ENERGY CONSERVATION WHY ? WHAT IS THE NEED? WHO WILL GAIN ?

1. ENERGY CONSERVATIONWHY ? WHAT IS THE NEED?WHO WILL GAIN ?

2. All India Power Shortages$Existing Supply : 368,046 M Units$Existing Demand : 414,000 M Unit$ Shortage : 11.5 %

3. POWER COST FOR LAST TEN YEARS3 – Fold Increase in Last Nine Years

4. NATIONAL POWER SCENE$Precarious$Adverse Impact On Industry$New Project Additions very slow$Action Plan Required for Improvement

5. COMPARISION OF POWER COST Comparative Power Cost In Different Countries

6. ENERGY SAVING POTENTIAL IN INDIAN INDUSTRY$Energy Saving Potential Rs.100,000.00 Million/yr$Equivalent 2500 MW$Investment Opportunity Rs.200,000.00 Million

7. ENERGY SAVING POTENTIAL In Industry – Electrical Devices Investment Potential Rs.42000 million

8. ENERGY COST AS % OFMANUFACTURING COST$Chlor Alkali Industry 65%$Cement Industry 40%$Paper Industry 25%$Chemical Industry 15%$Foundry 25%$Engineering Industry 10%

9. Energy Conservation : An Excellent opportunity for enhancing profit andimproving competitiveness

10. PROBLEMS FACEDLack of AwarenessDoubtingHigh Capital InvestmentLack Of Attractive Financing SchemesOver PromisesReliability Of EquipmentPricing of Energy need for Policy -Changes

11. POSSIBLE SOLUTIONSAwareness CampaignEncon MissionTraining to IndustryEnergy SummitEnergy NormsDemo ProjectsAward Schemes

12. ENERGY CONSERVATION AT MACRO LEVEL3-Pronged Approacha. Capacity Utilizationb. Fine Tuning c. Technology Up gradation(Target – Reduction in specific energy consumption)

13. MACRO LEVELMETHODOLOGYEnergy Input (a)= Unavoidable losses (c)+Theoretical Requirement (b)+Avoidable losses (d)

14. MACRO LEVELMETHODOLOGYFOCUS SHOULD BEa. To concentrate on avoidable lossesb. Quantify the lossesc. Identify ways and means for reductiond. Implementation

15. ENERGY CONSERVATION IN ELECTRICAL MOTORSA device which converts electrical energy into mechanical energyMajor source of energy consumptionMajor population- Induction motors

16. Motor Efficiency =O/P Power/Input PowerX100Watt Losses- Stator & rotor lossesIron LossesFriction & Windage lossesStray Load losses

17. Range Of losses In An Induction Motor

18. Motor Losses#Voltage dependent – Iron LossesMagnetizationEddy Current#Current Dependent –copper lossesStatorRotor#Mechanical losses –Friction and windage losses

19. Energy Waste- Causes@Use of less efficient motors@Oversized/undersized motors@Improper supply voltage@Voltage fluctuations@Poor power factor@Less efficient driven equipment@Idle running

20. Motor Efficiency ImprovementMotor operation in lightly loaded condition which is common practice in industry – Forced to operate in less efficient zone

21. Voltage Optimisation Impact on motor operating parameters$ Red. in volt. Dependent losses$ Capacity reduces.$ PF Improves$ Load Current drops.$ Load factor improves$ Efficiency improves

22. Optimisation of Lightly Loaded MotorsOptions – Lightly loaded motors+ Delta to permanent star connection+Auto star delta convertor+Soft start cum energy saver+Down Sizing+Overall voltage optimisation

23. Soft Start Cum Energy Saver% of Loading % Saving10 6020 3830 2040 1150 6.560 4.570 2.580 1.590 1.0

24. Optimise The Plant Operating Voltage Overall- Plant operating voltage plays vital role in energy saving-Suggested to have on line voltage optimization (OLTC)-Magnetization losses vary exponentially with the voltage* Capacity prop V2*Volt. Opt. will vary capacity*Should be implemented after analyzing the loading pattern of all motors

25. Energy Conservation in Electrical Distribution System* Componenets in electrical distributiona. HT/LT Circuit breakersb. Switches and Fusesc. Transformersd.Busbars/Cables (HT/LT)

26. Measures in Minimizing Distribution Losses* HT/LT Circuit BreakersMaintain the contact surface uniformity, through vigorous maintenanceSelect energy efficient fuses

27. Measures in Minimizing Distribution Losses* Transformers#Select energy efficient#wherever possible run in parallel#Loading should be optimal

28. Measures in Minimizing Distribution Losses* Bus Ducts /Power Cables# Select correct size# Bus duct with minimum joints and bends# Cables with minimum joints#Panel should be placed near to load wherever possible to minimize cable length & its losses# Cable should be terminated with proper crimping sockets

29. Methods and Procedures To Minimize The Distribution Losses* Voltage drop measurement# In a large complex distribution system voltage drops are common# Acceptable limit is 4-5 V/PHASE# More than 5V/phase indicates energy loss in system* Reasons For Voltage Drop# Poor Power Factor# Inadequate Cable size laid# Poor contact surface atCable terminationCable jointscontactors/switches

30. Case Study – Voltage DropFrom Engineering IndustryVoltage at substation – 415 VVoltage at LT panel – 398 VLoad Current – 180 to 200APF - 0.4 LAGCable size – 1RX3CX300 mm. sqRelocate 90 KVAR Cap bank from SS to LT panelReduced 50% of energy lossesAnnual Saving – Rs. 0.6 lacs

31. Energy Conservation in TransformersTransformer Efficiency – 98-99%Optimum Efficiency Occurs when Iron Losses = Copper Losses(Optimum eff. Occurs between 40% to 60 % of loading )Selection of Transformer should be based on TOCTOC = Price +(No load loss x loss value) +(load loss x loss value)

32. Three Phase Transformer Typical Loss ChartKVA Iron Loss FL Copper Loss500 1030 6860 750 1420 95001000 1770 118201250 1820 12000*loss is in watts

33. CASE STUDY 11KV CB CB 2000KVA 11KV/433V 2000KVA 11KV/433V CB CB 415V

34. CASE STUDYBackground *Cap of Xmer = 1600 KVA*Load on Xmer is 80 %*Iron Loss = 2.3 kw*copper loss = 21 kwSuggestion – Operate both transformer in parallel*One Xmer operation loss = 2.3+21(0.8)2= 15.7 kw*Both Xmer in operationloss = [2.3+21x(0.4)2]x2=11.3 kwAnnual Saving = Rs.0.78 lacs

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