ENERGY EFFICIENT TECHNOLOGIES IN ELECTRICAL SYSTEMS

ENERGY EFFICIENT TECHNOLOGIES IN ELECTRICAL SYSTEMS

Syllabus
Maximum demand controllers, Automatic power factor controllers, Energy efficient motors, Soft starters with energy saver, Variable speed drives, Energy efficient transformers, Electronic ballast, Occupancy sensors, Energy efficient lighting controls

MAXIMUM DEMAND CONTROLLERS

Maximum Demand Controller is a device designed to meet the need of industries conscious of the value of load management.
Alarm is sounded when demand approaches a preset value. If corrective action is not taken, the controller switches off non-essential loads in a logical sequence. This sequence is predetermined by the user and is programmed jointly by the user and the supplier of the device. The plant equipments selected for the load management are stopped and restarted as per the desired load profile. Demand control scheme is implemented by using suitable control contactors. Audio and visual annunciations could also be used.

AUTOMATIC POWER FACTOR CONTROLLER

Various types of automatic controls are available with relay / microprocessor logic. Two of the most common controls are: Voltage Control and KVAR Control Voltage Control Voltage is used as a source of intelligence. capacitors are applied at point where the circuit voltage decreases as circuit load increases. Generally, used where the applied the voltage decrease as circuit load increases and the drop in voltage is around 4 5 % with increasing load. This type of control is independent of load cycle. During light load time and low source voltage, this may give leading PF at the S/S, which is to be taken note of.

AUTOMATIC POWER FACTOR CONTROLLER

KILOVAR Control Kilovar sensitive controls are used at locations where the voltage level is closely regulated and not available as a control variable. The capacitors can be switched to respond to a decreasing power factor as a result of change in system loading. This type of control can also be used to avoid penalty on low power factor by adding capacitors in steps as the system power factor begins to lag behind the desired value. Kilovar control requires two inputs - current and voltage from the incoming feeder, which are fed to the PF correction mechanism, either the microprocessor or the relay.

AUTOMATIC POWER FACTOR CONTROLLER

Automatic PF Control Relay APFCR is installed to switch ON & switch OFF capacitors for PF correction. Different types of APFCR are available:
Same rating Capacitor switching Appropriate rating Capacitor switching Static VAR Control switching

ENERGY EFFICIENT MOTORS

1.Why is improving Motor efficiency important? Induction Motors consume 70% of total electrical 80% of motors are less than 15kW where efficiencies are generally lower with good scope for improvement Energy efficiency should be a major consideration when you purchase or rewind a motor Loading of motors also plays important role in selecting appropriate rated efficiency. energy

ENERGY EFFICIENT MOTORS

Watts Loss Area 1. Iron Efficiency Improvement 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. Use of more copper and larger conductors increases cross sectional area of stator windings. This lowers resistance (R) of the windings and reduces losses due to current flow (I). Use of larger rotor conductor bars increases size of cross section, lowering conductor resistance (R) and losses due to current flow (I). Use of low loss fan design reduces losses due to air movement. Use of optimized design and strict quality control procedures minimizes stray load losses.

2. Stator I 2 R

3. Rotor I 2 R

4. Friction & Windage 5. Stray Load Loss

ENERGY EFFICIENT MOTORS

ENERGY EFFICIENT MOTORS

What efficiency values should I use when comparing motors? IS-325 allows variation in efficiency, IS-12615 does not allow variation Efficiencies must be brought to common specification for comparison When should I consider buying energy efficient motors? For all new installations/modifications Instead of rewinding old standard efficiency motors To replace over sized under loaded motors As a part of energy conservation program considering motors that work in excess of 2000 hours per annum and ratings less than 37 kW Rewinding reduces efficiency by 1% to 2% or more if it is a very old motor. Better to replace with EE motor if rewinding cost

SOFT STARTERS
Usually the load starting torque is near zero, an induction motor will develop far too much torque when connected directly to the supply. So, At the instant of start-up, there is an un-necessary heavy power surge on both the electrical supply and the mechanical drive components. The sudden impact at start up on the load, followed by the rapid acceleration to full speed causes excessive wear on :1. Belts and pulleys 2. Gears and chains 3. Couplings and bearings and :4. Cavitation in pumps etc........

