Electrical Systems 2008

Energy Efficiency in Electrical System Focus Areas

Approach for energy conservation in Electrical systems Energy Saving electrical Equipment & Devices Case Studies

Energy Efficiency in Electrical System

CII Godrej GBC

Confederation of Indian Industry

Confederation of Indian Industry

Oversized / Under loaded motors

Efficiency of Motors at full load
70% to 96% based on capacity

Oversized / Under loaded motors

Range (H.P) 1-10 10-50 50-200 2001500 1500 & above % of Loss 14-35 09-15 06-12 04-07 4 At FL efficiency % 65-86 85-91 88-94 93-96 95-96

Approach -1 : Downsizing motor

Matching requirement Improved loading Improved efficiency Possible energy savings <5% Max efficiency for low capacity motors less

Efficiency of motors varying with loading

Lower operating efficiency during under loaded condition

In several applications, Loading of motors is less than 60%

Due to varying requirement ( Process) Improper selection
Confederation of Indian Industry

Confederation of Indian Industry

Oversized / Under loaded motors

Approach -2 : Converting delta to Permanent star connection
Applicable for loading less than 40% Reduction in torque & capacity by 1/3 Permanent reduction in capacity Energy saving : 10 to 20% of actual kW OLR setting of motor needs to be reduced to 58% Several case studies lathes, grinding m/cs, blowers etc.

CASE STUDY Convert Delta To Star Connection At Exhaust Blower Motor

Rated kW - 15 Kw Actual load Delta mode % Load = 4.5 kw = 30 %

Star mode = 3.5 Kw Savings in Kw = 1.0 kw Annual Saving = Rs. 0.24 Lakhs Caution Reset the OLR

Confederation of Indian Industry

Confederation of Indian Industry

This page was created using NitroPDF trial software. To purchase, go to http://www.nitropdf.com/

Oversized / Under loaded motors

Approach -3 : Auto star-delta-star converters
Applicable for varying load Under loading (less than 40%) for maximum time Auto change over from star-delta-star based on loading Energy saving : 10 to 20% Latest Applicable for high starting torque loads such as elevators, conveyors Not applicable - Frequent change in load conditions

Automatic Star-delta-star
Application - motors with shock loads Automatic star-delta-star converter has load sensor & Timer Capacity V2 Principle of Voltage optimization
Load Sensor Star Mode < 38% Energy Saving

%L

> 38% Mode Protection

Confederation of Indian Industry

Confederation of Indian Industry

Case study: Auto star-delta-star converter

Cement Plant, belt conveyor of 75kW capacity under loaded High starting torque required Running torque always less than 40% Auto star-delta-star converter Starting always DOL
Rated kW Actual kW % Loading In star mode consumes Savings in kW Annual savings Investment Payback period = 75.0 kW = 21.0 kW = 28 % = 17.2 kW = 3.8 kW = Rs 0.98 lakhs = Rs 1.20 lakhs = 13 months

Replacing old rewound motors with Energy Efficient Motors

Rewinding of motors drop in efficiency
Depends on type of fault Type of rewinder Quality of material & method of rewinding Reduction in efficiency ~0.5 - 1%

Energy efficient motor- improvement in efficiency 2 to 8% Replacing old rewound motors with energy efficient motor
Overall improvement 10-12%

Confederation of Indian Industry

Confederation of Indian Industry

Replacing old rewound motors with Energy Efficient Motors

Old motors can be replaced with energy efficient motor after 5 rewinding Best practice Maintaining Motor History card
Motor Name, Rated kW, V, I, PF, speed No.of rewinding Actual no-load details kW, V, I, PF after every rewinding Decision based on no-load details

Energy Efficient Motor

lesser slip Improved fan design Cooler operation & Increases motor insulation life 1.15 service factor Greater flexibility in handling voltage variations and imbalances High power factor - Eliminate need for PF correction

Practiced by many plants

Confederation of Indian Industry

Confederation of Indian Industry

This page was created using NitroPDF trial software. To purchase, go to http://www.nitropdf.com/

