Energy Conservation MGMT BILWC

6/29/2011
ARBIND KUMAR
VARIOUS FORMS ENERGY
Various forms of energy

Potential energy
Chemical Nuclear Mechanical stored energy Gravitational
Kinetic
Radiant Thermal Motion Sound Electrical
High and Low grade energy
1. High grade energy is concentrated Energy

Ex. electricity,Light energy, chemical energy
2. Low grade energy rapidly dissipates (molecules are more randomly

distributed)
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Ex. heat energy

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ENERGY CONVERSION
Oil burns to generate heat --> Heat boils water --> Water turns to steam --> Steam pressure turns a turbine --> Turbine turns an electric generator --> Generator produces electricity --> Electricity powers light bulbs --> Light bulbs give off light and heat
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ELECTRICAL ENERGY BASICS

Direct current: Non-varying unidirectional current

Current produced by batteries
Alternating Current: Reverses in regular recurring

intervals with alternate +ve and ve values at specified number of times per second In 50 cycle AC, current reverses direction 100 times a second (twice in one cycle
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KVA, KVAR, KW & PF

KVA = Kilovolts (KV) x Amperes(A)

Also called as as Apparent power Measures the electrical load of system Single phase = V x A/1000 Three phase = 1.732 x V x A /1000

KVAR is reactive power i.e. portion of apparent power that does no work KW is real power or work producing part of power
Single phase = V x A x PF/1000 Three phase = 1.732 x V x A x PF /1000 KWH is energy consumed by 1000 Watts in 1 hour
Power Factor (PF) is ratio of real power to apparent power

PF = KW/KVA or KW/Sq.rt (KW2 + KVAR2)
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CONNECTED LOAD, DEMAND FACTOR AND LOAD FACTOR
Connected Load is name plate readings (in KVA or KW) of all equipment in a industry Demand factor = maximum demand/ connected load Load factor = average load/ maximum load

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MAXIMUM DEMAND
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Relation between Energy consumed & Maximum Demand

In Normal calculation Energy = Power (in watt) x Time (in hour) But in actual consideration Energy consumed = MD x LF x H MD = Maximum Demand in KW LF = Load Factor = Actual energy consumption in 24hours
Peak load in KW x 24 hours
H = Nos. of Hour
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3 phase power measurement

A 3-phase AC induction motor (20 kW capacity) is used for pumping operation. Electrical parameter such as current, volt and power factor were measured with power analyzer. Find energy consumption of motor in one hour? (line volts. = 440 V, line current = 25 amps and PF = 0.90). Power = 3 x V x I x Cos Measured energy consumption = 3 x 0.440 x 25 x 0.90 x 1 = 17.15 kWh
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UNITS OF ENERGY

1 Joule (J) = 0.2390057 calorie (cal) = 9.47817210-4 British thermal unit (Btu) 1 cal = 4.184 J = 3.96566710-3 Btu 1 Btu = 1055.056 J = 252.1644 cal = 2.93071110-4 kilowatt-hour (kWh) 1 kWh = 3.6 Megajoule (MJ) = 0.8604207 Mcal = 3412.142 Btu
Power (Energy Rate) Equivalents 1 kilo att (kW) 1 kilo joule /second (kJ/s) 1 kilo att (kW) 3413 BTU/hour (Btu/hr.) 1 horsepo er (hp) 746 atts (0.746 kW) 1 Ton o re rigeration 12000 Btu/hr.
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COMMERCIAL & NON-COMMERCIAL ENERGY

Commercial energy is energy available at price

Examples are electricity, coal, lignite, oil, and natural gas
Non-commercial energy is energy not available in market for a price

Examples are firewood, cattle dung and agricultural wastes, solar energy, animal power, wind energy
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ELECTRICAL ENERGY CONSERVATION

Electrical Energy Conservation is a measure to save Electrical Energy without sacrificing the OUTPUT.
It implies:- > Efficient use of available electrical energy. > Innovation and Adoption of new technology for minimizing Losses and Misuses in all sectors 1.Industrial 2.Transport, 3.Agriculture 4.Residential etc. Saving electricity leads to reduction in environmental pollution, which is good for society as a whole.
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FACTS ---1. Indias Energy Intensity per unit GDP is higher by > 3.7 times of Japan > 1.4 times of Asia > 1.5 times of USA Indicates high wastage of energy but very high saving potential 2. Power shortage in the Country > Peak - 13% > Average - 8% 3. Additional 10,000 MW required by 2012 means Rs 8000 billion investment will be required
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Basic needs 0f Energy conservation

It is a vital infrastructure input for economical development of the country.

