Watt Loss

Typical 400A(Size 2) fuse should not consume more than 34 W(IS 13703)
L&T fuse consumes only 25W

Right sizing of Motors

Often motors are much more over rated with respect to actual load conditions Operating efficiencies are much lower
Replace rewound motors with new ones. At least, rewinding shall be done at the authorised rewinders of motor manufacturers.

Soft Starters

Used for smooth start of motors

Reduced broken yarn in textile mills Will save energy only if the loading is between 10-50%

Variable Frequency Drives (VFDs)

For applications where there is variation in flow Pumps,fans & blowers When retrofitting it may be necessary to replace the existing motor Energy savings potential is very high

Use energy efficient motors

Designed to minimise mechanical & electrical losses Uses better materials Costlier Payback period between 6 months to 2.5 years

Reducing Reactive Power

Improving Power Factor

Importance of Power Factor

Low Power Factor means Inefficient use of Electrical Energy Overloading of Transformer/Generator Overloading of Cable,Switchgear,Busbars Higher temperature due to increased losses Imposes larger kVA demand Limits No. of loads that can be connected Reduced revenue to Electrical Utilities

Benefits of Improving Power Factor

Avoid power factor penalties Reduction in current drawn Reduction in line losses Enables more load to be connected Reduction in kVA Demand Increased life of Electrical Equipment More revenue to Utilities

Advantages of P.F Correction

Reduction in KVAR Demand

Reduction in Switchgear Rating

Reduction in KVA Demand

Reduction in Transformer Rating

Reduction in Cable sizes

Reduction in Line Current

Reduction in Power loss

Reactive Power compensation

Reduces T&D losses

Releases blocked capacity Reduces heat losses & improves life of cables & other electrical equipment

Solutions

Requires investment in capacitors, panels & switchgear Capacitors should have low watt loss(0.5W/KvaR) Payback period from 6 months to 18 months

Load Management
Energy Monitoring Instruments

Load Management
Before trying to reduce the energy consumption, one must know the amount of energy consumed. For this, energy consumption must be measured. Market is flooded with a wide variety and range of power and energy measuring devices. Once the measurement is done, meters and devices are also available in plenty of types, ranges and makes to effect control of energy consumption.

L&T Range of Digital Meters

Single Phase Energy Meter

Three Phase Energy Meter (BM)

Three Phase Energy Meter (FM)

Pride - ER300P

Power Navigator - ER300N

Demand Controller - ER300D

QUASAR - Intelligent Meter

Use of Software in Energy Management

LnT EMS Version 1.0

Why Energy Management ?

Business environment demands you to know Energy usage

It is mandatory to know what are your major loads & how much quality power you use How much you pay for it ?

Features

Real Time Monitoring Superior Data Integrity Real Time & Historical Trends Alarm Management Intuitive Human Machine Interface Energy Cost Allocation Load Profiling Power Quality Monitoring Comprehensive Energy Reporting A Complete Networked Solution

Benefits...

Centralized Reporting, Management, Analysis and Administration Reduced Operating Costs Low cost solution Upward Compatible to Higher end software systems

Power quality
Non- linear loads like drives, electronic ballasts, CFLs, computers cause harmonic currents- currents of high frequencies No-sinusoidal currents on motors reduce motor efficiency by 5-7% Harmonic filters may be needed

Other initiatives..
Holistic approach -involving building design for example Reducing the rejection rate of finished product Preventive maintenance improper electrical termination can lead to temperature rise

Present realities

There are still many companies that have not implemented simple energy efficiency initiatives Many implemented but not maintainedsavings erode over time Initiatives with investment often postponed Plant management not evaluated on energy efficiency results

Finally,
If factory owners could be persuaded to retrofit there would be an immediate saving of 23% Buildings alone waste Rs 150 Cr of energy Energy saving movement has started with Rashtrapathi Bhavan leading by example.

We need,

Rs 800,000 Cr to add 100,000MW

We also need money for many other desperate needs

An unit saved = 3 units generated

To conclude

Sir Neil Armstrong said when he stepped on the surface of Moon A small step of a man . A giant leap for mankind. Similarly, small steps taken by all of us concerned in energy conservation in our homes, offices, industry, agriculture, etc., would definitely be a giant leap for the nation towards achieving energy independence and improvement of national economy.

Lets do it for the country