energy conservation mgmt bilwc

8/6/2019 Energy Conservation Mgmt BILWC

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ARBIND KUMAR 16/29/2011


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VARIOUS FORMS ENERGY

Potential energy Chemical

Nuclear Mechanical stored

energy

Gravitational

Kinetic Radiant

Thermal Motion

Sound

Electrical

Various forms of energy

High and Low grade energy

1. High grade energy is concentrated EnergyEx. electricity,Light energy, chemical energy

2. Low grade energy rapidly dissipates (molecules are more randomlydistributed)

Ex.heat energy


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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

ENERGY CONVERSION


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ELECTRICAL ENERGY BASICS

Direct current: Non-varying unidirectional current

Current produced by batteries

Alternating Current: Reverses in regular recurringintervals with alternate +ve and ve values at specifiednumber of times per second

In 50 cycle AC, current reverses direction 100 timesa 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 apparentpower 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 apparentpower 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 aindustry

Demand factor = maximum demand/connected load

Load factor = average load/ maximumload


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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 usedfor pumping operation. Electrical parameter such ascurrent, volt and power factor were measured withpower analyzer. Find energy consumption of motor in

one hour? (line volts. = 4 4 0 V, line current = 25 ampsand 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 thermalunit (Btu)

1 cal = 4.184 J = 3.96566710-3 Btu

1Btu =

1055

.05

6J = 252

.1644 cal = 2

.930

71110

-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 availableat 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, animalpower, 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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FACTSFACTS --------

1.1. Indias Energy Intensity per unit GDP is higher byIndias Energy Intensity per unit GDP is higher by

> 3.7 times of Japan> 3.7 times of Japan

> 1.4 times of Asia> 1.4 times of Asia

> 1.5 times of USA> 1.5 times of USA

Indicates high wastage of energy but very highIndicates high wastage of energy but very highsaving potentialsaving potential

2. Power shortage in the Country2. Power shortage in the Country

> Peak> Peak -- 13%13%

> Average> Average -- 8%8%

3. Additional 10,000 MW required by 2012 means Rs 80003. Additional 10,000 MW required by 2012 means Rs 8000billion investment will be requiredbillion investment will be required


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Basic needs 0f Energy conservation

It is a vital infrastructure input for economical developmentof the country.

Thermal power generation in India is about 80% with anefficiency 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% -- Expensiveeconomic 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 peakperiod


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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 thesupply of coal, oil and electricity.

Our oil consumption has increased 5 folds in thepast 27 years, after the energy crisis of 1973.About72% of our oil requirement is met through imports.

It is better to improve energy efficiency rather thansetup energy generation facilities to supplyinefficient 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 totalenergy produced

The fuel bill of Indian Railways for dieseltraction is huge on based on 278 & 208 billion

GTKM for freight & passenger on SpecificEnergy Consumption of 2.55 & 4.5 ltr.

The fuel bill of Indian Railways for electrictraction ---The fuel bill of Western Railways forelectric traction is of the order of 480 Cr.

The fuel accounts for approx. 25% ofIndianRailways 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 equalnumber of electric locomotives.

These locomotives consume 2000 million liters ofdiesel & 9000 million units of electricity annually.

The break up of energy used in 02 consecutive years

Energy Traction Non traction1. Electricity (Million KWH) 9,013 2,361

2. Diesel (Million liters) 2,007 33Traction 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


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BARRIERS TO ENERGY EFFICIENCY

1. Lack of awareness

2. Lack of Education & Training

3. Economic & market distortions4.Lack of standardization & labeling

on equipments/devices

5. Lack of financing6. Lack of effective coordination


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ENERGY CONSERVATION PROGRAMME

House Keeping proper procedure, utilization andequipments maintenance.

Process Improvement modification of existingequipments 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 energyconsumption in any installation is in Lighting only

Industrial Motors -- Electric motors constitutesabout 72% of the total industrial load, whereInduction motors are invariable used.

Air-conditioning -- Air-conditioning is anotherintensive operation. A combination of central AC with

packed individual units may prove more energyefficient.


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ENERGY SAVING APPROACH

Water supply system (Pumps)--- The efficiency of thepumping station varies from 10 to 70%.Prevention of wastage andleakage can save energy up to 5%.

Electric heating & Electrolysis--- Energy conservation in

electric heating is possible mainly by> Reducing heat losses Using more efficient equipment or processes.

Electric Energy consumed in electrolysis are given as:1. Storage batteries2. Electrolytic processes3. Recover waste heat4. 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 ofgetting people together to accomplish desiredgoals. Management consists of for five major

functions: planning

organizing

leading

coordinating controlling


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ENERGY MANAGEMENT

The strategy of adjusting and optimizingenergy, using systems and procedures so asto reduce energy requirements per unit ofoutput while holding constant or reducingtotal costs of producing the output from

these systems


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ENERGY MANAGEMENT

OVERVIEW

STEP 1

STEP 2

STEP 3STEP 4

STEP 5

STEP 6STEP 7


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STEP 1:

Commitment to Continuous Improvement

Irrespective of size or type of organization,the common element of successful energymanagement is commitment.

Organizations make a commitment to allocatestaff and funding to achieve continuousimprovement.


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STEP 1:

Appoint an Energy Director/Manager --Sets goals, tracksprogress, and promotes the energy management program.

Establish a EnergyT

eam --Executes energy managementactivities across different parts of the organization and ensuresintegration of best practices.

Institute an Energy Policy -- Provides the foundation for settingperformance goals and integrating energy management into anorganizations culture and operations


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RESPONSIBILITY OF ENERGY MANAGER C

oordinating & Directing the overall Energy Program Contact Point forSenior Management

Drafting an Energy Policy

Assessing the potential value ofImproved EnergyManagement

Creating & Leading the Energy Team.

