ENERGY AUDIT

D.S. MALLICK
 BACKGROUND….
1972 - Acknowledgement of energy

efficiency in “Fuel Policy

Committee” Report.

1975 - Formation of “Petroleum

Conservation Research
Association”.

…..
 Background [contd….]
1980–’90 – Agreement with :
• International Development (UK)
• German Federal Ministry
• USAID
to assist energy efficiency programme

Indian Institutions to offer similar

programme:
• TERI
• CII
• ICICI
…..
Background [contd….]

1984 – “Energy Management

Centre” created in the
Power Ministry, now
converted to “Bureau of
Energy Efficiency”.
 ENERGY MANAGEMENT

OBJECTIVES:

 Conservation of scarce & finite

resources by enhancing
efficiency of energy conversion
and end use
RESULT

 Improve profitability

 Reduce GHG emission

 Reduce solid waste and

thermal pollution
Sectarian Share of Commercial Energy

 Industry : 35%

 Agriculture : 30%

 Transport : 20%

 Domestic &
Commercial : 15%
 Present Energy Saving Potential in India

 Industry : 25%

 Agriculture : 30%

 Transport : 20%

 Domestic &
Commercial : 20%
Policies to Improve Energy Efficiency

 Good house keeping

 Regulation/Standards
 Industrial Co-generation
 Fuel switching
 Fiscal policies like tax rebates/subsidies
 Benchmarking
 Energy audit
 Information dissemination &demonstration
 R&D
 Energy Consumption & Scope for
Energy Conservation in Energy
Intensive Industries

Industry Energy cost Scope for

as % of Mfg. energy
cost consumption
Aluminium 40% 20%
Textile 13% 25%
Chloro Alkali 35% 15%
Petrochemical 7% 15%
Fertilizer 60% 10%
Paper 25% 20%
 Energy Consumption & Scope for
Energy Conservation in Energy
Intensive Industries [Contd..]

Industry Energy cost Scope for

as % of Mfg. energy
cost consumption
Cement 40% 10%
Glass/Cermics 30% 15%
Food 30% 15%
Steel 25% 10%
OVERALL SAVING POTENTIAL – 25%
 AGRICULTURE

 Around 18 million pump sets

 60% driven by electric motors,

rest by diesel engines.

 About 0.6 million pump sets being

added each year
Strategy for energy conservation
in Agriculture
 Conversion of diesel pump
to electric pump

 Community Scheme

 Energy efficient tilting

 Development of Fertilizer

 Development of Bio-technology
 Commercial Sector

Major end users :

 Lighting
 HVAC

Scope of energy conservation

- 15-20%
 Domestic Sector

 Household sector consumes

20% of total electricity

 Scope of energy conservation

- 15-20%
 TRANSPORT
• consumes 112 million te per year of oil in
transportation out of 114 MT consumption.
• 75% imported at 1,20,000 crores.
• As per PCRA, 20% saving in oil can be achieved
by following simple habits….

* good driving
* check tyre pressure
* avoiding spillage
* check fuel filters
* keep the engine well-tuned

-- so on - -
WHAT IS INDUSTRIAL ENERGY AUDIT?

• It serves the purpose of

identifying where energy
conservation opportunities
can be effected in a
plant/building
Energy Conservation at Macro
Level

• Measure of Encon activities

• Reduction in specific energy

consumption
Energy Conservation at Macro
Level…

Three pronged approach

 Capacity utilisation
 Fine-tuning
 Technology upgradation
Energy Conservation at Macro
Level…
• Excellent companies
have tapped all three
opportunities

• Separate teams with

common objective
Energy Audit Methodology

Systematic approach
Ask questions like :

• What?
• When?
• Why ?
• Where?
 Macro Level - Methodology
Any process/unit operation

Unavoidable losses
(c)
Energy Theoretical
Input (a) Requirement
(b)
(d)
Avoidable losses
a= b+c+d
 Macro Level Methodology….

