PRESENTATION on Energy Efficiency and Demand Side Management By Girish Kumar

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2. PRESENTATION on Energy Efficiency and Demand Side Management By GirishKumar Fuel Efficiency Engineer Certified Energy Auditor Phone: 091 8127206887 Email: girishkumar.bw@gmail.com Sponsored by SAVE ENERGY, SAVE MONEY, SAVE THE ENVIRONMENT

3. Contents • About PCRA • Energy Scenario • Energy Management and Conservation Strategy • Energy Audit • Demand Side Management • Energy Saving Opportunities in: • Transformers and Electricity Distribution • Motors • Compressors • Cooling Towers • DG Set • Refrigeration system • Illumination system 7. Energy Efficiency in Office 8. Energy Efficiency in Building Design

4. PCRA Offices Head Quarter : Delhi 4 Regional Offices : Delhi, Kolkata, Mumbai & Chennai 19 Sub Regional Offices : NR – Lucknow, Chandigarh, Jaipur & Dehradun ER – Bhubaneshwar, Guwahati, Patna & Ranchi WR – Ahmedabad, Pune, Nagpur, Raipur &Bhopal SR – Hyderabad, Kochi, Vizag, Belgaum, Bangalore & Coimbatore

5. Field Activities Transport Sector Domestic Sector Industrial Sector / Commercial Bldg Sector Transport Workshop Youth Programmes Energy Audit Driver Training Program Domestic Workshop Fuel Oil Diagnostic Study Save LPG Clinics Model Depot Study Walk Through Audits-SSI Other Activities Follow up Studies International Networking Field Activities I.T.P. Promote & Sponsor Energy Efficient R&D Industrial Workshop Empanelment of Auditors Agriculture Sector PAT Solutions Agriculture W/S ISO-50001:2011 Kisan Melas OGCF Awards Common to all Sectors Promote replication of PCRA efforts in Clusters Seminars/Technical Meets / Exhibitions

6. Energy Mix Pattern Source : *BP statistical Review, end 2010

7. Sector-wise Total Energy Consumption in India

8. Energy Intensity Energy Intensity is the ratio between the gross inland consumption of Energy and the Gross Domestic Product (GDP) for a given calendar year. It measures the energy consumption of an economy and its overall Energy Efficiency • 3.7 times of Japan • 1.55 times of US • 1.47 times of Asian Avg • 1.5 times of World Avg

9. ENERGY MANAGEMENT & CONSERVATION STRATEGIES

10. TOP MANAGEMENT COMMITMENT STAFF COMMITMENT ENERGY AUDIT ACTION PLAN MONITORING & TARGET SETTING REVIEW & DEVELOP PROFILE LONG PAY BACK PROJECTS ENERGY MANAGEMENT SYSTEM

11. WHAT IS ENERGY MANAGEMENT? Energy management is a disciplined activity organized for the more efficient use of Energy without reducing Production levels or lowering product quality, safety or Environmental standards Savings of 1 KW at the user end could mean a relief of 2 kw of the generation capacity depending upon the plant load factor, transmission, distribution losses and end-use efficiency THE PRINCIPLE UNDERLYING ALL ENERGY MANAGEMENT MUST BE COST EFFECTIVE. Energy Efficiency is the quickest, cheapest and cleanest way to reduce energy use and pollution.

12. THE ACTUAL ENERGY CONSUMPTION AND SAVINGS VARIABLES 1. PLANT CAPACITY AND UTILIZATION. 2. AGE. 3. MANUFACTURING PROCESS. 4. EQUIPMENT CONFIGURATION. 5. PRODUCT MIX. 6. PROCESS CONTROL SYSTEMS. 7. LAYOUT/SYSTEM DESIGN. 8. MAINTENANCE ASPECTS. 9. RAW MATERIAL CHARACTERISTICS. 10. OPERATIONAL PRACTICES OF PLANT PERSONNEL. 11. AND ABOVE ALL - THE MANAGEMENTS’ ATTITUDE.

13. BARRIERS TO ENERGY MANAGEMENT 1. TOP MANAGEMENT - Not aware of conservation potential - No commitment 2. EXPERIENCES - Successful ones are not shared 3. IMPLEMENTATION OF ENERGY EFFICIENT TECHNOLOGIES - Technological - Financial - Institutional

14. STRATEGIES FOR ENERGY MANAGEMENT Reduce Consumption Increase Efficiency Reduce Demand • Operation & Maintenance • Retrofit Project • New Equipments • 4. Improved Instrumentation 1.Consolidate and Reduce use 2. Employee Awareness 3. Management Commitment 4. Renewable Energy Resources

