CII 9th ENERGY EFFICIENCY SUMMIT 2010

ENCON IN ELECTRICAL SYSTEMS

ELECTRICAL ENERGY AUDIT FOR

POWER OPTIMISATION

By
B.G. Shankar
Managing Director
AGS-Energy Conservation Pvt. Ltd.
Hyderabad, AP

4th Sep’10

Electrical Comprehensive
Energy Audit Energy Audit

Power Process
Optimisation Optimisation

Energy Audit is an effective control device for

supervision and guidance of energy utilization.

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 Detailed Electrical Energy Audit

Saving Potential by Various Methods

Based on Payback Periods

Zero Cost Low Cost Med. Cost Capital Cost

Power Uniform Power Factor Energy Eff.

Optimisation Power Factor Improvement Equipment

Saving 5-7% Saving 0.2-0.5% Saving 0.2-0.3% Saving 0.2-1.0%

Payback Payback Payback Payback

Immediate <2 Months <12 Months >12 Months

Detailed Electrical Energy Audit is the first step for Power Optimization.

Measurements:
• Operational load parameters of all the individual drive motors from
2.2 KW to the highest range available.
• HT & LT incomer & distribution Network branch loads.
• Incoming & outgoing of Power Transformer load parameters.
• Study of Capacitor distribution for Uniform Power Factor.

Estimation of Savings:
• Based on Data Collected and real-time Measurements
• Based on various experiments and studies carried out at different plants

Power Consumption: Detailed Electrical Energy Audit helps to Identify

the reasons for the increased power consumption, if any, and the remedial
measures to minimise the wastage.

2
Every time the energy audit is carried out it rekindles the
interest in Energy Conservation as an important function.
Energy Auditors sharing their experience and knowledge with
the plant personnel, helps in fueling the innovative ideas for
further action of reduction in Specific Power consumption (SPC)
Any loose connections or heating of cables come to timely
vision.
Inform any irregularities in Energy meter CT connections for
rectification.
For an external agency due to unbiased vision, a few points for
energy conservation may be visible each time they perform the
audit and this would help in achieving further saving.

Before connecting Capacitor across the motor

37.6 Amps @ 0.64 PF

MCC M

55 KW Motor

After connecting Capacitor across the motor

25.6 Amps @ 0.94 PF

MCC M

55 KW Motor

15 KVAR

3
 CR-1 RM-1 CM-1
B
CR-2 RM-2 CM-2 P/P-1 P/P-2
E
405 V 405 416 421 400 402 422 414 F
67.2 A 117A 105A 243A 381A 384A 115A 89.6A O
35.2 KW 60.9 50.6 147 231 224 58.9 38.0
0.75 PF 0.74 0.67 0.84 0.87 0.84 0.70 0.59
R
E
50 KVAR 50 KVAR 50 KVAR 100 KVAR 100 KVAR 100 KVAR 50 KVAR 50 KVAR

These Capacitors were connected to improve Power Factor that reduced current flow

409 V 414 424 404 399 424

A
418 417
57.1A 81.4A 67.5A 186A 328A 328A 81.7A 60.2A F
39.0 KW 57.3 134 227 221 58.0 42.8
47.3
0.99
T
0.98 PF 0.99 0.97 0.99 0.99 0.98 0.97
E
R

1990-91 ACC Research and Consultancy Directorate

1998 ESG / AGS-EC
2004 Dr. K.K. Sasi, and Dr. T.B. Isha … Research material published in
Electrical India April’04
Powerboss - An electronic device assessing the load on the motor every
cycle of the supply and adjusting the voltage proportionately to the load

All truth passes through three stages. First, it is ridiculed.

Second, it is violently opposed. Third, it is accepted
as being self evident. --- Arthur Schopenhauer

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 IMPROVING EFFICIENCY OF PARTIALLY
LOADED INDUCTION MOTORS
Copper

Core

Motor Electrical Losses:

1) Copper Loss
2) Core Losses

Considering Frequency to be constant; Core loss is

proportional to the square of voltage.
Also magnetising component of the stator current decreases
due to decreased voltage and hence power factor improves
even at partial loads.

95

90

85

Losses in Ind. Motors

80
Copper Loss – Proportional to Sq. of
Load Current. (Variable with Load)
75 Core Loss – Proportional to Square of
Voltage (Constant)
70

25 50 100

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 VOLTAGE VS KILOWATTS OF A PARTIALLY
LOADED INDUCTION MOTOR

460

440

415

400
340
K
W 380

In this case 380 volts is the optimum voltage at which the power
consumption is minimum.
This is not true for all motors as they are loaded differently.
Power optimisation of the entire plant means studying all the
equipment and finding out the common acceptable voltage for
minimum consumption.