Thermal power generation in India is about 80% with an efficiency of 30 to 35 % One unit consumption of energy require 4 units of primary fuel at generating station Expensive physical resource Capacity cost about Rs. 4 to 5 crores /MW with transmission & distribution cost further increase to 60% -- Expensive economic resource No arrangement available to store generated electrical power Demand & Supply has to match instant to instant. Capacity created at Peak period remains ideal at off peak period
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ENERGY SCENE IN INDIA

India has 01% of the total Worlds energy resource but 16% of the Worlds population. The energy policy is oriented towards increasing the supply of coal, oil and electricity. Our oil consumption has increased 5 folds in the past 27 years, after the energy crisis of 1973.About 72% of our oil requirement is met through imports. It is better to improve energy efficiency rather than setup energy generation facilities to supply inefficient plants and inefficient equipments
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Electrical Power Supply in India

Installed capacity of 1,12,581 MW as on 31st May 2004 28,860 MW - hydro, 77,931 MW - thermal 2,720 MW - nuclear and 1,869 MW - wind (Ministry of Power).
Nuclear provides 2.4% of electricity generated Hydro contribution 25% as on 31st March 2004
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Sector wise Energy Consumption
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INDIAN RAILWAYS SHARE

Indian Railways consumes appx.3% of total energy produced The fuel bill of Indian Railways for diesel traction is huge on based on 278 & 208 billion GTKM for freight & passenger on Specific Energy Consumption of 2.55 & 4.5 ltr. The fuel bill of Indian Railways for electric traction ---The fuel bill of Western Railways for
electric traction is of the order of 480 Cr.
The fuel accounts for approx. 25% of Indian Railways working expenditure.
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Energy requirement on Indian Railway

Indian Railways is one of the largest railroad system in the world. To handle its vast freight & passenger traffic, it operates as many as 4000 diesel powered and equal number of electric locomotives. These locomotives consume 2000 million liters of diesel & 9000 million units of electricity annually. The break up of energy used in 02 consecutive years Energy Traction Non traction

Electricity (Million KWH) 9,013 2,361 2. Diesel (Million liters) 2,007 33 Traction Energy used for movement of trains Non-Traction Energy for stationary applications ( PUs, Workshops & other maintenance centers) Source Project report of Mr. Sharad Saxena, Director/RDSO/LKO
1.
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BARRIERS TO ENERGY EFFICIENCY
1. Lack of awareness 2. Lack of Education & Training 3. Economic & market distortions 4.Lack of standardization & labeling on equipments/devices 5. Lack of financing 6. Lack of effective coordination
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ENERGY CONSERVATION PROGRAMME

House Keeping proper procedure, utilization and equipments maintenance. Process Improvement modification of existing equipments and process Equipment replacement by energy saver Equipments Use of Non conventional energy solar, wind energy and gobar gas plant, Effective use of day lighting Task lighting
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ENERGY SAVING APPROACH

Lighting--- About 15% of the total energy

consumption in any installation is in Lighting only
Industrial Motors -- Electric motors constitutes

about 72% of the total industrial load, where Induction motors are invariable used.
Air-conditioning -- Air-conditioning is another

intensive operation. A combination of central AC with packed individual units may prove more energy efficient.
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ENERGY SAVING APPROACH

pumping station varies from 10 to 70%.Prevention of wastage and leakage can save energy up to 5%.
Water supply system (Pumps)--- The efficiency of the
electric heating is possible mainly by > Reducing heat losses Using more efficient equipment or processes.

1. 2. 3. 4.
Electric heating & Electrolysis--- Energy conservation in
Electric Energy consumed in electrolysis are given as:

Storage batteries Electrolytic processes Recover waste heat Use of efficient controls & Rectifiers.
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ENERGY MANAGEMENT
ENERGY IS EXPENSIVE, EFFICIENCY IS NOT
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MANAGEMENT
Management in simple terms means the act of getting people together to accomplish desired goals. Management consists of for five major functions: planning organizing leading coordinating controlling

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ENERGY MANAGEMENT
The strategy of adjusting and optimizing energy, using systems and procedures so as to reduce energy requirements per unit of output while holding constant or reducing total costs of producing the output from these systems
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Objective of Energy Management

1.
To achieve and maintain optimum energy procurement and utilization, throughout the organization To minimize energy costs / waste without affecting production & quality To minimize environmental effects.
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2.
3.
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ENERGY MANAGEMENT
OVERVIEW STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
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STEP 1:
Commitment to Continuous Improvement
Irrespective of size or type of organization, the common element of successful energy management is commitment. Organizations make a commitment to allocate staff and funding to achieve continuous improvement.
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STEP 1:

