energy resource management 1

8/2/2019 Energy Resource Management 1

http://slidepdf.com/reader/full/energy-resource-management-1 1/34

Energy Management Systems

ForEnergy Efficiency InCommercial Establishments

Presentation ToEnergium 2004, US-ERC & PCRA

By Abraham Varughese

Enercon Systems Pvt. Ltd.29th June 2004, J W Marriotts, Mumbai



Energy is

Expensive, Efficiency is NOT



Enercon Energy ManagementOne Stop Shop

Meters Industrial,Revenue

SoftwareNet-

working

Tech-

nology

Sales & Support

Network

PFControl

DemandControl

Energy AuditsTraining

GeneratorSynch

RemoteMonitorin

g

Harmonic Audits,Filters

Generator AMF



ref ref inresid V nV nV V )4096(4096

Machine

RTU/PLC

Alarm?

MTU

No

Yes

Operator Action?

Operator ACK No

YesMTU

RTU/PLC

Machine

Operator

*

*

MTU Flashes Alarm



EnergyManagement

Systems



Energy Management System

• Energy is not only electricity, it could beany other form of thermal, mechanical,

chemical etc.• Incorporate:-

- Temperature meters

- Flow Meters- Humidity meters

- Combustion monitors etc.



Energy Management System Applications

• Predictive Maintenance

• Root Cause Analysis

• Power Quality• Measurement and Verification

• Cost Allocation

• Smart Power Management

• Energy Resource Planning• Energy Balancing

• Breaker Status – remote monitoring

• Automated Energy Billing System for Townships



Initiatives ByGovernment



Initiatives By Government

• Energy Conservation Act, 2001

• Amendments In Electricity Act, 2003

• Both Acts Aimed At Promoting EnergyEfficiency in India

• 25000 MW saving potential to beachieved by year 2012 as per MOP plan



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



Enercon-Link Between Industry andThe Acts

Consumer

EnergyConservation

Act 2001

Electricity

Act 2003

Enercon



Energy Conservation Act, 2001

Major Provisions• Norms of processes and standards

• Identified Designated Industries• Accredited Energy Auditors

• Mandatory Energy Audits

• Building codes

• Energy Managers• Comply with norms and standards

• Submit Status Report on Energy Consumption

• Penalty for non-compliance



Case Studies

Energy AuditInstrumentation

Energy Management Networks



Energy Efficiency –Case Study

• A 2800 TPD Cement Plant

• Specific Energy 98 kWH/ton of cement,

best in India is 69 kWH/ton• Initiated Energy Efficiency Initiatives

• Zeroed in on equipment wise efficiency

• DCS was in place• Replaced Analog meters with Enercon

Digital Energy Meters



Cement Plant

• The Crusher specific energy recordedcontinued to be high - 2.32 kWH/ton of

cement

• Why?



Cement Plant

• Many attempts were made to reducespecific energy consumption in crushers

• Motor efficiency was first suspect asthey were old motors

• Overhauling of equipment carried out

• Installed capacitors at load ends toreduce cable heat losses

• Nothing yielded appreciable results



Cement Plant

• Accurate measurement still remained as aproblem with manual measurement of

energy» The DCS had real time production data

» But Energy was manually recorded daily

• The plant had eLAN installed for their mainfeeders

• The management decided to extend theeLAN network to the crusher motors



Cement Plant

• There were two crushers

»300 TPH each

• The eLAN kW Profile for the onecrusher shows 350kW loading. Butthere were also dips of 108 kW

• Why?



Cement Plant

• Found Crusher hopper emptyfrequently, and all drives of crusher

upto stacker running idle• Thus there were long periods of idle

operation of the crusher – 108 kW



Cement Plant

• Soon, the reason was found:

• Non-availability of material in thehopper of crusher due to mismatchingof number of dumpers running betweenlimestone/clay stockyards to crusher

head.



Cement Plant

• They added three more dumpers at acost of Rs. 24 lakhs

• Ensured full load on the crushers



Cement Plant

• Full load operation of the crushersensured reduction in energy per unit of

production due to better capacityutilisation

• The plant started switching off the

crushers 3 hours earlier than normal• The specific energy came down to 1.43

kWH/ton of cement from 2.32



Cement Plant

• Net saving of Rs. 27.7 lakhs for aboutper annum with investment payback of

less than one year• Enercon’s Total Energy Management

approach with process knowledge made

the difference



CASE STUDY – OFFICE BUILDING



Office Building

• A large office building

• Two transformers and two LT panels

• APFC relays installed with both panels

• Still average monthly power factor wasas low as 0.79

• Heavy LPF penalty of as high as Rs 2.4lakhs per month



Office Building

• Examined performance of all capacitors,replaced damaged ones

• Added more capacitors in the circuit

• The relays were checked suspectingmalfunctioning

• Approached the EB suspecting fault inthe trivector meter



Office Building

• The overall power factor remained atabout 0.8 after all these efforts

• Finally, the department decided toequip the building with eLAN and calledin Enercon



Office Building

• The load pattern as recorded by eLANindicated kW loading as low as 15 kW

after office hours, about 14 hours perday

• Same load pattern during Saturdays,

Sundays and Holidays• Decided to check the PF profile



Office Building

• The installed capacitors were all 25 kVAR rating each

• Due to low load none of the capacitors weregetting switched on

• Replaced the capacitors with lower rating of 10 kVAR each

• Relays started switching on capacitors• Power factor improved to above 0.95

• Resulted in annual saving of Rs. 28.8 lakhsper annum



MORE CASE EXAMPLES



eLAN For Energy Efficiency

• A Few Major Case Studies• About 12% savings in energy cost, based on

findings by eLAN in an automobile industry in

South India• Use of eLAN for process optimisation in a

cement plant in Western India• About 30% savings reported by use of eLAN

in a foot ware manufacturing industry inNorth India

• Use of eLAN for power factor correction in anoffice building




• Helps to evaluate most importantaspect of energy efficiency, Specific

Energy Consumption, On-Line• Can incorporate non-electrical meters

like flow, temperature, humidity,

pressure etc; making it a total energymanagement tool




• Over 150 installations all over India and Abroad

• Most of the clients use eLAN foridentifying energy saving opportunitiesin addition to specific energy evaluation

• Most of the clients reported substantialsavings in energy by use of eLAN



Thank you

energy resource management 1

Documents