1 training session on energy equipment electric motors presentation from the “energy efficiency...
TRANSCRIPT
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Training Session on Energy Training Session on Energy EquipmentEquipment
Electric MotorsElectric Motors
Presentation from the “Energy Efficiency Guide for Industry in Asia”
www.energyefficiencyasia.org
©© UNEP 2006 UNEP 2006
El ect ri cal E
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©© UNEP 2006 UNEP 2006
Training Agenda: Electric MotorsTraining Agenda: Electric Motors
Introduction
Types of electric motors
Assessment of electric motors
Energy efficiency opportunities
El ect ri cal E
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©© UNEP 2006 UNEP 2006
IntroductionIntroduction
• Electromechanical device that converts electrical energy to mechanical energy
• Mechanical energy used to e.g.• Rotate pump impeller, fan, blower
• Drive compressors
• Lift materials
• Motors in industry: 70% of electrical load
What is an Electric Motor?El ect ri cal E
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©© UNEP 2006 UNEP 2006
IntroductionIntroduction
How Does an Electric Motor Work?El ect ri cal E
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(Nave, 2005)
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IntroductionIntroduction
Three types of Motor LoadEl ect ri cal E
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Motor loads Description Examples
Constant torque loads
Output power varies but torque is constant
Conveyors, rotary kilns, constant-displacement pumps
Variable torque loads
Torque varies with square of operation speed
Centrifugal pumps, fans
Constant power loads
Torque changes inversely with speed
Machine tools
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©© UNEP 2006 UNEP 2006
Training Agenda: Electric MotorsTraining Agenda: Electric Motors
Introduction
Types of electric motors
Assessment of electric motors
Energy efficiency opportunities
El ect ri cal E
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
Classification of MotorsEl ect ri cal E
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Electric Motors
Alternating Current (AC) Motors
Direct Current (DC) Motors
Synchronous Induction
Three-PhaseSingle-Phase
Self ExcitedSeparately Excited
Series ShuntCompound
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
• Field pole• North pole and south pole
• Receive electricity to formmagnetic field
• Armature• Cylinder between the poles
• Electromagnet when current goes through
• Linked to drive shaft to drive the load
• Commutator• Overturns current direction in armature
DC Motors – ComponentsEl ect ri cal E
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(Direct Industry, 1995)
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
• Speed control without impact power supply quality
• Changing armature voltage
• Changing field current
• Restricted use
• Few low/medium speed applications
• Clean, non-hazardous areas
• Expensive compared to AC motors
DC motorsEl ect ri cal E
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
• Relationship between speed, field flux and armature voltage
DC motorsEl ect ri cal E
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Back electromagnetic force: E = KNTorque: T = KIa
E = electromagnetic force developed at armature terminal (volt) = field flux which is directly proportional to field currentN = speed in RPM (revolutions per minute)T = electromagnetic torqueIa = armature currentK = an equation constant
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
• Separately excited DC motor: field current supplied from a separate force
• Self-excited DC motor: shunt motor
El ect ri cal E
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El ect ri c M
otor s• Field winding parallel with armature winding
• Current = field current + armature current
Speed constant independent of load up to certain torque
Speed control: insert resistance in armature or field current
DC motors
(Rodwell Int. Corporation, 1999)
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
Self-excited DC motor: series motor
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DC motors
(Rodwell Int. Corporation, 1999)
• Field winding in series with armature winding
• Field current = armature current
• Speed restricted to 5000 RPM
• Avoid running with no load: speed uncontrolled
Suited for high starting torque: cranes, hoists
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
DC compound motor
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DC motors
Field winding in series and parallel with armature winding
Good torque and stable speed
Higher % compound in series = high starting torque
Suited for high starting torque if high % compounding: cranes, hoists
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
Classification of MotorsEl ect ri cal E
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Electric Motors
Alternating Current (AC) Motors
Direct Current (DC) Motors
Synchronous Induction
Three-PhaseSingle-Phase
Self ExcitedSeparately Excited
Series ShuntCompound
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
