Role of Industry in

EE
 ONE Unit saved is
TWO units generated

What does this

mean???
ONE Unit saved = 120 liters of H20
saved

What does this

mean???
Power generation accounts to 15% of fresh water
consumption in the world!!!
Energy Efficiency
Electrical Distribution System
 Power Factor
Power factor= kW = kW = Actual Power
KVA kW +KVAr Reactive Power

© Confederation of Indian Industry

 Power Factor Compensation
Centralized compensation
 Advantages
SS PANEL  Easy P.F maintenance

 Capacitor maintenance
REACTIVE CURRENT easy
PCC FLOW
 Disadvantages
CAPACITOR  More voltage drop in
BANK
distribution
MCC  Over heating of cable
resulting in failure
 Suitable if distance between
MOTOR PCC and MCC is less
© Confederation of Indian Industry
 Power Factor Compensation
Distributed Compensation
 Advantages
 Minimum voltage drop
SS PANEL
 Low distribution losses

 Disadvantages
PCC  Maintenance is difficult
 Applicable where
distribution is remote
MCC

MOTOR MOTOR
© Confederation of Indian Industry
 Power Factor Compensation
Mixed Compensation
 Advantages
SS PANEL  Good P.F control
REACTIVE CURRENT  Easy maintenance
FLOW
PCC  Low distribution losses
CAPACITOR
BANK  Common in Continuous
MCC Process industry

MOTOR © Confederation of Indian Industry

 Capacitor Selection
 Thumb rule KVA of the capacitor– 1/3 rd of HP
Rating of the motor
 Chart Method

 Formula Method
 Capacitor required (kVAr) = kW x Tan ( cos-11 – cos-1 2 )
Cos 1 - Present power factor
- Cos 2 – Desired power factor

© Confederation of Indian Industry

 Power factor – Individual compensation
 Motor end compensation
 Below 15 HP not economical
Above 30 Hp kVAr of capacitor bank – appx 25%
of motor HP
 Capacitor current Ic at rated voltage < 90% of
no-load current of motor
◼capacitor current exceeds the no load magnetizing current of
the motor, excessive voltage surges can occur
© Confederation of Indian Industry
14 © 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
 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

© 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
© Confederation of Indian Industry
 Case Study-Voltage Drops

 Present cable loss = 5.1 kW

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

Annual savings = Rs. 0.76 Lakhs

© Confederation of Indian Industry

 Motors

© Confederation of Indian Industry

 Why to have focus on Motors?

Electric motors
consume
63-70% of the electricity
used by in
industry

Source: U.S. Department of Energy

© Confederation of Indian Industry

LIFETIME COST OF AN ELECTRIC MOTOR

Purchase price
represents 2% of
motor life cost,
One Rewind
represents 0.7% of
cost
Electricity costs
accounts for
nearly 97%
© Confederation of Indian Industry
 Motors
❖ Motor
➢ Converts Electrical Energy into Mechanical
Energy
➢ Drives a mechanical load
❖ Types of mechanical loads
➢ Constant torque, variable speed loads
➢ Variable torque, variable speed loads

© Confederation of Indian Industry

Capacity of Motor - Horse Power ?

1 HP = 76 Kg-m per second

76 1 HP = 0.75 kW
Kg

Work – Force applied over a distance

Power – Rate of doing work

© Confederation of Indian Industry

 Motor Efficiency

Effectiveness with which a motor

converts Electrical energy to

Output
Mechanical energy
Input

Out put Power

Efficiency = X 100
Input Power

© Confederation of Indian Industry

 Motor Power
P
Loss Model
WF

PCL
PI PO
Motor Load
PSL
PCU
Typical range

Hp horsepower 5 - 200 HP
Pwf windage/friction losses 2.6 - 0.3 %
Pcl core losses (magnetization) 5 - 2.5 %
Psl stray load losses 2.2 - 0.5 %
Pcu I2R losses (copper losses) 9 -3%
Pkl total losses 18.8 - 6.3 %
N motor efficiency (po/pi) 84 % - 94%

© Confederation of Indian Industry

 Range Of Losses In
AC Induction Motor

Range ( H.P ) % of Loss At FL

Efficiency %

1 - 10 14 - 35 65 - 86
10 - 50 09 - 15 85 - 91
50 - 200 06 - 12 88 - 94
200 - 1500 04 - 07 93 - 96
1500 & above 4 95 - 96
© Confederation of Indian Industry
© Confederation of Indian Industry
 How to Find Out Motor Loading?
❖ A 3-Ph IM rated for 75 kW, 415 V, 150A,
0.85 draws 30 kW & 75 A.
❖ What is % loading on motor?
➢ 33 %
➢ 40 %
➢ 50 %
➢ 70 %

