energy conservation report

ENERGY CONSERVATION REPORT GTM#2

SYED AHMER ALI BUKHARI MANAGEMENT TRAINEE ELECTRICAL DEPARTMENT GTM # 2

DATED: April 12, 2012

PREPARED BY: SYED AHMER ALI BUKHARI

2 ENERGY CONSERVATION REPORT GTM # 2

INTRODUCTION

Electrical Energy is one of the most important ingredients in any industrial activity. However, its availability is not infinite. Global Energy crisis, as well as high cost of fuels resulted in more activities to conserve energy to maximum extent. The textile industry retains a record of the lowest efficiency in energy utilization and is one of the major energy consuming industries.

Energy conservation refers to efforts made to reduce energy consumption. Energy conservation can be achieved through increased efficient energy use, in conjunction with decreased energy consumption and/or reduced consumption from conventional energy sources.

Electrical Energy can be used in industries in number of ways;

1. Electrical Driving System 2. General Lighting 3. Air Conditioning

The Electrical Driving System consumes a high amount of electrical energy as compared to the other two ways. If we just consider GTM-2 then, more than 40% of our energy is consumed by motors in different ways (Circulation fans, Pumps, Exhaust etc).

Now the question arises that how we make our system efficient enough so that we can save a very huge amount of Electrical Energy.

The most commonly used device in any industry is MOTOR; also it is a very high consumer of electricity due to its inductive nature. Electric motors consume more than 60% of all electrical energy generated and are responsible for the loss of 10 to 20% of all electricity converted into mechanical energy. So, to reduce its consumption and to save the wasted energy we should consider following parameters,

1. Electric Power Supply 2. Motor Controllers 3. Electric Motor 4. Mechanical Transmission

For the best result of any application each component should be optimized for reliability and efficiency.

There are several essential ways by which we can save electrical energy consumption;

1. Use of Efficient Control System 2. Use of Energy Efficient Motor 3. Use of Synchronous Motors for Improved Power Factor.

My suggestion is that we should work on “Use of Efficient Control System” rather then replacing the existing motors with the energy efficient motors or synchronous motors which will increase our expenditure cost.



By using an efficient control system we can supply power in a most efficient way to the motors which can save energy up to 30-40% (depending on the application). For this purpose we can use a VFD of Frequency Inverter which is being used all over the world to save energy.

OUR PLAN:

Gulahmed Technical team has planed energy conservation program in three phases,

PHASE – 1:

Convert all DC drives/Auto transformer machines system to inverter base system or VFD system. In Gulahmed we started energy conservation work from machine driving system.

Following machines were converted from DC drive/Auto transformer machines system to VFD based system

MACHINE NAME KW BEFORE VFD KW AFTER VFD

Kohat Calander 22.94 16.39

Old J Box 30.88 22.06

Goller Mercerize (1.8m) 36.27 25.91

Goller Mercerize (2.8m) 39.71 28.37

RD-V 107.67 76.91

Stork Ager 54.71 39.08

Hot flue 12.30 8.79

Local Calander/7 Bowl Calander 16.85 12.04

Canada J Box + Dryer 50.30 35.93

Menzil Singeing N.W 1 8.47 6.05

Menzil Singeing W.W 15.00 10.71

Osthoff Singeing 32.29 23.07

Arioli Washing 80.31 57.37

TOTAL 507.75 362.68

As we can observe from the above table that the difference between KW without VFD and with VFD is 145.07 kW that means approximately 30% of electric energy is being saved by just installing VFDs on the machines.



TOTAL SAVING (KW) = 145.07

SAVING/DAY (Rs.) = 20,890.36/-

SAVING/MONTH (Rs.) = 5, 43,149.5/-

ANNUAL SAVING (Rs.) = 65, 17, 794/-

Note: All calculations are for 18 x 26 Hrs per month.



PHASE – 2:

New substation was established to solve voltage drop problem and enhancement in power capacity.

Substation Project of 4 MW capacity was executed at GTM2. The present load of the system is 2.MW AND 1.7MW is spare for any new installation in future.