SOFT STARTERS
Is based upon the silicon controlled rectifier or thyristor. By pulsing a thyristor, it switches from off to on until the current stops flowing though it - which occurs every half cycle in an AC. supply. By controlling electronically the thyristor turn on point, it is possible to regulate the energy passing through it.

SOFT STARTERS
By starting with a large delay angle (firing angle of SCR) and gradually reducing it , the motor terminal voltage is increased from a low value to full voltage, giving a smooth, step less, start. Starting methods:
Voltage ramp (with & without kick-start) Current limit (with & without kick-start)

Stopping methods
Soft stop with voltage ramp Smart motor braking SMB

Special Controls
Preset slow speed Slow speed with braking

MOTOR STARTERS

600-700%

DIRECT-ON-LINE

STAR-DELTA

CURRENT

SOFT START

100%

TIME

SOFT STARTERS - ADVANTAGES

Optimising continuously, improves the part-load efficiency by reducing the degree of over-fluxing of the stator in the motor The part load PF of the motor is improved. This produces a significant reduction in kVAr and kVA, as well as a useful reduction in kW. Electrical losses in the stator and feed cables are also reduced. Motor performance is not impaired. The life of frequently-started drives and of reversing drives is considerably extended by the soft start action.

VARIABLE SPEED DRIVES

BY installing Variable speed drives Substantial energy saving can be achieved in addition to the other benefits such as smooth variation in flow / pressure increased motor life precise output control. Classification: Fluid coupling Eddy current drives Electronic control systems Slip-power recovery systems

VARIABLE SPEED DRIVES

Basic laws of fluid mechanics Flow is proportional to Speed Head is proportional to (Speed)2 Power is proportional to(Speed)3 Theoritically------- If a pump is overdesigned for 30% flow with 100 kW power drawn, then optimising speed to required flow can P=(0.7)3* 100 kW =65% of original power

VARIABLE SPEED DRIVES Earlier technologies used Wound rotor controllers with resistors Constant potential DC motors armature series resistance control Variable speed clutches MG sets Gears/Pulleys Variable speed fluid coupling Rotary or static frequency converters with

VARIABLE SPEED DRIVES

Speed Control Alternatives for AC Induction Motors Electro-Mechanical Control Methods Gears, pulleys, etc. Variable pulley sheaves Gears Chains Friction Drives Multi-speed Motors Eddy-current drives Advantages Disadvantages

Low Cost Low power savings; high Low Cost maintenance costs Low Cost Stepped speed control; lower Low Cost efficiency than singly-speed Operation at 2 or 4 motors fixed speeds Needs DC excitation; low Simple; relatively low efficiency at below 50% rated cost; step less speed speed control Low efficiency at below 50% Fluid coupling drives Simple, relatively lost rated speed. cost; stepless speed control.

VARIABLE SPEED DRIVES

Speed Control Alternatives for AC Induction Motors VSD
Voltage Control 25 kW, 20-100% Cycloconverter 75 kW, X 30-50% of Supply frequency Voltage source invertor 750 kW, 100 : 1 Current source inverter 25 kW, 100:1 Pulse width modulation 750 kW, 100:1 Slip power recovery 500 kW 50 100% (Kramer) 50 150% (Scherbius)

Advantages
Simple: low cost

Disadvantages
Harmonic; low torque; low efficiency; limited speed range.

Solid State Electronic Control Methods

Can operate down to zero Complex circuit Design; poor power speed, High torque factor at low speeds capability No regenerative braking; problems a Good efficiency; simple low speed (10%) circuit design Regenerative braking; simple circuit design Good power factor; low distortion VSD power rating less than motor rating Poor power factor; poor performance at low speed No regenerative Braking; slightly less efficient than VSD Can use only with slip-ring induction motor

Eddy Current drives

Eddy current clutch mechanism is used. Primary member connected to shaft-and freely revolving secondary member is connected to load shaft which is excited by varying DC to induce eddy currents in shaft. The interaction of two fluxes gives rise to a torque at load shaft which can be varied . Poor efficiency

Solid state electronic VSD

Controls the voltage and frequency delivered to the motor to change its speed. Typical full-load efficiencies > 95% Efficiency of VSDs generally decrease with speed but since the torque requirement also decreases with speed for many VSD applications, the absolute loss is insignificant. In a suitable operating environment, frequency controllers are relatively reliable and need little maintenance. Major disadvantages: Harmonics are high

Slip Power Recovery Systems

More efficient alternative speed control mechanism for use with slip-ring motors. By varying rotor voltage to control speed & dissipating power through resistors, the excess power is collected from the slip rings and returned as mechanical power to the shaft or as electrical power back to the supply line. Tends to be economical only in relatively high power applications and where the motor speed range is 1:5 or less.