Securing resources to implement strategic EnergyManagement

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 usefor all major facilities and functions in theorganization and establishing for measuring future

results of efficiency.

Efforts by:

Understanding Current & Past energy use.

Identify opportunities to improve energyperformance and gain financial benefits.


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ASSESS PERFORMANCE PROCESS1. Data Collection & Management

2. Base lining

3. Benchmarking

4. Analysis

5. Technical Assessments

6. Audits


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STEP 3:

SET GOALS -- Setting CLEAR & MEA

SURABLEgoals is critical for understanding intends results,

developing effective strategies and reapingfinancial gains.

Basis for tracking & Measuring progress.

Communicating and posting goals can motivate staffto support Energy Management efforts.

The Energy Director/Manager in conjunction withthe Energy Team typically develops GOALS.


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SET GOALS

OBJECTIVE

1. Determine Scope

2. Estimate Potential for Improvement

3. Reduce Environment Impact


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STEP 4:

CREATE ACTION PLANSuccessful 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 PROGRESSIt includes formal review of both energy use

Data and the activities carried out as

compared to our performance goals.STEPS

1. Measures results

2. Review action plan

3. Documentation


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STEP 7:

RECOGNIZE ACHIEVEMENTSProviding & seeking recognition for energymanagement achievements is proven step for

sustaining momentum and support for program.

Key Steps in providing & gaining recognition1. Providing Internal Recognition

2. 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 useof 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), Labourand

Materials.

Energy would emerge as a top ranker for costreduction

Primary objective of Energy Audit is todetermine ways:

1. to reduce energy consumption per unit of productoutput

2. to lower operating costs.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. Preliminary energy audit uses existing, or easilyobtained data

2. Establish energy consumption in the organization

3. Estimate the scope for saving

4. Identify the most likely areas for attention

5. Identify immediate (no-/low-cost) improvements

6. Set a reference point

7. 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 growthof Economy & Industries of the developing countries.The new construction of Power Plant is strongly objected bythe Environmentalists.

It is difficult for the existing and potential newEnergy 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 PROCEDURESIN GENERAL

STEPSSTART-UPMEETING

COLLECTINGBASIC DATA

FIELD WORK

DATAANALYSIS

REPORTING

IMPLEMENTATION

OFSAVING 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. Aluminium 2. Fertilizers

3. Iron and Steel 4. Cement;

5. Pulp and paper 6. Chlor Akali;

7. Sugar 8. Textile;

9. Chemicals 10. Railways;

11. Port Trust 12. Transport13. Petrochemicals & Refineries

14. Power Stations, T & D companies

15. Commercial buildings >500 kW


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Electricity Billing

HT or LT TariffTwo Part tariff for HT Consumers

The consumer pays fortwo 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, butthe time integrated demand over the predefinedrecording cycle.

As example, in an industry, if the drawl over a recordingcycle of 30 minutes is :

2500 kVA for 4 minutes 3600 kVA for 12minutes

4100 kVA for 6 minutes

3800 kVA for 8 minutes

The MD recorder will be computing MD as:

(2500x4) +(3600 x 12) + (4100 x 6) + (3800 x 8) = 3606.7 kVA30


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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 currentthrough it. The principle parts of an incandescent lamp, also knownas GLS (General Lighting Service) lamp include the filament, thebulb, the fill gas and the cap.

Reflector lamps:Reflector lamps are basically incandescent, provided with a highquality internal mirror, which follows exactly the parabolic shape ofthe lamp. The reflector is resistant to corrosion, thus making thelamp maintenance free and output efficient.

Gas discharge lamps:The light from a gas discharge lamp is produced by the excitation ofgas 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 VapourLamps (MVL)

Sodium VapourLamps (HPSV/LPSV)

Metal Halide Lamps


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Lighting System Approach

eilingi t re

Lamps (light so rce)Ballast

Lens or Diff ser

loor

S itch

or S rfacehe Re irement

alls


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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

hoto sensors


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Energy savings in lighting System

1. Install energy efficient lamps,

Metal halide in place of Mercury and SVL lamps

CFT in place of incandescent lamps

1. Clean North roof glass, translucent sheet andluminaries regularly

2. Separate lighting Transformer

To isolate from power feeder

To avoid voltage fluctuation problem3. Install Servo stabilizer if separate transformer is not

feasible.


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Transformers


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Types ofTransformers

Power transformers : Used in transmissionnetwork 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 lowervoltage 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. Load loss (or copper loss)2. No load loss (or iron loss)

The total transformer loss, PTOTAL, at anyload 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 = 2 x 2.8 = 5.6

Load loss = 2 x (750)2 x 11.88

(1000)

= 13.36 kW

Total Loss = 5.6 + 13.36 = 18.96

b) 3 transformers in operation :

No load loss = 3 x 2.8 = 8.4 KW

Load loss = 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 capacitorsat load end.

Optimum loading of transformers in the system.

Opting for lower resistance All Alluminium Alloy

Conductors (AAAC) in place of conventional AlluminiumCored Steel Reinforced (ACSR) lines

Minimizing losses due to weak links in distribution

network such as jumpers, loose contacts, old brittle

conductors.


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MESSAGE

Cogeneration plant 80%

Combined cycle 50%

Coal fired power plant 35%

Gasoline Engine 16%

Human being 12%

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 designedcreature on earth has managed to develop machines

which are fare more efficient than their own design.


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Contact

ARBIND KUMARAssistant Professor/Electrical

Indian Railways Institute of Mechanical &

Electrical Engineering

Jamalpur, ihar - 811214

Tel : (06344) 243184

241778

Mob:09431611180 (official)

09431249487

Fax: 06344 243293

mail : [email protected]

.irimee.ac.in

energy conservation mgmt bilwc

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