Energy Efficient Motor Part load Operation 94 90 80 76 1 5 10 Horsepower 50 100 Standard motor Energy efficient motor

Case Study : Energy Efficient Motor

Textile plant, installed 5 nos x 11 kW of energy efficient motors Energy savings achieved
Standard motor : 85.5% Eff, Cost Rs.13,600/each EE motor : 91.5% Eff, Cost Rs.18,000/-each
Annual Savings Additional investment Payback period : Rs.58,500/: Rs.22,000/: 5 months

Confederation of Indian Industry

Confederation of Indian Industry

Estimation of efficiency at site

Motor efficiency measurement kits available Without disconnecting motor
Measurement of electrical parameters
kW, V, I, PF, Speed, Stator resistance

Overall Voltage optimization

Loading of all motors in plant Overall voltage optimization in case of loading less than 80% in all motors Reduction in applied voltage
Reduced iron loss in all motors, No increase in current due to lower loading of motors

Analysis with motor efficiency measurement kit

Reduction in voltage depends on actual loading

Vary plant to plant

Estimation of efficiency closer to lab value

Confederation of Indian Industry

Recommend to reduce in steps Availability of OLTC with AVR control in transformer

Confederation of Indian Industry

Case Study: Overall Voltage optimisation Distribution Transformer 2000 kVA, 433 Volts Supply Voltage LT Motors Loading : 20 80% Transformer tap position reduced from normal tap
Voltage before optimization = 420 Volts Average Load Optimized voltage = 850 -900 KW = 400 405 V

Role Of Frequency In Process Plant

Pumps, fans & compressors are major loads 50 - 60 % power consumption Majority of loads are centrifugal in nature Power cons. Rpm3 10 - 20% over design is common Excess head & capacity controlled Controlled using valves/dampers/ recirculation Energy inefficient methods of control
Confederation of Indian Industry

Annual Savings

Rs.1.3 Lakhs

Confederation of Indian Industry

This page was created using NitroPDF trial software. To purchase, go to http://www.nitropdf.com/

Role Of Frequency In Process Plant

Variable frequency drives are ideal choice Captive Power Plant Reduce the frequency and optimise Majority of case low frequency is helpful reduce energy consumption Reduction in Frequency depends on capacity utilisation of Pumps, Fans, Mills and other drives
Confederation of Indian Industry

Optimise the TG set operating frequency Paper Plant Background

6.8 MW & 21 MW TG sets 23-24 MW load, 6.6 kV supply voltage Frequency optimisation Average Load Optimised freq Energy reduction
Annual Savings
Confederation of Indian Industry

= 49.5 Hz = 23 MW = 49 Hz = 220 kW
= Rs 38.64 lakhs

Loss in Transformer
Losses contributed by
Core No load loss Copper Loss Depends on load

Transformers
Transformer efficiency - 98-99% Optimum efficiency occurs, where

Iron losses

Copper losses

Confederation of Indian Industry

Confederation of Indian Industry

Three Phase Transformer-Typical Loss Chart

KVA Rating 500 750 1000 1250 Iron Loss 1030 1420 1770 1820 FL copper loss 6860 9500 11820 12000

Types Of Transformers
Distribution Transformer Normal Efficiency- 98% to 99% Iron losses is 10% to 15% of full load copper losses Optimum efficiency occurs between 40% to 60% of loading

Loss in watts
Confederation of Indian Industry Confederation of Indian Industry

This page was created using NitroPDF trial software. To purchase, go to http://www.nitropdf.com/

Case Study
11 KV

Case Study
Background

CB

CB

Capacity of transformer 2000 KVA Load on the transformer is 80% Iron loss = = 2.3 Kw 21 Kw

2000 KVA 11 KV / 433 V 80% Load

2000 KVA 11 KV / 433 V

CB

CB

F L Copper loss

415 V
Confederation of Indian Industry Confederation of Indian Industry

Operate Both The Transformers In Parallel

Loss calculation One transformer operation (2.3) + 21 x (0.8) 2 = 15.7 KW Both transformers are in operation [(2.3) + 21 x (0.4) 2]x 2 = 11.3 KW Annual Savings= Rs. 1.40 Lakhs