Focus should be:

• To concentrate on avoidable
losses
• Quantify the losses
• Identify ways & means for
reduction
• Implementation
PUMPS
 TYPES OF PUMPS

Centrifugal
Moderate pressure (upto 6000 m
wc)
• Moderate Capacity (upto 10,000
m3/hr)
- Upto 30,000 m3/hr in case of
concrete volute pumps
• General applications
 LIFE CYCLE COST FOR A PUMP

Initial Cost 2%

Maintenance Cost 8%
Energy Cost 90%
 Energy Parameters

Major parameters are

 Capacity or flow

 Head or pressure

 Efficiency
 Efficiency

 Pump  (%) = Pump output

Input to pump[BHP(O)]

 
Pump  (%) = Flow (lps) x Head (m) x Sp.Gr.
102 x (motor) x kw (I)
 
 
 Actual Efficiencies
 Normal = 60-75%

 Best = 78-80%
(upto 85% efficiency in case of
horizontal split casing pumps)

 Worst = 30-60%
 Depends on Type of Impeller

• Open : Best – 60%

• Semi-open : 65%

• Closed : 80%
 Pumps Formulae..

 Capacity : (RPM)

 Head : (RPM)2

 Power : (Capacity x Head)

(RPM)3
 Pumps Formulae

If the RPM is reduced by say 10%,

what will Happen to the

• Capacity : Reduce by 10%

• Head : Reduce by 19%

• Power : Reduce by 27%

 Reasons for excess power
consumption

 Wrong selection
 Over design
 Improper layout
 Old inefficient pumps
 Multiple smaller size pumps
 Ad-hoc decisions
 Approach to Energy Conservation

in Pumps
Install Flow & Energy meters for all major
pumps
 Observe Flow & Power consumption
pattern
- Hourly, Shift & daily basis
 Identify pumps having major power
consumption
 Explore Energy saving possibilities
- Apply 80-20 rule
 Algorithm for Oversized
Pumps…
 Major problem is over-sizing of
pumps

 Indicated by valve control or

recirculation

 Scan all pumps for valve control

 Algorithm for Oversized Pumps

 Concentrate on pumps with less than

40% valve opening

 Cross check design with actual

requirements

 Look for alternatives

- Impeller reduction
- Correct size pump
 Pump Capacity Control…

 On/Off type
 Recirculation
 Valve control
 Pump speed control
- RPM reduction (pulley)
 Mechanical systems
- Variable fluid coupling
- Variable gear boxes
 Effect of Various Capacity Controls
kw in %

VFD Ideal

Q in %
Use Gravity Flow as Much as Possible

3.5 HP
Hot well pump
Hot well
Use Gravity Flow as Much as Possible
Use Gravity Flow as Much as Possible
Use Gravity Flow as Much as Possible
 Optimum Margins
Excessive margins – due to uncertainty

Optimum margins required

 Head - 10%

 Capacity - 10%

 Power - 10 to 20%
 FANS & BLOWERS
 Simple Definition
* Machines to move gases (or) gases
mixed with small solid particles

 Operation of fans similar to pumps

 Broad Classification
* Centrifugal
* Axial
Difference Between Fans, Blowers
and Compressors
As per ASME Definition….

Equipment Specific Pressure rise

Pressure* (mm WG)
Fans < 1.11 1136
Blowers 1.11 to 1.20 1136-2066
Compressors > 1.20
* Ratio of discharge pressure to suction
pressure
 Energy Saving Potential

Fans & Blowers – Major Energy Consumer

• Cement
• Paper
• Power Plants
• Sugar
- Energy consumption – 10 to 25%
depending on Type of Industry

- Energy Saving Potential – about 25%

 Fans & Blowers - Formulae

 Capacity: (RPM)

 Head : (RPM)2

 Power : (Capacity x Head)

: (RPM)3
 Effect of Various Capacity Controls
kw in %

VFD Ideal

Q in %
 Throttling of a Fan

 Suction / Delivery

 Why?
Power Consumption – Oversized Fan

Fan designed Actual requirement

. 1,20,000 m3/hr. . 90,000 m3/hr.

. 650 mm Wg . 510 mm Wg
Potential in oversized Fan

Energy saving potential in oversized fan

= P across damper x Power Cons.

