ENERGY CONSERVATION

WHY ?
WHAT IS THE NEED?
WHO WILL GAIN ?
All India Power Shortages
$Existing Supply : 368,046 M Units
$Existing Demand : 414,000 M Unit
$ Shortage : 11.5 %
 POWER COST FOR LAST TEN YEARS
3 – Fold Increase in Last Nine Years

4.5 4.5
4.16 4.2 4.21 4.22 4.25
4 3.75
3.5 3.47
3.15
3
2.5
UNIT PRICE
2 (Rs/Kwh)
1.5
1
0.5
0
1997 1999 2001 2003 2005
 NATIONAL POWER SCENE

$Precarious
$Adverse Impact On Industry
$New Project Additions very slow
$Action Plan Required for Improvement
 COMPARISION OF POWER COST
Comparative Power Cost In Different
Countries
4.5
4.5
4
3.5
3
2.5
2 2 UNIT PRICE
1.7
(Rs/Kwh)
1.5 1.25
1
1
0.5
0
India USA China Saudi Europe
Arabia
ENERGY SAVING POTENTIAL IN
INDIAN INDUSTRY

$Energy Saving Potential

Rs.100,000.00 Million/yr

$Equivalent 2500 MW

$Investment Opportunity
Rs.200,000.00 Million
 ENERGY SAVING POTENTIAL In Industry –
Electrical Devices
Equipment MW Saving Savings in Rs. Million
VFD 350 8750
Soft Starter 80 2000
Auto Star Delta 80 2000
EE Motors 125 3125
Lighting Volt stabilizers 80 2000

Energy Effi Chokes 40 1000

Auto Lux Level 5 125

Controller
On/Off temp 80 2000
Control
Total 840 21000

Investment Potential Rs.42000 million

 ENERGY COST AS % OF
MANUFACTURING COST

$Chlor Alkali Industry 65%

$Cement Industry 40%
$Paper Industry 25%
$Chemical Industry 15%
$Foundry 25%
$Engineering Industry 10%
 Energy Conservation :
An Excellent opportunity for
enhancing profit and
improving competitiveness
 PROBLEMS FACED

Lack of Awareness
Doubting
High Capital Investment
Lack Of Attractive Financing Schemes
Over Promises
Reliability Of Equipment
Pricing of Energy need for Policy
-Changes
POSSIBLE SOLUTIONS

Awareness Campaign
Encon Mission
Training to Industry
Energy Summit
Energy Norms
Demo Projects
Award Schemes
 ENERGY CONSERVATION AT
MACRO LEVEL
3-Pronged Approach
a. Capacity Utilization
b. Fine Tuning
c. Technology Up gradation
(Target – Reduction in specific
energy consumption)
 MACRO LEVEL
METHODOLOGY
Energy Input (a)
= Unavoidable losses (c)
+Theoretical Requirement (b)
+Avoidable losses (d)
 MACRO LEVEL
METHODOLOGY
FOCUS SHOULD BE
a. To concentrate on avoidable
losses
b. Quantify the losses
c. Identify ways and means for
reduction
d. Implementation
 ENERGY CONSERVATION IN
ELECTRICAL MOTORS
A device which converts electrical
energy into mechanical energy
Major source of energy consumption
Major population- Induction motors
 Motor Efficiency =O/P
Power/Input PowerX100
Watt Losses-
Stator & rotor losses
Iron Losses
Friction & Windage losses
Stray Load losses
Range Of losses In An Induction
Motor
 Motor Losses
#Voltage dependent –
Iron Losses
Magnetization
Eddy Current
#Current Dependent –
copper losses
Stator
Rotor
#Mechanical losses –
Friction and windage losses
 Energy Waste- Causes
@Use of less efficient motors
@Oversized/undersized motors
@Improper supply voltage
@Voltage fluctuations
@Poor power factor
@Less efficient driven equipment
@Idle running
 Motor Efficiency Improvement
Motor operation in lightly loaded
condition which is common
practice in industry – Forced to
operate in less efficient zone
 Voltage Optimisation
Impact on motor operating
parameters
$ Red. in volt. Dependent losses
$ 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
connection
+Auto star delta convertor
+Soft start cum energy saver
+Down Sizing
+Overall voltage optimisation
Soft Start Cum Energy Saver
% of Loading % Saving
10 60
20 38
30 20
40 11
50 6.5
60 4.5
70 2.5
80 1.5
90 1.0
 Optimise The Plant Operating
Voltage Overall
- Plant operating voltage plays vital
role in energy saving
-Suggested to have on line voltage
optimization (OLTC)
-Magnetization losses vary
exponentially with the voltage

* Capacity prop V2
*Volt. Opt. will vary capacity
*Should be implemented after
analyzing the loading pattern of all
motors
 Energy Conservation in
Electrical Distribution System
* Componenets in electrical
distribution
a. HT/LT Circuit breakers
b. Switches and Fuses
c. Transformers
d.Busbars/Cables (HT/LT)
 Measures in Minimizing
Distribution Losses
* HT/LT Circuit Breakers
Maintain the contact surface
uniformity, through vigorous
maintenance
Select energy efficient fuses
Measures in Minimizing Distribution
Losses
* Transformers
#Select energy efficient
#wherever possible run in parallel
#Loading should be optimal
Measures in Minimizing Distribution
Losses
* Bus Ducts /Power Cables
# Select correct size
# Bus duct with minimum joints and
bends
# Cables with minimum joints
#Panel should be placed near to load
wherever possible to minimize cable
length & its losses
# Cable should be terminated with
proper crimping sockets
 Methods and Procedures To Minimize The
Distribution Losses
* Voltage drop measurement

# In a large complex distribution system voltage

drops are common
# Acceptable limit is 4-5 V/PHASE
# More than 5V/phase indicates energy loss in
system

* Reasons For Voltage Drop

# Poor Power Factor
# Inadequate Cable size laid
# Poor contact surface at
Cable termination
Cable joints
contactors/switches
 Case Study – Voltage Drop
From Engineering Industry
Voltage at substation – 415 V
Voltage at LT panel – 398 V
Load Current – 180 to 200A
PF - 0.4 LAG
Cable size – 1RX3CX300 mm. sq

Relocate 90 KVAR Cap bank from SS

to LT panel
Reduced 50% of energy losses
Annual Saving – Rs. 0.6 lacs
Energy Conservation in Transformers

Transformer Efficiency – 98-99%

Optimum Efficiency Occurs when
Iron Losses = Copper Losses
(Optimum eff. Occurs between 40%
to 60 % of loading )

Selection of Transformer should be

based on TOC
TOC = Price +(No load loss x loss
value) +(load loss x loss value)
Three Phase Transformer Typical Loss
Chart
KVA Iron Loss FL Copper Loss
500 1030 6860
750 1420 9500
1000 1770 11820
1250 1820 12000

*loss is in watts
 CASE STUDY
11KV

CB CB

2000KVA 2000KVA
11KV/433V 11KV/433V

CB CB

415V
 CASE STUDY
Background
*Cap of Xmer = 1600 KVA
*Load on Xmer is 80 %
*Iron Loss = 2.3 kw
*copper loss = 21 kw

Suggestion – Operate both transformer in

parallel
*One Xmer operation
loss = 2.3+21(0.8)2= 15.7 kw
*Both Xmer in operation
loss = [2.3+21x(0.4)2]x2=11.3 kw
Annual Saving = Rs.0.78 lacs
THANK YOU