Initially the power was given from GTM-1 Power house and the average distance between GTM1 LT (Low Tension) Room and GTM2 Power was about 215Meters and the design was not as per standard and due to this long distance we were facing voltage drop problem in our machines and wasting about Rs. 9.0 million in terms of power losses. In addition to power losses we were facing the following problems:

• Voltage drop due to long distance • Old system had not defined proper cable route • During any Short Circuit we had to face difficulties to find the exact cable route • Old system (LT Panel) became overloaded and there was not any capacity to install

any spare breaker We calculated all power losses and gave all above justification to the Management about the old system and got approval to execute a centralized Substation in GTM2 having the following features:

• Minimize Voltage drop • New system has proper defined cable route • Defined cable route will reduce down time to trace the faults • The new system has a capacity of 1.7MW for future expansion • New system has proper earthing system



EXECUTIVE SUMMARY:

Project Electricity Capacity of GTM-2 4 MW

Project Estimated Cost 29.767 Million rupees

Project Actual Cost 30.13 Million rupees

Start Date 12/11/2009

Execution date 16/3/2010

First PDB Was connected on 26/3/2010

Last PDB Was Connected on 25/5/2010

Electrical Load Saved 0.443 MW

Annual Savings Rs. 9.0 Million /Year

& per month Saving 0.75 Million/month

MATERIAL SAVED AFTER PROJECT EXECUTION:

1- Transformer 1500KVA 02Pcs Rs. 2.0 Million

2- LT Panel 01 Pc Rs. 2.4 Million

3- Power Cable Saved Rs. 21.5 Million

Total cost of the above Rs. Rs. 25.9 Million

Difference = Approved Amount - Material Saving Net Cost (29.767-25.9)= 3.87Million

PAYBACK OF THE SYSTEM:

If we compare the difference and per month energy saved amount, it will take 05 months as a payback period, which is major achievement of the project.



CONDITION BEFORE THE INSTALLATION OF SUBSTATION:



CONDITION AFTER THE INSTALLATION OF SUBSTATION:



PHASE – 3: Installation of VFDs in machines circulation fan motors. What is VFD?

Introduction:

A variable-frequency drive (VFD) is a system for controlling the rotational speed of an alternating current (AC) electric motor by controlling the frequency of the electrical power supplied to the motor. A variable frequency drive is a specific type of adjustable-speed drive. Variable-frequency drives are also known as adjustable-frequency drives (AFD), variable-speed drives (VSD), AC drives, micro-drives or inverter drives.

Variable-frequency drives are used in a wide number of applications to control pumps, fans, hoists, conveyors, and other machinery.

Use and Benefits:

AC motor-driven applications that do not require full speed can save energy by controlling the motor with a variable speed drive. Energy cost saving with variable torque can be significant, often paying for the cost of VFD within a matter of months. In variable torque applications such as fans and blowers, the torque required varies roughly with the square of the speed, and the horsepower required varies roughly with the cube of the speed, resulting in a large reduction of horsepower for even a small reduction in speed. The motor will consume only 25% as much power at 63% speed than it will at 100% speed.

In the United States, an estimated 60-65% of electrical energy is used to supply motors, 75% of which are variable torque fan, pump and compressor loads, 18% of the energy used in the 40 million motors in the U.S. could be saved by efficient energy improvement technologies such as VFDs Only about 3% of all AC motors are provided with AC drives.



RECENT PROJECTS:

Following machines were recently converted from direct 3 phase supply system to VFD based system. The detail is as under,

1. RD-V:

Consumption of Electric power on circulation of RD-V (with & without VFD) for one motor.