Total pressure rise

= [(720 – 500)/(10 – (-720)] x 289 KW

= (220/730) x 289 kw

= 87 kw
 Install VFD for Boiler ID Fan
 Control by Varying Speed
 Damper – 100% Open

Power with damper = 53 kw

Power with VFD = 29 kw
Savings = 24 kw
 
Annual Savings – Rs.7.76 Lakhs
Investment – Rs.6.85 Lakhs
Payback period – 11 Months   
Replace Centrifugal Fans with Axial Fans

Advantages

o High efficiency of 85%

o Lower weight
o Lower starting torque requirements for the
motor
o Lesser foundation requirements
o Nearly same efficiency for a wide range of
operation – part load & full load efficiencies
are almost same
Replace Centrifugal Fans with Axial Fans

Parameters Centrifugal Axial

Capacity (m3/h) 181880 120000

Pressure (WG) 0.98” 1”

Power (KW) 22 12

Efficiency () 41% 80%

Annual savings : Rs.2.9 Lakhs

Investment : Rs.1.5 Lakhs
Payback : 6 months
MOTORS
 Watts Losses
 Stator & Rotor Losses – I2R

 Iron Loss

 Friction & Windage Losses

 Stray Load Losses

Motor Power Loss Model

Motor Load

Typical range
 Motor Efficiency - Improvement

Capacity  Voltage2

 Energy Waste - Causes

• Use of less efficient motors

• Oversized/under loaded motors
• Improper supply voltage
• Voltage fluctuations
• Poor power factor
• Less efficient-driven equipment
• Idle running
 Voltage Optimisation
Impact on motor operating parameters

 Reduction in voltage dependent losses-

Drop in Magnetization current
 Capacity reduces
 PF improves
 Load current drops
 Load factor improves
 Efficiency improves
 Optimisation of Lightly Loaded Motors

Options – Lightly loaded motors

 Delta to permanent star – Steady load

applications
 Automatic star-delta-star converters –
for shock loads
 Soft starter cum energy savers – high starting
starting torque applications
 Down sizing
 Overall voltage optimization
 Optimisation of Lightly Loaded Motors

Option based on

• Nature of load

• Load factor

• Economic option
 Convert Delta to Star Connection At
Lightly Loaded Motors

Motor  and power factor varies with % loading

For lightly loaded motors (38%)

 Voltage related losses – high
 Power factor is very low
 More copper losses
 Motor operates in less efficiency range
Convert Delta to Star Connection
At Lightly Loaded Motors

Motors normally operated in delta mode

Lightly loaded motors can be operated in star

mode

Effect on motor performance operating in star

mode
 Reduction in voltage related loses
 Operates with improved P.F.
 Reduction copper losses
 Motor efficiency improves
 CASE STUDY
Convert Delta to Star Connection at Exhaust
Blower Motors
 Rated kw – 39 kw (4 nos.)

 Actual load

• Delta mode = 10.5 kw

• Star mode = 8.0 kw
• % Load = 35%
• Savings in kw = 2.5 kw

Annual Saving = Rs.3.0 Lakhs

 Automatic Star-delta-star

 Application – motors with shock loads

 Automatic star-delta-star converter has load

 sensor & Timer

 Capacity  V2

 Principle of voltage optimisation

 CASE STUDY
Install Automatic Star Delta Star
Starter for Coal Crushers

 Most of the time lightly loaded

 Subject to heavy load
• Rated KW = 90.0 kw (3 nos.)
• Actual load = 35.0 kw
• In star mode consumes = 33.0 kw
• Savings in kw = 6.0 kw

Annual Savings : Rs.4.78 Lakhs

Investment : Rs.1.00 Lakhs
Payback period : 3 months
 Soft Start Cum Energy Saver..

Continuously senses the load

Applies voltage automatically in accordance

with the load factor-close loop control system

Supplies energy needed to perform work task

Smooth accelerating facility

Ideal for belt conveyors and fluctuating loads

 Soft Start Cum Energy Saver..