15. ENERGY AUDIT

16. Definition of Energy Audit “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”

17. SCOPE OF ENERGY AUDIT • REVIEW OF ELECTRICITY BILLS • LOAD & MAX DEMAND MANAGEMENT • TRANSFORMERS • DG SET • MOTIVE LOAD • ILLUMINATION SYSTEM • AIR COMPRESSORS • REFRIGERATION & AIR CONDITIONING • BOILERS AND FURNACES • STEAM UTILISATION

18. SCOPE OF ENERGY AUDIT • REVIEW OF ELECTRICITY BILLS : Improvement of PF, Minimum Monthly Charges, Reduction of Contract demand, Discussion on Electricity Board Rules and Tariff structure. • LOAD & MAX DEMAND MANAGEMENT: Study of loading pattern, identifying essential and nonessential loads. • TRANSFORMERS : No load losses, % Loading. • DG SET: Cost of power generation, waste heat recovery, alternate fuel, reasons for high fuel consumption.

19. SCOPE OF ENERGY AUDIT • MOTIVE LOAD: Percentage loading, V, I, PF & KW measurement, Energy saving options. • ILLUMINATION SYSTEM: Replacement by efficient lighting, Lux level measurement and comparison with standard, daylight use, new energy saving devices. • AIR COMPRESSORS: Evaluate SPC (KW/100CFM), Leakage Test, Capacity Test, compressor options, Energy saving devices, optimization of operating Pr. • REFRIGERATION & AIR CONDITIONING Calculation of KW/ TR, identify factors to improve it, performance of refrigerant compressor, chilling unit, CTs.

20. GENERALMETHODOLOGY • EXPLAIN THE SCOPE OF WORK AND GET A COMMITMENT FROM PLANT INCHARGE AND ELCTRICIAN FOR THEIR ASSISTANACE. • COLLECT CRITICAL DATA. • TAKE A ROUND OF THE INSTALLATION. • UNDERTAKE ENERGY AUDIT & IDENTIFY AREAS OF IMPROVEMENT. • ESTABLISH TECHNO-ECONOMIC FEASIBILITY FOR PROPOSED MEASURES UNDER EACH AREA. • PREPARE CAPITAL COST ESTIMATES.

21. GENERALMETHODOLOGY • FORMULATE ENERGY CONSERVATION MEASURES & CATEGORISE SUCH AREAS INTO - • NO INVESTMENT • MARGINAL INVEST ( 0 -12 MONTHS P.B.P) • MEDIUM INVEST. ( 12-24 MONTHS P.B.P) • CONVINCE MANAGEMENT FOR INITIATING NO COST MEASURES & BUDGETTING LOW & MARGINAL COST MEASURES. • FORMULATE TIME SCHEDULE FOR IMPLEMENTATION • EDUCATE, TRAIN & DEVELOP PLANT PERSONNEL ON ENERGY CONSERVATION • PERIODIC CLOSE FOLLOW UP TO ASCERTAIN IMPLEMENTATION OF RECOMMENDATIONS.

22. Demand Side Management (DSM)

23. ElectricPowerSupplySystems

24. What are the components of Electricity Billing? ForIndustry:TwoParttariffforHTConsumers Theconsumerpaysforthefollowingcomponents. 1.EnergyChargesforkWhconsumed 2.MaximumdemandCharges(kVA)registered 3. PFpenaltyorPFincentives 4. TOD,(peakandnon-peak) 5. Penaltyforexceedingcontractdemand 6. FuelCostadjustments 7. ElectricityDutyCharges 8. Meterrentals 9. SurchargeifmeteringisatLTsideinsomeoftheutilities

25. ElectricalLoadManagement •Thegoalofpeakloadmanagementisto reducethemaximumelectricitydemandto lowertheelectricitycosts •Aloadcurveis usefulforintegrated loadmanagement bypredicting patternsofdrawl, peaksandvalleysin demand KVA Hours Dailyloadcurveofanengineeringindustry

26. PeakLoadManagementStrategies 1)ShiftingNon-Criticaland Non-ContinuousProcess LoadstoOff-Peaktime 2)SheddingofNon- Essential Loadsduring PeakTime 3)OperatingIn-House GenerationorDiesel Generator(DG)Setsduring PeakTime 4)OperatingAir Conditioning unitsduring off-peaktimes andutilizing coolthermal storage 5)InstallationofPower FactorCorrection Equipments Reschedulingoflargeelectricloadsandequipment operationsindifferentshifts,thesecanbeplannedand implementedtominimizethesimultaneousmaximum demand. Itispossibleto installdirectdemandmonitoringsystems, whichwillswitchoffnon-essentialloadswhenapreset demandisreached. ConnecttheDGsetsfordurationswhendemandreaches The Peakvaluein order to reducetheloaddemandtoa considerableextentandminimizethedemandcharges. Reducethemaximumdemandbybuildingupstorage capacityofproducts/materials,water,chilledwater/hot water,usingelectricityduringoffpeakperiods. Themaximumdemandcanalsobereducedattheplant Level byusingcapacitorbanksandmaintainingthe optimumpower factor.

