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CII 9 ENERGY EFFICIENCY SUMMIT 2010 ENCON IN … B … · CII 9th ENERGY EFFICIENCY SUMMIT 2010...
Transcript of CII 9 ENERGY EFFICIENCY SUMMIT 2010 ENCON IN … B … · CII 9th ENERGY EFFICIENCY SUMMIT 2010...
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By B.G. Shankar Managing Director
AGS-Energy Conservation Pvt. Ltd. Hyderabad, AP
ELECTRICAL ENERGY AUDIT FOR POWER OPTIMISATION
CII 9th ENERGY EFFICIENCY SUMMIT 2010ENCON IN ELECTRICAL SYSTEMS
4th Sep’10
Energy Audit is an effective control device for supervision and guidance of energy utilization.
Comprehensive Energy Audit
Electrical Energy Audit
Power Optimisation
Process Optimisation
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Detailed Electrical Energy Audit
Zero Cost Low Cost Med. Cost Capital Cost
Saving Potential by Various Methods Based on Payback Periods
Power Optimisation
Uniform Power Factor
Power Factor Improvement
Energy Eff. Equipment
Saving 5-7% Saving 0.2-0.5% Saving 0.2-0.3% Saving 0.2-1.0%
Payback Immediate
Payback <2 Months
Payback <12 Months
Payback >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.
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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.
MMCC
Before connecting Capacitor across the motor 37.6 Amps @ 0.64 PF
After connecting Capacitor across the motor 25.6 Amps @ 0.94 PF
MMCC
55 KW Motor
55 KW Motor
15 KVAR
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CM-1RM-2 CM-2RM-1CR-1 CR-2 P/P-1 P/P-2
41489.6A
38.00.59
422115A
58.90.70
416105A
50.60.67
405 V67.2 A35.2 KW0.75 PF
405117A60.90.74
421243A
1470.84
400381A
2310.87
402384A
2240.84
409 V57.1A39.0 KW0.98 PF
41481.4A
57.30.99
424186A
1340.99
404328A
2270.99
41867.5A
47.30.97
399328A
2210.98
42481.7A
58.00.97
41760.2A42.80.99
50 KVAR100 KVAR50 KVAR50 KVAR 50 KVAR 100 KVAR 50 KVAR100 KVAR
BEFORE
AFTER
These Capacitors were connected to improve Power Factor that reduced current flow
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
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.
Copper
Core
Motor Electrical Losses:1) Copper Loss
2) Core Losses
75
80
85
90
70
95
1005025
Losses in Ind. Motors
Copper Loss – Proportional to Sq. of Load Current. (Variable with Load)
Core Loss – Proportional to Square of Voltage (Constant)
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VOLTAGE
K W
460
380340
440
415
400
VOLTAGE VS KILOWATTS OF A PARTIALLY LOADED INDUCTION MOTOR
In this case 380 volts is the optimum voltage at which the powerconsumption 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.
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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CONCLUSIONSElectrical 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
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23
24
25
26
27
28
29
30
18-Jan 19-Jan 21-Jan 3-Mar 5-Mar
Running HourskWh/MT Mat erialProduct ion/ 400TPH/15
s
Before Power Optimisation After Power Optimisation
PYRO PROCESS
10
0
5
10
15
20
25
30
3-Jan 17-Jan 21-Jan 23-Jan 12-Feb 21-Feb 28-Feb 2-Mar
Runni ng Hour skWh/ MT Mater ialPr oducti on/ 1000TPH/ 40
Before After RAW GRINDING (24 Hr Basis)
VARIATION IN ENERGY CONSUMPTION - RAW MILL NO.1
20.66
20.1
19.46
18.5618.85
24.38
20.09 20.1
21.62
20.16
18.5518.29
18.24
15
16
17
18
19
20
21
22
23
24
25
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
Ener
gy C
onsu
mpt
ion
(Kwh
/Ton
)
Before After
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VARIATION IN ENERGY CONSUMPTION - RAW MILL 2
20.04
20.92
19.5219.29
20.01
18.7518.76
18.62
18.918.76
19.12
19.48
17
17.5
18
18.5
19
19.5
20
20.5
21
21.5
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
Energ
y con
sump
tion (
Kwh/T
on)
Before After
10500
11000
11500
12000
12500
13000
13500
1 2 3 4 5 6 7
KWh/HV*2
DISTRIBUTION NETWORK
12
0
20
40
60
80
100
120
140
Earlier Consumption (1999-00)
Power Optimisation (1999-00)
Process Improvement (2000-01)
Power Optimisation (2002-03)
Coromandel Cements Ltd.
Specific Electrical Energy Consumption in Units / Ton of Cement
128122
98 95
82
83
84
85
86
87
88
89
Present Consumption Zero Cost Method Low Cost Method (RS 260,000)
Medium Cost Method (RS 750,000)
Estimated Cost for Implementation
Specific Electrical Energy Consumption in Units / Ton of Cement
88.0
84.5
84.083.8
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