Applications

Centrifuges

Crushers

Chippers

Extruders

Agitators
 CASE STUDY
Install Soft Starter Cum Energy Saver
For Identified Simplex Machines

 Rated kw of the motor = 15.0 kw

 Actual load = 6.5 kw
 Loading = 43%
 Type of load = Varying
 Total no. of machines
in operation = 10 Nos.

Annual Saving = Rs.5.50 Lakhs

Investment = Rs.5.00 Lakhs
Payback period = 11 months
 Optimise the plant operating
Voltage - Overall

Plant operating voltage plays a critical role in

energy conservation

Suggested to have on line voltage optimising

devices to regulate the operating voltage as
required

Magnetization losses vary exponentially with

the voltage
 Optimise the plant operating
Voltage – Overall..

Capacity  V2

Torque  V2

Voltage optimisation will vary the capacity of

the motor

Implemented after analysing the loading

pattern of all motors
 CASE STUDY
Voltage Optimisation - Overall
o Engineering industry – operated with OLTC
Transformer
o Majority of the motors are loaded less than 50%
o Voltage before optimisation = 425v
o Kw load at 425v = 2800 kw
o Optimised voltage = 400v
o Kw reduction at 400v = 45kw

Annual Savings = Rs.13.80 Lakhs

 Role of Frequency in Process Industry

 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

 Role of Frequency in Process Industry

 Controlled using valves/dampers/recirculation

 Energy inefficient methods of control

 Variable frequency drives are ideal choice

 Majority of case low frequency is helpful –

reduce energy cons.
Energy Management Based on Frequency

ø Operate captive power plant (DG set & TG

set) at lesser frequency incase of process
industry

ø Speed correction (pulley size adjustment)

in case of textile & engineering industry

ø Optimise system voltage based on

frequency
 Optimise the TG Set Operating
Frequency – 16.0 MW
Case study from Paper Industry

Operating frequency = 50 hz
Respective mw consumption = 12 mw
Majority of the equipment loading=50 – 80%
Reduced operating frequency to = 49 hz
Reduction in frequency = 1 hz
Reduction in kw = 300 kw

Annual Savings achieved = Rs.72.0 Lakhs

 Energy Efficient Motor

 More Cu wire in stator and rotor to cut

resistance losses
 Longer stator and rotor cores to reduce
magnetic losses
 Precision air gaps to reduce current
requirements
 Improved windings and lamination designs to
maximise energy consumption
 Special steel processing in stator to minimise
core losses
 Energy Efficient Motor..

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

 Better quality bearings are used

 Replace Conventional Old Motors With
Energy Efficient Motors

Þ It has been implemented in many industries

Þ Case study is from one of the textiles industry

Þ Ring frames are vital and continuously

operating equipment in textile industry

Þ Total number of RF machines – 30 Nos.

Replace Conventional Old Motors With
Energy Efficient Motors
Continuous operation
Results:

Motors Rated No Load Load

kw kw kw
Old motor 15.0 23.2 9.92
Energy efficient 15.0 1.56 7.36
motor
Difference in 0.76 2.56
consumption
Annual Savings : Rs.23.0 lakhs
Investment : Rs.12.0 lakhs
 Rewound Motors

Motor Burning

 Quality of insulation between stampings

deteriorated
 Eddy current losses increase
 Magnetic property deteriorated
 Magnetic losses increase
 Causes drop in efficiency
 Rewound Motors

Bearing failure
 Rotor scratches stator
 Air gap becomes uneven
 Torque induced not uniform
 Net torque developed is low
 Causes drop in efficiency

 Motors replacement should be analysed

case to case basis

 Maximum 3 times motor can undergo

rewinding – normal failure
Electrical Distribution System
 Voltage Drop Measurement

In a large complex distribution system,

voltage drops are very common

Acceptable limit in a 3Ph. System is

4-5v/phase

More than 5v/phase indicates energy

loss in the distribution
 Voltage Drop Measuring Procedure

 Measuring instruments should be calibrated

 Simultaneous measurement of voltage in the

feeding and receiving end of the feeder

 Measure P.F. & current

 Note the capacity of the power cable used

 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

 From Engineering Industry

Measurements

 Voltage at sub station = 415V

 Voltage at LT panel = 398V
 Load current = 180-200A
 Power factor = 0.4 Lag
 Cable size = 1R x 3C x 300Sq.mm
 Case Study – Voltage Drops

 Relocate 90KVAR Capacitor bank from SS to

LT panel

 Reduced 50% of energy loss

(Approx. 1Kw/Ph.)