27. Load Management: Staggering of motors

28. Maximum Demand Controller

29. Example Transformer loading –1160/1500 = 78 % Capacitors totaling 410 kVArinstalled in  each of the 13 large motors Transformer loading –913/1500 = 61 % Max Demand Reduction: 1160 – 913 KVA = 247 KVA Saving 21%

30. Where to Locate Capacitors? Formotorsof50hpandabove,itis besttoinstallpowerfactorcorrection capacitorsatthemotorterminalssince distributioncircuitloadingisreduced. Thesecondarrangementshows capacitorbanksconnectedatthe busforeachmotorcontrolcentre. ThiscompromisetoMethod1will reduceinstallationcosts. Theleastexpensivemethodshows capacitorbanksconnectedatthe serviceentrance.However,the disadvantageisthathigherfeeder currentsstillflowfromtheservice entrancetotheendofline equipment.

31. Automatic Power Factor Controllers AutomaticPowerFactorControlRelay

32. Transformer • Astaticelectricaldevicethat transformselectricalenergy fromonevoltagelevelto another • • Consistsoftwoormorecoils thatareelectricallyinsulated butlinkedmagnetically Thenumberofturnsonthe 2ndcoil(connectedtothe load)totheturnsonthe1st coil(connectedtothepower source)istheturn’sratio 3phasecore&coil assemblyofatransformer

33. TransformerLosses&Efficiency Figure:Transformerlossvs.% Loading • • Thetransformerlossesareduetoconstantandvariablelosses Thebestefficiencyoccursattheloadwhereconstantlossandvariablelossare equal 2 PTOTAL=PNO-LOAD+(LoadKVA/RatedKVA)2xPLOAD PTOTAL=PNO-LOAD+(%Load/100)xPLOAD

34. Energy Efficient Transformers • Mostenergylossindry‐typetransformers • occursthroughheatorvibrationfrom • the core. • Thenewhigh‐efficiencytransformers • minimisetheselosses. • Amorphousmaterialisused–ametallic • glass alloyforthecoretheexpected • reductionin energylossoverconventional(SiFecore) transformersisroughlyaround70%,whichis quitesignificant. • Byusinganamorphouscore–withunique physicalandmagneticproperties‐thesenew typesoftransformershaveincreasedefficiency evenatlowloads‐98.5%efficiencyat35% load • • • 1600 kVAAmorphous Core Transformer

35. Standards & Labeling Programme for  Distribution Transformers Thestandardtransformerratingscoveredundertheenergylabelingschemeis16,25, 63,100,160and200kVAandnonstandardratingsfrom16kVAto200kVA.IntheBEE labelingprogramme,thetotaltransformerlossesat50%and100%loadinghavebeen defined. • 1star 2star 3star 4star 5star Max Losses at 100% (Watts) 555 785 1415 2020 2800 3300 Max Losses at 100% (Watts) 520 740 1335 1910 2550 3000 Max Losses at 100% (Watts) 480 695 1250 1800 2200 2700 Max Losses at 100% (Watts) 440 635 1140 1650 1950 2300 Max Losses at 100% (Watts) 400 595 1050 1500 1700 2100 Max Losses at50% (Watts) 200 190 490 700 1000 1130 Max Losses at50% (Watts) 165 235 430 610 880 1010 Max Losses at50% (Watts) 150 210 380 520 770 890 Max Losses at50% (Watts) 135 190 340 475 670 780 Max Losses at50% (Watts) 120 175 300 435 570 670 Rating kVA 16 25 63 100 160 200

37. ELECTRIC MOTORS • It is estimated, that during its working life a motor consumes 100 times more energy than the cost of motor. A 15 Hp motor running on an average 15 hrs a day • 10Kw X 15 Hrs x 365 = 54750 kWh • Annual running cost = 2.25 lakhs (Rs 4.1/kWh) • 10 years = 22.5 lakhs • Cost of normal motor = 0.22 lakhs

38. CASE STUDY OF USING HIGH EFFICIENCY MOTOR Life of a motor about : 10 years Name plate rating at full load : 15 kW Rated Motor efficiency at full load (η) : 86% Actual Power Consumption on full load : 15/0.86=17.4 kW Efficiency of Motor after rewinding or over sizing : 80% Power Consumption now : 15/0.80=18.7 kW Replacing the motor with high efficiency : 90% Power consumption after replacement : 15/0.90=16.7 kW If motor is running on an average 15 hrs a day the saving: • 2Kw X 15 Hrs x 365 = 10950 kWh • Annual saving = Rs 45000 (Rs 4.1/kWh) Cost of normal motor = Rs 22000 Payback = 6 months