• Electrical current reverses direction
• Two parts: stator and rotor• Stator: stationary electrical component
• Rotor: rotates the motor shaft
• Speed difficult to control
• Two types• Synchronous motor
• Induction motor
AC MotorsEl ect ri cal E
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(Integrated Publishing, 2003)
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
• Constant speed fixed by system frequency
• DC for excitation and low starting torque: suited for low load applications
• Can improve power factor: suited for high electricity use systems
• Synchronous speed (Ns):
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AC Motors – Synchronous motor
Ns = 120 f / PF = supply frequencyP = number of poles
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
• Most common motors in industry
• Advantages:
• Simple design
• Inexpensive
• High power to weight ratio
• Easy to maintain
• Direct connection to AC power source
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AC Motors – Induction motor
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
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Components
• Rotor
• Squirrel cage: conducting barsin parallel slots
• Wound rotor: 3-phase, double-layer, distributed winding
AC Motors – Induction motor
• Stator• Stampings with slots to carry 3-phase windings
• Wound for definite number of poles
(Automated Buildings)
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
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AC Motors – Induction motor
How induction motors work• Electricity supplied to stator
• Magnetic field generated that moves around rotor
• Current induced in rotorElectromagnetics
Stator
Rotor
• Rotor produces second magnetic field that opposes stator magnetic field
• Rotor begins to rotate(Reliance)
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
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AC Motors – Induction motor
• Single-phase induction motor• One stator winding
• Single-phase power supply
• Squirrel cage rotor
• Require device to start motor
• 3 to 4 HP applications
• Household appliances: fans, washing machines, dryers
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Type of Electric MotorsType of Electric Motors
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AC Motors – Induction motor
• Three-phase induction motor• Three-phase supply produces magnetic
field
• Squirrel cage or wound rotor
• Self-starting
• High power capabilities
• 1/3 to hundreds HP applications: pumps, compressors, conveyor belts, grinders
• 70% of motors in industry!
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
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AC Motors – Induction motor
Speed and slip
• Motor never runs at synchronous speed but lower “base speed”
• Difference is “slip”
• Install slip ring to avoid this
• Calculate % slip:
% Slip = Ns – Nb x 100 Ns
Ns = synchronous speed in RPMNb = base speed in RPM
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©© UNEP 2006 UNEP 2006
Type of Electric MotorsType of Electric Motors
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AC Motors – Induction motor
Relationship load, speed and torque
At start: high current and low “pull-up” torque
At start: high current and low “pull-up” torque
At 80% of full speed: highest “pull-out” torque and current drops
At full speed: torque and stator current are zero
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©© UNEP 2006 UNEP 2006
Training Agenda: Electric MotorsTraining Agenda: Electric Motors
Introduction
Types of electric motors
Assessment of electric motors
Energy efficiency opportunities
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©© UNEP 2006 UNEP 2006
Assessment of Electric MotorsAssessment of Electric Motors
Motors loose energy when serving a load
• Fixed loss
• Rotor loss
• Stator loss
• Friction and rewinding
• Stray load loss
Efficiency of Electric MotorsEl ect ri cal E
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(US DOE)
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©© UNEP 2006 UNEP 2006
Factors that influence efficiency• Age• Capacity• Speed• Type• Temperature• Rewinding• Load
Efficiency of Electric MotorsEl ect ri cal E
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Assessment of Electric MotorsAssessment of Electric Motors
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©© UNEP 2006 UNEP 2006
Motor part load efficiency• Designed for 50-100% load
• Most efficient at 75% load
• Rapid drop below 50% load
Efficiency of Electric MotorsEl ect ri cal E
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(US DOE)
Assessment of Electric MotorsAssessment of Electric Motors
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©© UNEP 2006 UNEP 2006
• Motor load is indicator of efficiency
• Equation to determine load:
Motor LoadEl ect ri cal E
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Load = Pi x HP x 0.7457
= Motor operating efficiency in %HP = Nameplate rated horse powerLoad = Output power as a % of rated powerPi = Three phase power in kW