Annual Savings = Rs.0.60 Lakhs

TRANSFORMERS
 Losses in Transformer
 Efficient Transformer – 1% loss
 Substantial at higher ratings

 Losses contributed by

 Core – Noload loss

 Conductor – Depends on load

 To Reduce Iron Loss

Various core metals designed

• Alloying steel with silicon

• Hot rolled grain oriented silicon steel

• Cold rolled grain oriented silicon steel

• Latest - amorphous
 Transformers

 Transformer efficiency = 98 - 99%

 Optimum efficiency occurs, where

Iron losses = Copper losses

Three Phase Transformer –
Typical Loss Chart

KVA Rating Iron FL copper

Loss loss
500 1030 6868
750 1420 9500
1000 1770 11820
1250 1820 12000
* Loss in watts
 Types of Power 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
 Types of Power Transformers
Power transformer

• Normal efficiency - 99% to 99.5%

• Iron losses is 20% to 25% of full load

copper losses

• Optimum efficiency occurs between

60% to 80% of loading
 POWER CAPACITORS
How poor operating power factor cost money?

 Maximum demand increases for the same

load

 Draws more current for the same load

 More distribution voltage drop i.e. loss

in the distribution cable increase

 Copper loss in the transformer increase

 POWER CAPACITORS…

 Capacitor banks install to improve

power factor
 Allowable power loss = 3-5 w/Kvar

Reasons for failure

 Ageing
 Input voltage and frequency fluctuation
 Harmonics present in the system
 Temperature around the bank
 Poor quality capacitors use in the
construction
 Replace Faulty Capacitor Banks

 Power measurement taken with digital

power meter

Indication:

 Power consumption above the

permissible level

 Temperature on the body is above

ambient temperature
 Replace Faulty Capacitor Banks….

 Identified 10 Nos. of 50 kvar faulty banks

Annual savings = Rs.1.8 Lakhs

Investment = Rs.2.2 Lakhs

Payback = 14 months
LIGHTING SYSTEM
 Lighting

Essential for any working environment

Power consumption - 2 to 10% for

different industries
 Terminologies

 Flux emitted by lamp – lumens

 Luminous Efficacy – Lumens / watt

 Illuminance = Lumens / sq. meter (Lux)

 Colour Rendering Index – Colours of surfaces

illuminated by a given light source
 Types Of Lamps

 Incandescent lamps (GLS)

 Gas Discharge Lamps

 Fluorescent Lamps (FTL)
 Compact Fluorescent Lamps
 Mercury Vapour Lamps
 Sodium Vapour Lamps
 Metal Halide Lamps

 LED Lamps
Comparison of Various Lamps

Type Watt Lumens Efficiency

GLS 100 1380 14
Fluorescent
. Slim 36 2450 68
. Conventional 40 2770 69
Colour-80 series 36 3250 90
HPMV 250 13500 54
HPSV 250 27000 108
Metal halide 250 17000 68
CFL 20 1200 60
CFL Compact Fluorescent Lamps

 High efficiency lamp

 Low Wattage – Less heat dissipation

 Excellent colour rendering

 Long life – 8000-10000 glowing hours

 Highly suitable – living rooms, lounges,

corridors, hotels and canteens
 Comparison of GLS & CFL

GLS Watts 40 60 100

Lumens 425 720 1380

CFL Watts 9 15 20

Lumens 400 900 1200

 Case Study
Replacing GLS Lamps with CFL

Automobile Unit

 Corridors & Canteen – 100 Nos. of

60 watts GLS lamps
 Replaced with 15 watts CFL

Annual Savings : Rs.0.56 lakhs

Investment : Rs.0.40 lakhs
Payback period : 9 months
Energy Efficient Fluorescent Lamps

Tri-phosphor fluorescent powder technology

High colour rendering Ra-85 (conventional

FL Ra-65)

High luminuous efficacy

Conventional : 68 lumens/w
Energy efficient : 90 lumens/w
Energy Efficient Fluorescent Lamps..

