Technical Workshop on

1. Technical Workshop on Adoption of energy efficient process technologies & practices and implementation of Energy Conservation Act 2001 in Textile Sector by C.K.Sharma

2. Savings in the Electrical System

3. Project • Start Date • Finish date • Cost

4. Project • Start Date • Finish date • Cost • Operating cost – minimum. ( EA plays the role)

5. Operating cost • How to reduce: • Reduce energy bill • Better utilization of manpower • Reduce wastage of • Electricity • Oil • Water • Material

6. Building comprises of • Civil • Electrical • Mechanical • Plumbing and firefighting

7. If the cost of building is Rs. 100 crores (say), the cost of electrical works is approximately Rs. 10 crores. This is about 10% of the total cost.

8. Electrical • Internal Wiring • Distribution boards • LT Panel • Transformer • HT Panel • HT and LT Cables • Lighting • Fire Detection • Earthing • Lightning Protection • UPS power supplies • Standby DG sets

9. Of all the above subjects the project needs to cut cost in various ways 1. Proper selection of equipment without affecting the output 2. Purchasing higher efficient equipments at a little more price 3. Use controls to shut off unwanted equipment when not required – it could be PLC or motion sensors. 4. Quality of erection

10. SINGLE LINE DIAGRAM

11. The SLD has the following: • HT Breaker • Transformer • Air Circuit Breakers in LT Panel alongwith Moulded Case Circuit Breakers. • 600 Volt XLPE Cables • Subpanels and Distribution Boards • Equipments (Motors) Let us look at Cables, Transformer and Motor.

12. XLPE Cables

13. Case 2: Ambient 40 deg C, Spacing = touching

14. Case 2: Ambient 40 deg C, Spacing = touching

15. Comparision of Cost

16. Transformer- Oil vs. Dry

17. Transformer- Oil vs. Dry -- Recovery period • KVA rating 500 750 1000 • Cost of transformer – oil Lacs 5.3 6.62 8 • Cost of transformer – dry Lacs 7.5 10.1 11.9 • Diff in cost Lacs 2.2 3.48 3.9 • Recovery period Years 2.54 2.34 2.92

18. 500 KVA Transformer

19. 750 KVA Transformer

20. 1000 KVA Transformer

21. Motors • Motor loads account for more than 50% of electricity consumption. Any saving in energy consumption will result in huge saving. • There is possibility of 15 to 25% saving in motor drives

22. New Type of Motor drives • Super conductor motors – low temperature : Range = -173 deg C to -195 deg. C. Super conductivity is the ability of certain materials when cooled to extremely low temperature offer very low resistance. Cooling media is liquid nitrogen. Capacity 1000 HP

23. New Type of Motor drives • Permanent magnet (PM) motors –Stator is with permanent magnet or stator with three windings producing a rotating field and a rotor with one or more permanent magnet that reacts with rotating field of stator. Most common type of PM motors is brushless DC motor. Speed is varied by varying the rate at which the magnetic field is reversed.. Capacity upto 600 HP.

24. New Type of Motor drives • Copper Rotor motors • Very low loss magnetic steel motors Replace aluminium in rotor ‘squirrel cage’ structure of motor with copper. Since the conductivity of copper is higher as compared to aluminium, it results in higher efficiency

25. New Type of Motor drives • Switched reluctance motors – Excellent for speed control, precise control, high vibration tolerance. It has high pulsating magnetic flux resulting in high noise. These motors are not for civilian use

26. New Type of Motor drives • Written pole motors – Hybrid of Induction motor during startup & synchronous motor upon reaching full speed. Range – 15HP tp 75 HP

27. New Type of Motor drives • Adjustable Speed Drive (ASD) • Magna Drive – Fixed rare earth magnet create an induced electromotive force to transfer torque. The physical connection between motor and load is replaced with gap of air. The amount of torque transferred is controlled by varying the air gap in the assembly. These motors are suitable for direct driven equipments e.g. fans, pumps, blowers etc. Range 20Hp to 1000 HP • Payback Drive – Similar to Magna Drive but instead of earth magnets, an electro magnet is used to control the speed of motor. These motors are suitable for belt driven equipments. Range 3HP tp 200 HP.

28. How to maintain / increase the efficiency of existing equipments • Service the equipment regularly • Take the warnings seriously. If a breaker trips, look for fault in the system. Do not forcibly switch ON. • Calibrate the meters and instruments regularly • Avoid accidents • General cleaning • Good Housekeeping • Control material wastage • Check oil leakage • Check water leakage • Garbage disposal • Keep movement areas free of obstacles

29. How to increase the efficiency of system • Keep a watch on operations of system • Monitor the readings • Record the readings. Recording is the beginning of Savings of everything – manpower, material, energy. • Building Automation

30. How to increase the efficiency of manpower employed • Listen to his suggestion carefully. • Give him sufficient space to work • Good lighting • Comfortable chair to sit and work • Develop new skills • Have training programmes

31. Lightning Protection

32. Damage due to Lightning strike • Building structure • All voltage sensitive equipments • Personal Computer • Laptop • Digital Camera • Computer operated machine • Server

33. Conclusion • 200000 sq. ft. office building has a power consumption of 800 KW maximum • 4 watts per sq.ft. • 40 watts per sq. mtr • BEE standard is 90 watts per sq. mtr

34. Thank You for the patience