39. ENERGY CONSERVATION TIPS --- MOTORS • Install high efficiency motor (as a replacement policy) • %loading < 50% replace with efficient & smaller size motor. Energy efficient motors can save at least 4-5% on account of power consumption and in cases payback period may be within a year. • Install soft start cum energy saver for lightly loaded motors. • Instead of Rewinding replace by high efficiency motor. If rewinding is not done properly the efficiency can reduce by 5 - 8% • Properly size to the load for optimum efficiency. • %loading < 30% change connection from delta to star • Avoid no load running. • Use of VFD for variable torque loads like blowers or pumps as Q N, H N2 & P N3

40. ENERGY CONSERVATION TIPS --- MOTORS • Replacing or Trimming of impeller dia or changing the pulley incase of pumps where fixed lower speed is reqd • Optimise operating voltage level of motor for lightly loaded motors.Check for under-voltage and over-voltage conditions. • Balance the three-phase power supply, imbalanced • voltage can reduce 3 - 5% in motor input power. • Energy efficient motors can save at least 4-5% on account of power consumption and in cases payback period may be within a year. • Use of flat belt in place of V- belt reduces power consumption by 12%. • Check alignment. • Provide proper ventilation.

42. ENERGY CONSERVATION OPPORTUNITIES IN COMPRESSED AIR SYSTEM Air is Free!!! CompressedAir is not free!!!

43. 60 to 80% of power is lost as heat. • Some energy is lost in friction.

45. Compressor • Reduce air compressor discharge pressure to the lowest • acceptable setting. Reduction of 1 kg/cm2 air pressure • (8 kg/cm2 to 7 kg/cm2) would result in 9% input power • savings & 10% reduction in compressed air leakage. • Use the highest reasonable dryer dew point settings. • Turn off refrigerated and heated air dryers when the air • compressors are off. • Take air compressor intake air from the coolest location, • Every 5 0C reduction in intake air temperature would • save 1% compressor power. • Avoid fouling of heat exchangers & air-oil separators. • Minimise leakage in the compressed air system Compressed air leak from 1 mm hole size at 7 kg/cm2 pressure would mean power loss equivalent to 0.5 kW. • .

46. Compressor • Use a properly sized compressed air storage receiver. • Consider alternatives to compressed air such as blowers • for cooling, hydraulic rather than air cylinders, electric • rather than air actuators, and electronic rather than • pneumatic controls. Replace pneumatic tools by electrical • Install roots blower for tank agitation. • Use nozzles or venturi-type devices rather than blowing • with open compressed air lines. • Maintain Compressor for improving SPC (kW/100CFM) • Option of installing VFD for preventing unloading • Increase in pipe sizing and Air Receiver for absorbing pulsation sudden requirement and pressure drops • Do not use compressed air for cleaning purpose • Switch off compressors during lunch time.

48. Cooling Towers • Control cooling tower fans based on leaving water temperatures. • Control to the optimum water temperature as determined from cooling tower and chiller performance data. • Use two-speed or variable-speed drives for cooling tower fan control if the fans are few. Stage the cooling tower fans with on-off control if there are many. • Turn off unnecessary cooling tower fans when loads are reduced. • Replace slat-type drift eliminators with high-efficiency, low-pressure-drop, self-extinguishing, PVC cellular units. • Optimize cooling tower fan blade angle on a seasonal and/or load basis. • Shut off loads that are not in service

49. Cooling Towers • Replace conventional aluminum fans with Fibre Reinforced Plastic (FRP) fans • Cover hot water basins (to minimize algae growth that contributes to fouling). • Balance flow to cooling tower hot water basins. • Periodically clean plugged cooling tower water distribution nozzles. Or install new nozzles. • Replace splash bars with self-extinguishing PVC cellular-film fill. • On old counterflow cooling towers, replace old spray-type nozzles with new square-spray ABS practically-non-clogging nozzles. • Re-line leaking cooling tower cold water basins. • Check water overflow pipes for proper operating level.

50. Cooling Towers • Correct excessive and/or uneven fan blade tip clearance and poor fan balance. • If possible, follow manufacturer's recommended clearances around cooling towers and relocate or modify structures, signs, fences, dumpsters etc. that interfere with air intake or exhaust. • Optimize chemical use. • Consider side stream water treatment. • .Install interlocks to prevent fan operation when there is no water flow. • Automate blow down to minimize it. Optimize blowdown flow rate. Send blow down to other uses. • Take blow down water from the return water header.