Appoint an Energy Director/Manager -- Sets goals, tracks progress, and promotes the energy management program. Establish a Energy Team --Executes energy management activities across different parts of the organization and ensures integration of best practices. Institute an Energy Policy -- Provides the foundation for setting performance goals and integrating energy management into an organizations culture and operations
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RESPONSIBILITY OF ENERGY MANAGER

Coordinating & Directing the overall Energy Program Contact Point for Senior Management Drafting an Energy Policy Assessing the potential value of Improved Energy Management Creating & Leading the Energy Team. Securing resources to implement strategic Energy Management Assuring accountability & commitment from core parts of the Organization. Measuring, Tracking, Evaluating and Communicating results / outputs.
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STEP 2:

ASSESS PERFORMANCE --It is the periodic process of evaluating energy use for all major facilities and functions in the organization and establishing for measuring future results of efficiency.
Efforts by: Understanding Current & Past energy use. Identify opportunities to improve energy performance and gain financial benefits.
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ASSESS PERFORMANCE

1.
PROCESS
Data Collection & Management Base lining Benchmarking Analysis Technical Assessments Audits
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2. 3. 4. 5. 6.
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STEP 3: SET GOALS -- Setting

CLEAR & MEASURABLE goals is critical for understanding intends results, developing effective strategies and reaping financial gains. Basis for tracking & Measuring progress. Communicating and posting goals can motivate staff to support Energy Management efforts. The Energy Director/Manager in conjunction with the Energy Team typically develops GOALS.

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SET GOALS
OBJECTIVE
1.
Determine Scope Estimate Potential for Improvement Reduce Environment Impact
2.
3.
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STEP 4:
CREATE ACTION PLAN
Successful organizations use a detailed Action Plan to ensure a systematic process to implement energy performance measures.
OBJECTIVE
Define Technical steps and targets Determine roles and resources Work with the energy team to communicate the Action Plan to all areas of organization.

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STEP 5:
IMPLEMENT ACTION PLAN
Gaining the support & Cooperation of key members at different levels within the Organization is an important factor for successful action plan implementation in many organizations.
STEPS

Create a Communication Plan Raise Awareness Build Capacity Motivate Track & Monitor
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STEP 6:
EVALUATE PROGRESS
It includes formal review of both energy use Data and the activities carried out as compared to our performance goals. STEPS
1. 2. 3.
Measures results Review action plan Documentation
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STEP 7:
RECOGNIZE ACHIEVEMENTS
Providing & seeking recognition for energy management achievements is proven step for sustaining momentum and support for program.
Key Steps in providing & gaining recognition

1. 2.
Providing Internal Recognition Receiving External Recognition
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If you cant measure.. You cant manage !
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Definition of Energy Audit

As per the Energy Conservation Act, 2001, Energy Audit is defined as
the verification, monitoring and analysis of use of energy including submission of technical report containing recommendations for improving energy efficiency with cost benefit analysis and an action plan to reduce energy consumption
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Why Energy Audit ?

Three top operating expenses are Energy (both electrical and thermal), Labour and Materials. Energy would emerge as a top ranker for cost reduction Primary objective of Energy Audit is to determine ways:
to reduce energy consumption per unit of product output to lower operating costs.
1.
2.
It provides a bench-mark (Reference point) for managing energy in the organization

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Types of Energy Audit

1.
Preliminary energy audit
2.
Detailed energy audit
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Preliminary Energy Audit Methodology

1. 2. 3. 4. 5. 6. 7.
Preliminary energy audit uses existing, or easily obtained data Establish energy consumption in the organization Estimate the scope for saving Identify the most likely areas for attention Identify immediate (no-/low-cost) improvements Set a reference point Identify areas for more detailed study/measurement
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Detailed Energy Audit

Evaluates all energy using system, equipment and include detailed energy savings and costs Carried out in 3 phases:
Pre-audit Phase Audit Phase Post-Audit
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HOW TO SETUP ENERGY AUDIT SYSTEM ?