Assessment of Electric MotorsAssessment of Electric Motors
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©© UNEP 2006 UNEP 2006
Three methods for individual motors
• Input power measurement• Ratio input power and rate power at 100%
loading
• Line current measurement• Compare measured amperage with rated
amperage
• Slip method• Compare slip at operation with slip at full
load
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Assessment of Electric MotorsAssessment of Electric Motors
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©© UNEP 2006 UNEP 2006
Input power measurement
• Three steps for three-phase motors
Step 1. Determine the input power:
Motor LoadEl ect ri cal E
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Pi = Three Phase power in kWV = RMS Voltage, mean line to
line of 3 PhasesI = RMS Current, mean of 3 phasesPF = Power factor as Decimal
1000
3xPFxIxVPi
Assessment of Electric MotorsAssessment of Electric Motors
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©© UNEP 2006 UNEP 2006
Input power measurementStep 2. Determine the rated power:
Step 3. Determine the percentage load:
Motor LoadEl ect ri cal E
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rr xhpP
7457.0
%100xP
PiLoad
r
Load = Output Power as a % of Rated PowerPi = Measured Three Phase power in kWPr = Input Power at Full Rated load in kW
Pr = Input Power at Full Rated load in kWhp = Name plate Rated Horse Powerr = Efficiency at Full Rated Load
Assessment of Electric MotorsAssessment of Electric Motors
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©© UNEP 2006 UNEP 2006
Result
1. Significantly oversized and underloaded
2. Moderately oversized and underloaded
3. Properly sized but standard efficiency
Motor LoadEl ect ri cal E
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Action→ Replace with more efficient,
properly sized models
→ Replace with more efficient, properly sized models when they fail
→ Replace most of these with energy-efficient models when they fail
Assessment of Electric MotorsAssessment of Electric Motors
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©© UNEP 2006 UNEP 2006
Training Agenda: Electric MotorsTraining Agenda: Electric Motors
Introduction
Types of electric motors
Assessment of electric motors
Energy efficiency opportunities
El ect ri cal E
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©© UNEP 2006 UNEP 2006
1. Use energy efficient motors
2. Reduce under-loading (and avoid over-sized motors)
3. Size to variable load
4. Improve power quality
5. Rewinding
6. Power factor correction by capacitors
7. Improve maintenance
8. Speed control of induction motor
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Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
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©© UNEP 2006 UNEP 2006
• Reduce intrinsic motor losses
• Efficiency 3-7% higher
• Wide range of ratings
• More expensive but rapid payback
• Best to replace whenexisting motors fail
Use Energy Efficient MotorsEl ect ri cal E
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(Bureau of Indian Standards)
Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
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©© UNEP 2006 UNEP 2006
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Power Loss Area Efficiency Improvement
1. Fixed loss (iron) Use of thinner gauge, lower loss core steel reduces eddy current losses. Longer core adds more steel to the design, which reduces losses due to lower operating flux densities.
2. Stator I2R Use of more copper & larger conductors increases cross sectional area of stator windings. This lower resistance (R) of the windings & reduces losses due to current flow (I)
3 Rotor I2R Use of larger rotor conductor bars increases size of cross section, lowering conductor resistance (R) & losses due to current flow (I)
4 Friction & Winding
Use of low loss fan design reduces losses due to air movement
5. Stray Load Loss Use of optimized design & strict quality control procedures minimizes stray load losses
(BEE India, 2004)
Use Energy Efficient Motors
Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
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©© UNEP 2006 UNEP 2006
Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
• Reasons for under-loading• Large safety factor when selecting motor
• Under-utilization of equipment
• Maintain outputs at desired level even at low input voltages
• High starting torque is required
• Consequences of under-loading• Increased motor losses
• Reduced motor efficiency
• Reduced power factor
2. Reduce Under-loadingEl ect ri cal E
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©© UNEP 2006 UNEP 2006
Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
• Replace with smaller motor• If motor operates at <50%
• Not if motor operates at 60-70%
• Operate in star mode• If motors consistently operate at <40%
• Inexpensive and effective
• Motor electrically downsized by wire reconfiguration
• Motor speed and voltage reduction but unchanged performance
2. Reduce Under-loadingEl ect ri cal E
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©© UNEP 2006 UNEP 2006
Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
• Motor selection based on
• Highest anticipated load: expensive and risk of under-loading
• Slightly lower than highest load: occasional overloading for short periods
• But avoid risk of overheating due to
• Extreme load changes
• Frequent / long periods of overloading
• Inability of motor to cool down
3. Sizing to Variable LoadEl ect ri cal E
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X
Motors have ‘service factor’ of 15% above
rated load
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Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
Motor performance affected by
• Poor power quality: too high fluctuations in voltage and frequency
• Voltage unbalance: unequal voltages to three phases of motor
4. Improve Power QualityEl ect ri cal E
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Example 1 Example 2 Example 3
Voltage unbalance (%) 0.30 2.30 5.40
Unbalance in current (%) 0.4 17.7 40.0
Temperature increase (oC) 0 30 40
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©© UNEP 2006 UNEP 2006
Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
Keep voltage unbalance within 1%
• Balance single phase loads equally among three phases
• Segregate single phase loads and feed them into separate line/transformer
4. Improve Power QualityEl ect ri cal E
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©© UNEP 2006 UNEP 2006
Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
• Rewinding: sometimes 50% of motors
• Can reduce motor efficiency
• Maintain efficiency after rewinding by
• Using qualified/certified firm
• Maintain original motor design
• Replace 40HP, >15 year old motors instead of rewinding
• Buy new motor if costs are less than 50-65% of rewinding costs
5. RewindingEl ect ri cal E
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©© UNEP 2006 UNEP 2006
Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
• Use capacitors for induction motors
• Benefits of improved PF
• Reduced kVA
• Reduced losses
• Improved voltage regulation
• Increased efficiency of plant electrical system
• Capacitor size not >90% of no-load kVAR of motor
6. Improve Power Factor (PF)El ect ri cal E
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©© UNEP 2006 UNEP 2006
Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
Checklist to maintain motor efficiency
• Inspect motors regularly for wear, dirt/dust
• Checking motor loads for over/under loading
• Lubricate appropriately
• Check alignment of motor and equipment
• Ensure supply wiring and terminal box and properly sized and installed
• Provide adequate ventilation
7. MaintenanceEl ect ri cal E
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©© UNEP 2006 UNEP 2006
Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
• Multi-speed motors
• Limited speed control: 2 – 4 fixed speeds
• Wound rotor motor drives
• Specifically constructed motor
• Variable resistors to control torque performance
• >300 HP most common
8. Speed Control of Induction MotorEl ect ri cal E
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©© UNEP 2006 UNEP 2006
Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
• Variable speed drives (VSDs)
• Also called inverters
• Several kW to 750 kW
• Change speed of induction motors
• Can be installed in existing system
• Reduce electricity by >50% in fans and pumps
• Convert 50Hz incoming power to variable frequency and voltage: change speed
• Three types
8. Speed Control of Induction MotorEl ect ri cal E
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©© UNEP 2006 UNEP 2006
Energy Efficiency OpportunitiesEnergy Efficiency Opportunities
Direct Current Drives
• Oldest form of electrical speed control
• Consists of
• DC motor: field windings and armature
• Controller: regulates DC voltage to armature that controls motor speed
• Tacho-generator: gives feedback signal to controlled
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8. Speed Control of Induction Motor
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Training Session on Energy Training Session on Energy EquipmentEquipment
Electric MotorsElectric Motors
THANK YOUTHANK YOU
FOR YOUR ATTENTIONFOR YOUR ATTENTION
©© UNEP 2006 UNEP 2006
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© UNEP 2006© UNEP 2006
Disclaimer and ReferencesDisclaimer and References
• This PowerPoint training session was prepared as part of the project “Greenhouse Gas Emission Reduction from Industry in Asia and the Pacific” (GERIAP). While reasonable efforts have been made to ensure that the contents of this publication are factually correct and properly referenced, UNEP does not accept responsibility for the accuracy or completeness of the contents, and shall not be liable for any loss or damage that may be occasioned directly or indirectly through the use of, or reliance on, the contents of this publication. © UNEP, 2006.
• The GERIAP project was funded by the Swedish International Development Cooperation Agency (Sida)
• Full references are included in the textbook chapter that is available on www.energyefficiencyasia.org