40% more lumens

Ideal choice – new projects and

Places where existing lighting is poor

Paint shops, assembly bays, printing press,

Inspection areas
 Case Study
Replace Conventional Lamps
with EE Fluorescent Lamps

Engineering
Engineering Unit
Unit

Assembly
Assembly && Inspection
Inspection area
area –– 1600
1600 nos.
nos. of
of
36
36 Watts
Watts EE
EE Fl.
Fl. Lamps
Lamps –– at
at design
design stage
stage

Annual
Annual Savings
Savings :: Rs.1.20
Rs.1.20 lakhs
lakhs
 HPSV Lamps
 High efficiency - 108 Lumens/watt
 Colour rendering – Fair
 Godowns, storage yards, ware house,
highways, flood lighting and street lighting
Comparison of HPMV & HPSV

HPMV Watts 80 125 250 400

Lumens 3500 6250 13500 23000

HPSV Watts 70 150 250 400

Lumens 5800 13500 27000 47500

 Case Study
Replace HPMV Lamps with HPSV Lams

Cement Plant
 Street lighting, yard lighting and some
plant area
. 120 Nos. 250 watts HPMV

Replaced by 120 Nos. 150 watts HPSV

Power Savings : 12 KW
Annual Savings : Rs.1.60 lakhs
Investment : Rs.2.00 laksh
Payback period : 15 months
 Metal Halide Lamps
 Gas discharge lamps – iodide additives

 Excellent colour rendering (Ra-69)

 Highlight output

 Suitable for colour critical areas

 Uses HPMV ballast – additional igniter

 LED Lamps

 More suitable for panel indication

 Power consumption of the filament panel

indication lamps = 14-15 w/lamp

 Power consumption of the LED panel

indication lamps = 0.5 – 1.0 w/lamp

 Power savings = 14 W/lamp

 LED Lamps..

Advantages

 More life – 10000 hrs.

 Withstand for +/- 25% voltage fluctuation

 Energy efficient

 Cannot be used for illumination purpose

 LED Lamps..
Applications

Panel indication

Tower lighting

Textile machines post lamps

Signature

Board display lighting

 LED Lamps..
Case study from textile unit

 No. of filament lamps installed = 4000 nos.

 No. of lamps glowing = 2000 nos.
 Total power savings achieved = 28 KW

Annual Savings = Rs.8.0 lakhs

Investment = Rs.8.0 lakhs
Payback period = 12 months
 Lighting Control
Voltage Reduction – Discharge Lighting

Optimum voltage for discharge lighting –

205 – 210 volts
Reduction in voltage by – 15%

• Proportional drop in power consumption – 15%

• Insignificant drop in illumination level

• Only digital lux meters – measure the drop

(1-2%)
 Options – Voltage Reduction

Dedicated Lighting Transformer – different tap

settings – Ideal at Design stage

Automatic voltage regulation

- servo stabilizer

Advantages

* Reduction in power consumption

* Increases – life of lamp
 Case Study
Install Automatic Servo Voltage
Stabilizer in Lighting Feeder

Engineering Unit
Lighting load : 240 kw
Operating lighting voltage : 240 volts

Auto voltage stabilizer (300kv)-installed

Optimum voltage : 205 – 210 volts
Power savings : 30 kw (12.5%)

Annual Savings : Rs.4.40 lakhs

Investment : Rs.3.00 lakhs
Payback period : 9 months
 Installation of HF Electronic Ballast

Conventional ballast – Inherent losses -

14 – 15 watts / choke

HF Ballast – operates at high frequency –

20 kHz to 22 kHz
. Low loss – 1 to 2 watts/choke
. High power factor
. Instant start-up
. Operates at low voltage
. Low heat dissipation – less load on
air conditioners
 Installation of Electronic Ballast..

Case study from Engineering Unit

 No. of lamps installed = 2500 nos.