Increasing Energy demand is resulted for the rapid growth of Economy & Industries of the developing countries. The new construction of Power Plant is strongly objected by the Environmentalists.
It is difficult for the existing and potential new Energy Sources to meet the increasing demands. So, assisting Industries to save Energy & Enhance the Energy Productivity are regarded as high-priority task of concerning Organizations.
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ENERGY AUDIT PROCEDURES IN GENERAL

STEPS
START-UP MEETING COLLECTING BASIC DATA FIELD WORK DATA ANALYSIS REPORTING IMPLEMENTATION ARBIND KUMAR OF SAVING MEASURES
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Energy Audit Instruments

Electrical measuring Instruments Light Intensity Measuring Instruments Lux meter Speed Measuring Instruments Tachometer Temperature Measuring Instruments Ultrasonic flow meter Fuel efficiency monitor Combustion analyzer Infrared pyrometers Manometer Leak detectors
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Designated Industries
1. 3. 5. 7. 9. 11. 13. 14. 15.
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Aluminium 2. Fertilizers Iron and Steel 4. Cement; Pulp and paper 6. Chlor Akali; Sugar 8. Textile; Chemicals 10. Railways; Port Trust 12. Transport Petrochemicals & Refineries Power Stations, T & D companies Commercial buildings >500 kW
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Electricity Billing HT or LT Tariff

Two Part tariff for HT Consumers
The consumer pays for two components. - Energy Charges for kWh consumed - Maximum demand Charges (kVA) registered PF penalty or PF incentives MD Penalty
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Maximum Demand Recording

It is important to note that while maximum demand is recorded, it is not the instantaneous demand drawn, but the time integrated demand over the predefined recording cycle. As example, in an industry, if the drawl over a recording cycle of 30 minutes is : 2500 kVA for 4 minutes 3600 kVA for 12 minutes 4100 kVA for 6 minutes 3800 kVA for 8 minutes The MD recorder will be computing MD as:
= 3606.7 kVA
(2500x4) +(3600 x 12) + (4100 x 6) + (3800 x 8) 30
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Lighting

Lamps: Lamp is equipment, which produces light. Incandescent lamps: Incandescent lamps produce light by means of a filament heated to incandescence by the flow of electric current through it. The principle parts of an incandescent lamp, also known as GLS (General Lighting Service) lamp include the filament, the bulb, the fill gas and the cap.
Reflector lamps:
Reflector lamps are basically incandescent, provided with a high quality internal mirror, which follows exactly the parabolic shape of the lamp. The reflector is resistant to corrosion, thus making the lamp maintenance free and output efficient.
Gas discharge lamps: The light from a gas discharge lamp is produced by the excitation of gas contained in either a tubular or elliptical outer bulb.
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METAL HALIDE LAMPS
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Commonly used discharge Lamps

Fluorescent tube lamps (FTL) Compact Fluorescent Lamps (CFL) Mercury Vapour Lamps (MVL) Sodium Vapour Lamps (HPSV/LPSV) Metal Halide Lamps
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Lighting System Approach

Ballast eiling Lamps (light so rce) i t re Lens or Diff ser S itch
alls he Re irement or S rface
loor
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Lighting Controls
On/off flip s itches Timer control & a to timed s itch off resence detection
Luminary grouping / Group S itching Day light linking, blinders, corrugated roof sheets Dimmers , Lighting voltage controllers
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hoto sensors
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Energy savings in lighting System

1. 2. 3. 4. 5. 6.
Make maximum use of natural light Switch off when not required Modify lighting layout to meet the need Select light colours for interiors Provide timer switches. Provide lighting Transformer to operate at reduced voltage
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Energy savings in lighting System

1. 1.
2.
3.
Install energy efficient lamps, Metal halide in place of Mercury and SVL lamps CFT in place of incandescent lamps Clean North roof glass, translucent sheet and luminaries regularly Separate lighting Transformer To isolate from power feeder To avoid voltage fluctuation problem Install Servo stabilizer if separate transformer is not feasible.
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Transformers
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Types of Transformers

Power transformers : Used in transmission

network of higher voltages, deployed for step-up and step down transformer application (400 kV, 200 kV, 110 kV, 66 kV, 33kV,22kW)
Distribution transformers: Used for lower

voltage distribution networks as a means to end user connectivity. (11kV, 6.6 kV, 3.3 kV, 440V, 230V)
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Transformer losses
1. 2.
Load loss (or copper loss) No load loss (or iron loss) The total transformer loss, PTOTAL, at any load level can then be calculated from:
PTOTAL = PNO-LOAD+ (% Load)2 x PLOAD
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Case Example:
For a load of 1500 KVA the plant has installed three numbers of 1000 KVA transformers. The No load loss is 2.8 KW and the full load loss 11.88 KW. Estimate the total loss with 3 transformers in operation and 2 transformers in operation. a) 2 transformers in operation : No load loss Load loss
= = = =
2 x 2.8 = 5.6 2 x (750)2 x 11.88 (1000) 13.36 kW 5.6 + 13.36 = 18.96
Total Loss b) 3 transformers in operation : No load loss Load loss
= 3 x 2.8 = 8.4 KW = 3 x (500)2 x 11.88 = 8.91 KW (1000)
Total loss = 17.31 KW Savings by loading all the 3 transformers = 13200 kWh.
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Transformer Loss vs. Load
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Ways to minimise distribution losses