Fluid Coupling
Most of their operating time at well below their rated load. Generally an oversized motor is selected to cope with more than twice normal load at start-up. High starting torque is required to overcome the inertia of heavily loaded machinery. Motors operate less efficiently than it is designed to do and greater energy losses occur than if the same duty were performed by a lesser rated motor. Ability of the Fluid Coupling is to provide a soft start and yield overload protection for the motor.

Fluid Coupling Role of Fluid Coupling Smaller Motor for Running Duty Reduced Current Demand During Starting Reduced Heating in Motor Over Load Protection

ENERGY EFFCIENT TRANSFORMERS

Dry-type transformers, for a variety of reasons, have largely replaced oil-filled units within industrial, commercial and institutional buildings. But first cost is not the last cost of any transformer. Complete life-cycle costs must be carefully examined along with the economics of high-efficiency dry-type transformers.

ENERGY EFFCIENT TRANSFORMERS

Advantages Fire Safe. Zero Maintenance No monitoring Environment friendly Clean & compact installation Reduced civil costs. Disadvantages High capital cost Limitations in Harmonic environment Replacement/repair cost high

ENERGY EFFCIENT LIGHTING

Electronic Ballast
Conventional ballasts make use of the kick caused by sudden physical disruption of current in an inductive circuit to produce the high voltage required for starting the lamp and then rely on reactive voltage drop in the ballast to reduce the voltage applied across the lamp. The high frequency electronic ballast overcomes the above drawbacks. The basic functions of electronic ballast are: To ignite the lamp To stabilize the gas discharge To supply the power to the lamp significant benefit resulting from this phenomenon is the absence of stroboscopic effect, thereby significantly improving the quality of light output.

Ballasts for Fluorescent Lamps

Magnetic
supply frequency (50Hz) operation May produce audible hum May produce noticeable lamp flicker Less efficient lamp operation

Electronic
High frequency (20 to 50 kHz) operation Quiet No noticeable lamp flicker More efficient lamp operation

Ballasts for Fluorescent Lamps

Electronic Ballast Types Instant start
Most efficient May sacrifice lamp life if frequently switched Cannot be dimmed

Rapid start and Programmed start

Generally consumes an additional 2 watts More gentle starting for frequent switching Can be dimmed (if a dimming ballast is selected)

ENERGY EFFCIENT LIGHTING

Compact Fluorescent Lamp: The new low energy and highly cost effective compact fluorescent lamp is a recent addition to modern lighting technology and is an attractive alternative to incandescent lamps.
Energy Cost Comparison Lamp Incandescent Compact Fluorescent Wattage W 60 9 Efficacy LM/W 12 67 Average Life (Hrs) 1000 7500 Energy Saving % 80

ENERGY EFFCIENT LIGHTING CONTROL

Timers& Timed Switches Sensors & Photocells

ENERGY EFFCIENT LIGHTING CONTROL Timers can be effectively utilized for basic on/off
operation of lighting fixtures. By utilizing low voltage relays, large numbers of fixtures can be controlled by a single timer, thereby making it very cost effective.

Timed Switches are switches that incorporate a timed

function, to ensure that the fixtures are turned off after a preset interval of time, typically one to two hours.

ENERGY EFFCIENT LIGHTING CONTROL

Sensors
Three Types of Occupancy Sensors:

Passive Infrared Ultrasonic Dual-Technology (a combination of PIR and Ultrasonic)

Passive Infrared Occupancy Sensors

Triggered by the movement of a heat-emitting body through their field of view. Best suited for enclosed Occupants must direct site sensor. small, spaces. be in line-ofview of the

Ultrasonic Occupancy Sensors

Emit an inaudible sound wave. Triggered by changes in the reflected sound. Provides coverage without gaps.

Monitored Savings of Occupancy Sensors

Private Offices Conference Rooms Classrooms Restrooms
(Savings Do Not Include HVAC Reduction)
Source: Lighting Research Center, Study For EPA in 158 Locations

45% 50% 51% 68%

NATURAL LIGHTING
Use of natural lighting saves tremendous amount of lighting energy. One has to integrate natural lighting along with bay lighting in industrial workshops.