© Confederation of Indian Industry

 Performance of Motor at Partial Load
❖ Motor loading is critical factor
❖ Motor  and power factor varies with
% loading
❖ For lightly loaded motors
➢ Voltage related losses - high
➢ Power factor is very low
➢ More copper losses
➢ Motor operates in less efficiency range

© Confederation of Indian Industry

Basic Formulas

Power = 3 V I Cos 

Cos  is power factor

Capacity  Torque

 Voltage 2

© Confederation of Indian Industry

 Optimization Of Lightly Loaded Motors

❖ Options
➢ Delta connection to permanent star
connection -Steady load application
➢ Automatic star-delta-star converters- for
variable loads
➢ Soft starter cum energy savers - High
Starting torque applications
➢ Variable voltage devices
➢ Down sizing
➢ Overall voltage optimization

© Confederation of Indian Industry

 Energy Efficient Motor
❖ Use of lower loss silicon
steel
❖ Longer core
❖ Thicker wires
❖ Thinner laminations
❖ Smaller air gap between
stator and rotor
❖ Improved winding and
lamination designs to
minimise energy
consumption
© Confederation of Indian Industry
 Energy Efficient Motor
❖ Lesser slip
❖ Copper instead of aluminum bars in
the stator
❖ 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
© Confederation of Indian Industry
 Energy Efficient Motors
New efficiency classes defined by IEC
Super premium Super premium
IE4
efficiency * efficiency
Premium
IE3 Premium
efficiency

High efficiency IE2 Comparable to EFF1

Standard
IE1 Comparable to EFF2
efficiency

IEC standard indicated a Super Premium class with

15% lower losses than the IE3
© Confederation of Indian Industry
IE efficiency classes for 50 Hz 4-pole motors

© Confederation of Indian Industry

© Confederation of Indian Industry
National Motor Replacement Program

© Confederation of Indian Industry

 National Motor Replacement Program

Motor Replacement Program to encourage the use of

energy efficient motors adhering to IE-3 standard
0.75 kW to 75 kW with loads such as pumps, fans,
blowers, air compressors etc
Energy Servicing Company (ESCO) Model

© Confederation of Indian Industry

Lighting System

© Confederation of Indian Industry

Adequacy of Lux levels
at various locations

© Confederation of Indian Industry

Recommendations on Illuminance
 The recommended lux levels are recommended as a
range
 Eg : L-R-H (20-30-50)
 As circumstances may be different for different interiors
of same application
 For different conditions of same kind of activity

 ‘R’ represents middle value that generally apply

 ‘H’ should be used in cases where visual work is
critical and errors are costly to rectify
 ‘L’ is used when speed and accuracy is not important
& task is executed occasionally
41 © Confederation of Indian Industry
IES - Recommendations

© Confederation of Indian Industry

Recommendation – Lux adequacy
 By replacing an old lamp with a new one, lux levels will be
increased slightly
 Luminare reflection comes down for an old lamp
 Task lighting can be provided at required locations – to meet the
standards
 IS 6665 suggests
◼ Distribution of light with a maximum and minimum illumination at any point should
not be more than one-sixth above or below the average level in the area

© Confederation of Indian Industry

 Replacing Conventional fans with EE BLDC fans

• Less power consumption (50%-60%) • Avg 1.5 times cost of conventional fans
• Longer life (5 year warranty)

Conventional fans BLDC Fans

Power consumption :
Power consumption : 28 – 35 W
70 – 100 W Power consumption : Power consumption : 1
250 W 60 W
© Confederation of Indian Industry
 Replacing Conventional fans with EE BLDC fans

High Volume Low speed (HVLS) fans

• Move slowly and distribute large amounts of air at low rotational speed
• Less Power consumption
• Higher life
• Cover larger diameter
Capacity starts from 0.5 kw

© Confederation of Indian Industry

Energy Conservation
in

Air Compressors &

Compressed Air System

Confederation Of Indian Industry

Energy Management Cell
 Air is Free!!!
Compressed air is costly!!!
 Single Acting, Two Stage Reciprocating
Compressor *Filter Dryer

Motor starter
Inlet filter

Inter cooler After cooler

Motor
Relief
valve
Trap Trap
(Drain) (Drain)
Pressure
switch

Receiver

Trap
(Drain)
 Why Inter-cooler?
➢ Compressed air leaves cylinder at high
temperature

❑ Density is lower

❑ Volumetric  decreases

➢ Inter cooling reduces temperature & volume

➢ Mass of air delivered increases

➢ Inter-cooler generally saves 7 %

Thumb rule : Every 4°C rise in inlet air temperature results
in a higher energy consumption by 1 % to achieve
equivalent output
Optimal Utilisation of Compressors
Background
37 kW compressor in
operation
At present loading - 30%
Unloading - 70%

Power consumption
Unload - 9 kW
Loading - 27 kW
Install 15 kW ON/OFF Air Compressor and Use
Existing 37 kW Air Compressor as Standby

Action
➢ Install 15 KW package air compressor
➢ Saves no-load power
➢ Use existing compressor as stand-by

Savings - Rs.59,000
Investment - Rs.50,000
Rs.
Rs.