Replace Eddy Current Drives with Variable Frequency Drives Eddy current drives Speed control 55 kW motor for Cane carrier Electromechanical device
Set Value DC Supply

Confederation of Indian Industry

Confederation of Indian Industry

Replace Eddy Current Drives with Variable Frequency Drives Eddy current drives Loss increases with reduction in speed Latest VFD for speed control of cane carriers VFD operating efficiency 96 - 98% Energy Saving potential 25 -30%
Confederation of Indian Industry

Replace Eddy Current Drives with Variable Frequency Drives Eddy current drives 55 kW Actual Load 42 kW Eddy current drive loss 13 kW

Annual Savings Investment Payback

: : :

Rs.1.60 Lakhs Rs.2.75 Lakhs 21 Months

Confederation of Indian Industry

This page was created using NitroPDF trial software. To purchase, go to http://www.nitropdf.com/

Auto Power Factor Controllers

Maintaining high Power factor Incentive from various SEBs Most plants Maintaining around 0.99 PF with Leading PF during low load Auto Power Factor controllers
Maintains 0.99 to unity PF (Monthly average) Avoids leading PF Reduction in distribution losses Incentive from Electricity boards
Confederation of Indian Industry

Auto Power Factor Controllers

Thyristor switched capacitors
Maintaining unity PF for large plant with varying load

Advantages
Frequent switching capability Fast response Less than 20 ms Transient free switching Heavy duty design Harmonic absorption

Auto PF Controllers ensures healthy of electrical system and Reduces distribution losses
Confederation of Indian Industry

Case study - Auto Power Factor Controllers

7000 kVA load Engineering Unit 250 kVAr x 2 Nos of APFC panel Incentive for high power factor (0.99 avg) Rs.9.0 Lakhs/Yr Reduction in Distribution Losses Rs.1.62 Lakhs/yr Very Attractive, wherever Incentive for high PF
Annual Savings Investment Payback : Rs. 10.62 Lakhs : Rs.6.0 Lakhs : 7 Months
Confederation of Indian Industry

Voltage Drop Measurement

In a large complex distribution system, voltage drops are very common Acceptable limit in a 3 Ph. System is 4-5 Volts / Phase More than 5V/Phase indicates energy loss in the distribution

Confederation of Indian Industry

Reasons For Voltage Drop

Poor power factor Inadequate cable size laid Poor contact surface at Cable Termination Cable joints Contactors/Switches

Case Study-Voltage Drops

Voltage drop PCC to MCC
Measurements Voltage at Sub station = 418 V Voltage at DB end = 405 V Drop in Voltage = 13 Volts Load current = 225 A Power factor = 0.6 Lag Cable size = 1R x 3C x 300 Sq.mm
Confederation of Indian Industry

Confederation of Indian Industry

This page was created using NitroPDF trial software. To purchase, go to http://www.nitropdf.com/

Case Study-Voltage Drops

Present cable loss = 5.1 kW

CII Godrej GBC Achievements

950 Detailed Audits Conducted

Capacitor installed at Load end 60 kVAr Reduction cable loss = 2.5 kW Capacitor relocated

Annual savings

Rs. 0.76 Lakhs

Rs. 1950 Million Savings Achieved

Confederation of Indian Industry

Confederation of Indian Industry

Facilities with CII-Godrej GBC

Team of experienced engineers
Energy, Environment, Water

To Sum up
Energy efficient electrical Equipment
Continuous improvement in Technology Reliable & Successful Huge energy saving potential

Sectoral strengths
Paper, Cement, Chemical, Pharma, Fertilizer, engineering, Automobile & other industries

State-of-the-art instruments Access to international Green service organizations/experts

USAID, CIDA, UNIDO,

Several approaches for energy conservation Electrical Engineers to Tap the potential

Databank
Confederation of Indian Industry Confederation of Indian Industry

Thank you
Visit us: www.greenbusinesscentre.com Queries k.sivaram@ciionline.org
Confederation of Indian Industry

This page was created using NitroPDF trial software. To purchase, go to http://www.nitropdf.com/