VOLTAGE

By observing the running load parameters.

By Studying KW verses Voltage at different
loads.
By Analyzing various Short Term Tests for the
best to achieve optimum voltages.
Past experience from various tests / trials
conducted at different plants.
By monitoring critical loads that are more than
90% of the rated capacity.
By observing the current in the network
distribution.

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 ADDITIONAL BENEFITS OF
POWER OPTIMIZATION

a) A cleaning tool for electrical equipment and

machinery.
b) Reduces peak demand on Captive Power
Plants.
c) Improves Overall Performance of Electrical
System.
d) A vision of the entire plant.
e) Exposes any weak and hidden points in the
electrical system for corrective measures.

Saving Potential In Process Plants

Through Power Optimisation

With the existing facilities of the process

plant, just by fine-tuning the operational load
parameters, energy consumption can be
reduced by about 5-7%

As power optimisation does not require any

investment for achieving the saving, it is called
a Zero Cost method.

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 CONCLUSIONS
Electrical Energy Audit is an effective control device for
supervision and guidance of energy utilisation. Also helps to
identify wastage of energy and necessary conservation steps by
Zero, Low, Medium and Capital cost methods.

Detailed Electrical Energy Audit is very essential for Power

optimisation that can be done with out any investment where
automatic OLTC is provided on the incoming main transformer.

Power Optimisation reduces energy consumption of the overall

plant by about 5%. Due to reduction in energy wastage, the
machinery life increases.

Effective utilisation of capacitors by uniform distribution

according to the load and at load end reduces cable losses

Power factor improvement at LT distribution network improves

cable life due to reduced flow of current.

Power factor improvement through capacitors and through

power optimisation improves equipment reliability apart from
saving.

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 The following slides with Bar Graph is made
with the similar conditions for
comparing the Kwh/Ton of Material

Before and After Power Optimisation.

i.e.,
Same Production
• Same Rate of Production
• Same Running Hours

PYRO PROCESS
30
Before Power Optimisation After Power Optimisation
29 Running Hours
kWh/MT Mat erial
Production/ 400
28 TPH/15

27

26
s
25

24
23

22
18-Jan 19-Jan 21-Jan 3-Mar 5-Mar

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 RAW GRINDING (24 Hr Basis)
30 Runni ng Hour s
kWh/ MT Mater ial Before After
Pr oducti on/ 1000
25 TPH/ 40

20

15

10

0
3-Jan 17-Jan 21-Jan 23-Jan 12-Feb 21-Feb 28-Feb 2-Mar

VARIATION IN ENERGY CONSUMPTION - RAW MILL NO.1

25

Before 24.38 After

24

23
Energy Consumption (Kwh/Ton)

22 21.62

21
20.66
20.16 20.09 20.1
20 20.1

19.46
19
18.55 18.85
18.56 18.29
18 18.24

17

16

15
8/30/2005 9/1/2005 9/3/2005 9/5/2005 9/7/2005 9/9/2005 9/11/2005 9/13/2005 9/15/2005

DATE

10
 VARIATION IN ENERGY CONSUMPTION - RAW MILL 2
21.5

Before After
21 20.92

20.5

20 20.04 20.01
Energy consumption (Kwh/Ton)

19.48
19.5 19.52
19.12 19.29

19 18.9
18.76 18.76
18.75 18.62
18.5

18

17.5

17
9/2/2005 9/3/2005 9/4/2005 9/5/2005 9/6/2005 9/7/2005 9/8/2005 9/9/2005 9/10/2005 9/11/2005 9/12/2005 9/13/2005 9/14/2005 9/15/2005

DATE

DISTRIBUTION NETWORK
13500

13000

12500

KWh/H
12000
V*2

11500

11000

10500
1 2 3 4 5 6 7

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 Specific Electrical Energy Consumption in Units / Ton of Cement

140

128
122
120

100
98 95

80

60

40

20

0
Earlier Consumption Power Optimisation Process Improvement Power Optimisation
(1999-00) (1999-00) (2000-01) (2002-03)

Coromandel Cements Ltd.

Specific Electrical Energy Consumption in Units / Ton of Cement

89

88 88.0

87

86

85

84.5
84.0
84
83.8

83

82
Present Consumption Zero Cost Method Low Cost Method Medium Cost Method
(RS 260,000) (RS 750,000)

Estimated Cost for Implementation

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