 No. of lamps glowing = 1800 nos.

 Total power savings achieved = 25 kw

Annual Savings = Rs.6.7 lakhs

Investment = Rs.7.2 lakhs
Payback period = 13 months
Summary Recommendations
 Maximum utilisation of natural light

 Select energy efficient lamps

 Installation of mirror-optic luminaries

 Fixing lights at optimum height

 Optimum voltage for lighting system

 Use energy efficient HF Ballast

....
Summary Recommendations [contd..]

 Use timer control switches for outside

lighting system

 Use movement sensor and dimmer

control system, wherever required.

 Proper grouping of lights and proper

control system
ENERGY CONSERVATION

IN

STEAM SYSTEM
 Importance of Steam System

Steam as heat transfer medium

 High specific heat capacity

 High latent heat

 Cheap and easily available

 Non toxic and inert

 High heat transfer coefficient

 Steam System
Considerable savings can be achieved by
systematic steam system audit.

Audit should cover:

• Steam Balance
• Steam turbine performance
• Condensate recovery
• Steam traps
• Co-generation
• Recycling waste heat
CO-GENERATION
WHAT IS COGENERATION?

COMBINED GENERATION OF

HEAT AND POWER

 WHY IT IS ECONOMIC ?

1. The conventional 2.Co-generation scheme

method of power uses this reject energy
generation in a fossil
fired power station has as process heat input
to reject about 60 - and hence, efficiency
70% of input energy. can reach 100%.
This is law of nature
and can never be
reversed.
COGEN ROUTES

1. High pressure steam - back pressure

or condensing-cum -extraction turbine
- extraction steam to process.

2. Gas turbine - exhaust heat - waste

heat recovery boiler - process steam
 CENTRAL POWER STATION
ENERGY SCENARIO

• INPUT : 100%
• TURBINE OUTPUT : 35%
• CONDENSER LOSS : 55%
• STACK LOSS : 9%
• MISC. LOSS : 1%
STEAM TURBINE CO-GEN PLANT WITH
BACK PRESSURE TURBINE -

A TYPICAL ENGERY DISTRIBUTION

SCENARIO

• FUEL INPUT : 100%

• STEAM TURBINE OUTPUT : 10%
• PROCESS STEAM : 74%
• STACK LOSS : 15%
• MISC. LOSS : 1%
 EXTRACTION CONDENSING
TURBINE CO-GEN PLANT -

A TYPICAL ENGERY DISTRIBUTION

SCENARIO

• FUEL INPUT : 100%

• STEAM TURBINE OUTPUT : 20%
• PROCESS STEAM : 25%
• CONDENSER LOSS : 39%
• STACK LOSS : 15%
• MISC. LOSS : 1%
 GAS TURBINE WITH
WASTE HEAT RECOVERY

A TYPICAL ENGERY DISTRIBUTION

SCENARIO

• FUEL INPUT : 100%

• GAS TURBINE POWER : 30%
• PROCESS STEAM : 44%
• STACK LOSS : 25%
• MISC. LOSS : 1%
 HOW TO SELECT OPTIMUM ROUTE
OF CO-GEN ALTERNATIVE
• To study the process and energy
fluctuation
• Review the impact of process fluctuation
• Select design power : steam ratio
• Select the optimum cycle configuration -
energy-wise
• Study and work out the cost
effectiveness of the selected option
• Sometimes, the most energy efficient
option is not the most cost effective one
TYPICAL APPLICATION
OF CO-GENERATION
 A Typical Integrated Pulp &
Paper Mill Consumes:

 1300 Kwh/Te of Paper of Electricity

 10 Te/Hr. of Steam as Heat Input

Alternate 1

Electricity To
from Grid Paper
Plant
Steam as
Boiler
Heat
Input
Alternate 2

High TG
Pr./Temp.
Boiler

As Heat Output
Steam
Alternate 2 has a Payback Typically
Less than 2 Years..
Such Opportunity Exists in

 Textile Plant

 Sugar Mill

 Rice Mill

 Chemical Plant
Power : Steam Ratio – The
most important criterion to
select the most cost-effective
configuration