Motor Data:

KW 22 RPM 1400 Volt 400 Amp 43 Freq 50Hz Cos Φ 0.86 So according to the formula P(FL) = 25.6 kW Running Load (Without VFD): RPM 1390 Volt 400 Amp 39 Freq 50Hz So according to the formula P(RL) = 23.2 kW Running Load (With VFD): RPM 1390 Volt 400 Amp 28 Freq 50Hz So according to the formula, P(VFD) = 16.6 kW Total no. of circulation motors = 6

ENERG

In tabul P(FL)*6kW

153.6

GRAP

Note: A

20

40

60

80

20

40

60

80

GY CONSER

lar form,

6 P(RLkW

139.2

PHICAL

All calculati

0

00000

00000

00000

00000

W7

0

000000

000000

000000

000000

RVATION R

L)*6 P(VkW

2 99

REPRES

ions are for

W/O VFD781747.2

KW

W/O VFD6253977.6

R

REPORT GTM

VFD)*6 W

9.6

SENTATI

18 x 26 Hrs

With VF559353

W/YEAR

With V6 447482

Rs./YEAR

P

M # 2

Difference P(RL)-P(VFD) 39.6

ION OF P

s per month

FD Diff3.6 222

VFD S28.8 17

R

PREPARED

Saving PUnit (Rs.) 316.80

PER YEA

h.

ference2393.6

Savings79148.8

BY: SYED AH

Per SavingMonth(Rs.) 14826

AR CONS

HMER ALI B

g Per h

SavYea(Rs

62.4 177

SUMPTIO

BUKHARI

11

ving Per ar s.) 79148.8

ON:

1



2. MONFORT THERMEX:

Consumption of Electric power on circulation of Monfort Thermax (with & without VFD) for one motor.

Motor Data:

KW 11 RPM 1400 Volt 400 Amp 22 Freq 50Hz Cos Φ 0.86 So according to the formula P(FL) = 13 kW Running Load (Without VFD): RPM 1390 Volt 400 Amp 17 Freq 50Hz So according to the formula P(RL) = 10 kW Running Load (With VFD): RPM 1390 Volt 400 Amp 10 Freq 50Hz So according to the formula, P(VFD) = 6 kW Total no. of circulation motors = 10

ENERG

In tabul P(FL)*kW

130

GRAP

Note: A

20

40

60

20

40

60

GY CONSER

lar form,

10 P(RLkW

100

PHICAL

All calculati

0

00000

00000

00000

W

0

000000

000000

000000

RVATION R

L)*10 P(VkW

60

REPRES

ions are for

W/O VFD561600

KW

W/O VFD4492800

R

REPORT GTM

VFD)*10 W

0

SENTATI

18 x 26 Hrs

With VF33696

W/YEAR

With V26956

Rs./YEAR

P

M # 2

Difference P(RL)-P(VFD) 40

ION OF P

s per month

FD Diff0 22

VFD S680 17

R

PREPARED

Saving PUnit (Rs.) 320

PER YEA

h.

ference24640

Savings797120

BY: SYED AH

Per SavinMonth(Rs.) 14976

AR CONS

HMER ALI B

ng Per h

SavYea(Rs

60 179

SUMPTIO

BUKHARI

13

ving Per ar s.) 97120

ON:

3



FUTURE PLAN:

I consider following machines on which we can work to save energy.

1. K-1600 2. K-2800 3. BABCOCK Stenter

ELECTRICAL ENERGY SAVING ON K-1600: Motor Data: kW 12 RPM 2800 Volt 400 Amp 23 Freq 50Hz Cos Φ 0.86 So, according to the formula, P(FL) = 13.7 kW Running Load (Without VFD): Volt 400 Amp 19 Freq 50Hz So, according to the formula, P(RL) = 11.32 kW Running Load (With VFD): Volt 400 Amp 11 Freq 50Hz So, according to the formula, P(VFD) = 6.55 kW Total number of circulation motors = 7

ENERG

In tabul P(FL)*7kW

96

GRAP

Note: A

20

40

20

40

GY CONSER

lar form,

7 P(RLkW

79.24

PHICAL

All calculati

0

00000

00000

W4

0

000000

000000

RVATION R

L)*7 P(VkW

4 45

REPRES

ions are for

W/O VFD445011.84

KW

W/O VFD3560094.72

R

REPORT GTM

VFD)*7 W

.85

SENTATI

18 x 26 Hrs

With VF257493

W/YEAR

With V2 205994

Rs./YEAR

P

M # 2


ION OF P

s per month

FD Diff3.6 187

VFD S48.8 150

R

PREPARED


PER YEA

h.

ference7518.24

Savings00145.92

BY: SYED AH


AR CONS

HMER ALI B

g Per h

SavYea

2.16 150

SUMPTIO

BUKHARI

15

ving Per ar (Rs.)