Relocating transformers and sub-stations near to load centers, reducing LT network, (or increasing HT / LT ratio). Re-routing and re-conductoring such feeders and lines where the losses / voltage drops are higher. Power factor improvement by incorporating capacitors at load end. Optimum loading of transformers in the system. Opting for lower resistance All Alluminium Alloy Conductors (AAAC) in place of conventional Alluminium Cored Steel Reinforced (ACSR) lines Minimizing losses due to weak links in distribution network such as jumpers, loose contacts, old brittle conductors. 65 ARBIND KUMAR 6/29/2011

MESSAGE
Human Beings depending on the extent of physical activities, have an overall efficiency between 8% and 16% in converting food energy into physical work. The most intelligent and most complex designed creature on earth has managed to develop machines which are fare more efficient than their own design.
Cogeneration plant Combined cycle Coal fired power plant Gasoline Engine Human being
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80% 50% 35% 16% 12%

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Contact
ARBIND KUMAR Assistant Professor/Electrical Indian Railways Institute of Mechanical & Electrical Engineering Jamalpur, ihar - 811214
Tel : (06344) 243184 241778 Mob:09431611180 (official) 09431249487 Fax: 06344 243293
mail : aparbind1956@indiatimes.com
.irimee.ac.in
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Energy Conservation MGMT BILWC

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6/29/2011

VARIOUS FORMS ENERGY

Various forms of energy

High and Low grade energy

1. High grade energy is concentrated Energy

2. Low grade energy rapidly dissipates (molecules are more randomly

Ex. heat energy

ELECTRICAL ENERGY BASICS

Direct current: Non-varying unidirectional current

Alternating Current: Reverses in regular recurring

KVA, KVAR, KW & PF

KVA = Kilovolts (KV) x Amperes(A)

Power Factor (PF) is ratio of real power to apparent power

CONNECTED LOAD, DEMAND FACTOR AND LOAD FACTOR

Relation between Energy consumed & Maximum Demand

3 phase power measurement

COMMERCIAL & NON-COMMERCIAL ENERGY

Commercial energy is energy available at price

Non-commercial energy is energy not available in market for a price

ELECTRICAL ENERGY CONSERVATION

Basic needs 0f Energy conservation

ENERGY SCENE IN INDIA

Electrical Power Supply in India

Sector wise Energy Consumption

INDIAN RAILWAYS SHARE

Energy requirement on Indian Railway

BARRIERS TO ENERGY EFFICIENCY

ENERGY CONSERVATION PROGRAMME

ENERGY SAVING APPROACH

Lighting--- About 15% of the total energy

Industrial Motors -- Electric motors constitutes

Air-conditioning -- Air-conditioning is another

ENERGY SAVING APPROACH

Water supply system (Pumps)--- The efficiency of the

Electric heating & Electrolysis--- Energy conservation in

Electric Energy consumed in electrolysis are given as:

ENERGY IS EXPENSIVE, EFFICIENCY IS NOT

Objective of Energy Management

RESPONSIBILITY OF ENERGY MANAGER

STEP 3: SET GOALS -- Setting

Determine Scope Estimate Potential for Improvement Reduce Environment Impact

Measures results Review action plan Documentation

Key Steps in providing & gaining recognition

Providing Internal Recognition Receiving External Recognition

If you cant measure.. You cant manage !

Definition of Energy Audit

As per the Energy Conservation Act, 2001, Energy Audit is defined as

Why Energy Audit ?

It provides a bench-mark (Reference point) for managing energy in the organization

Types of Energy Audit

Preliminary energy audit

Detailed energy audit

Preliminary Energy Audit Methodology

Detailed Energy Audit

HOW TO SETUP ENERGY AUDIT SYSTEM ?

ENERGY AUDIT PROCEDURES IN GENERAL

Energy Audit Instruments

Electricity Billing HT or LT Tariff

Maximum Demand Recording

(2500x4) +(3600 x 12) + (4100 x 6) + (3800 x 8) 30

METAL HALIDE LAMPS

Commonly used discharge Lamps