Payback - 11 months
 Capacity Test (Pumping Method)
P2 - P1 1
Average Compressor Delivery = . VR .
P t
P1 = Initial pressure in receiver
P2 = Final pressure in receiver
P = Atmospheric pressure
VR = Volume of air receiver
t = Time taken for charging the receiver
from P1 to P2
 Compressed Air System

C
F
Artificial
M
Demand (rkVA)

Total Demand
Base (kVA)
Demand
(kW) Time

Reduce Artificial Demand to reduce Total Demand

 Install Intermediate controller for
Compressed air system
Observation
Artificial demand - compressor tries to maintain
higher set pressure in the entire system
Consumption increases at
 Open end users such as cleaning
 Leakage of compressed air increases
Results in increased compressor power
consumption
Compressed Air Pressure Real Time Data

82
80
78
76
74
PSIG

72
70
68
66
64
62
60
11:05 12:15 13:37 14:36 15:58
Time

2
The problem with fluctuating Air
Pressure
Higher Energy Consumption

Increased maintenance costs

Higher operating costs

Interruptions in production schedules

Install Intermediate controller for
Compressed air system
 Minimise Leakages

➢ Common in all industries

➢ Tricky
➢ Quantification
 Leakage Test
❖ Close all user points
❖ Charge the lines
❖ Note: On-load time of compressor (T)
Off-load time of compressor (t)
❖ Q : Capacity of compressor
T
Air leakage : L = .Q
T+t
Air leakage
% air leakage = x 100
Compressor capacity
 Cost Of Leakage At 7kg/cm2

Power
Orifice dia Air Leakage Annual Savings
Wasted
(mm) (cfm) @ Rs.3.50/kWh.
(kW)
1.6 6.5 1.26 Rs.35,000
3.2 26.0 5.04 Rs.1,40,000
6.4 104.0 20.19 Rs.4,25,000
 List Of Energy Saving Ideas In
Compressed Air System
➢ Select correct size air compressor
➢ Operate compressor at required
pressure
➢ Install VFD
➢ Minimise system losses - Proper line
sizing
➢ Replace compressed air with blower air
for agitation
➢ Replace pneumatic tools with electric
tools
 List Of Energy Saving Ideas In
Compressed Air System

➢ Provide ball valves at the user point to

avoid compressed air wastage
➢ Use transvector nozzles in air hoses
➢ Cool inlet air to the compressor
➢ Provide sensors to sense unloading
and switch off
➢ Replace inefficient compressors
➢ Install high efficiency dryers
ENERGY CONSERVATION
IN
CENTRIFUGAL PUMPS
 Pumps – Simple Definition

Machines designed to
Overhead
❖ Transport fluid tank

❖ Add energy

Pump

Well
 What is Head?

What will be the

pumping pressure ?

Water

Kerosene

Mercury
600 m3/h
50 m WC
 Efficiency

BHP(O)

Pump output
Pump  (%) =
Input to pump [BHP(O)]

Flow (lps) x Head (m) x Sp. Gr.

Pump  (%) =
102 x  (motor) x kW (I)
 Actual Efficiencies

❖ Normal = 60-75%

❖ Best = 78-80%
(upto 89% efficiency in case of horizontal
split casing pumps)

❖ Worst = 30-60%
 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%

 Approach to energy conservation in
pumps ...
❖ Install Flow & Energy meters for all major
pumps
❖ Observe Flow & Power consumption pattern
➢ Hourly, Shift and daily basis
❖ Identify pumps having major power
consumption
❖ Explore Energy saving possibilities
➢ Apply 80-20 rule
 Pump Capacity Control
❖ On/off type
❖ Recirculation

❖ Valve control
❖ Pump speed control
➢ RPM reduction (pulley)
❖ Mechanical systems
➢ Variable fluid coupling
➢ Variable gear boxes
 Pump Capacity Control

❖ Electrical
➢ Eddy current drives
➢ Variable frequency drives

❖ Pump modification
➢ Lower impeller size
➢ Correct size pump

❖ Combination of small and big pumps

 Optimum Margins

Excessive margins - due to uncertainity

Optimum margins required

❖ Head - 10%
❖ Capacity - 10%
❖ Power - 10 to 20%
To sum-up

First priority in any industry

❖ Avoid pump, if possible

❖ Installation of next lower size impeller

❖ Installation of correct size pump

❖ Installation of variable speed drive