00145.92

ON:

5



TOTAL COST OF SAVING IN 5 YEARS = Rs. 7500729.6/- TOTAL EXPENDITURE COST = Rs. 875000/- BREAK EVEN TIME = 12 MONTHS



ELECTRICAL ENERGY SAVING ON K-2800: Motor Data: kW 12 RPM 2800 Volt 400 Amp 23 Freq 50Hz Cos Φ 0.86 So, according to the formula, P(FL) = 13.7 kW Running Load (Without VFD): Volt 400 Amp 19 Freq 50Hz So, according to the formula, P(RL) = 11.32 kW Running Load (With VFD): Volt 400 Amp 11 Freq 50Hz So, according to the formula, P(VFD) = 6.55 kW Total number of circulation motors = 5

ENERG

In tabul P(FL)*5kW

68.5

GRAP

Note: A

20

40

20

GY CONSER

lar form,

5 P(RLkW

56.6

PHICAL

All calculati

0

00000

00000

W3

0

000000

RVATION R

L)*5 P(VkW

32

REPRES

ions are for

W/O VFD317865.6

KW

W/O VFD2542924.8

R

REPORT GTM

VFD)*5 W

2.75

SENTATI

18 x 26 Hrs

With VF18392

W/YEAR

With V8 14713

Rs./YEAR

P

M # 2


ION OF P

s per month

FD Diff4 133

VFD S392 10

R

PREPARED


PER YEA

h.

ference3941.6

Savings071532.8

BY: SYED AH


AR CONS

HMER ALI B

g Per h

SavYea(Rs

4.4 107

SUMPTIO

BUKHARI

18

ving Per ar s.) 71532.8

ON:

8



TOTAL COST OF SAVING IN 5 YEARS = Rs. 5357664/- TOTAL EXPENDITURE COST = Rs. 625000/- BREAK EVEN TIME = 8 MONTHS



ELECTRICAL ENERGY SAVING ON BABCOCK STENTER: Motor Data: kW 6.5 RPM 1400 Volt 400 Amp 13 Freq 50Hz Cos Φ 0.82 So, according to the formula, P(FL) = 7.38 kW Running Load (Without VFD): Volt 400 Amp 11 Freq 50Hz So, according to the formula, P(RL) = 6.25 kW Running Load (With VFD): Volt 400 Amp 6.6 Freq 50Hz So, according to the formula, P(VFD) = 3.75 kW Total number of circulation motors = 12

ENERG

In tabul P(FL)*kW

88.56

GRAPH

Note: A

20

40

60

20

40

GY CONSER

lar form,

12 P(RLkW

75

HICAL RE

All calculati

0

00000

00000

00000

W

0

000000

000000

RVATION R

L)*12 P(VkW

45

EPRESENT

ions are for

W/O VFD421200

KW

W/O VFD3369600

R

REPORT GTM

VFD)*12 W

TATION O

18 x 26 Hrs

With VF25272

W/YEAR

With V20217

Rs./YEAR

P

M # 2

Difference P(RL)-P(VFD) 30

OF PER YE

s per month

FD Diff0 16

VFD S760 13

R

PREPARED

Saving PUnit (Rs.) 240

EAR CONS

h.

ference68480

Savings347840

BY: SYED AH

Per SavinMonth(Rs.) 11232

SUMPTION

HMER ALI B

ng Per h

SavYea(Rs

20 134

N:

BUKHARI

21

ving Per ar s.) 47840

1



TOTAL COST OF SAVING IN 5 YEARS = Rs. 6739200/- TOTAL EXPENDITURE COST = Rs. 762000/- BREAK EVEN TIME = 6 MONTHS

energy conservation report

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