Energy Conservation Awareness Workshop For
Students of Final Year Engineering
(An Exclusive Program for Engineering Colleges in Gujarat)
Organized & Sponsored by
Gujarat Energy Development Agency
A Government of Gujarat Organization -

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ENERGY IN INDIA
WHY SAVE ENERGY
INTRODUCTION TO ELECTRICITY
ELECTRICITY CONSUMPTION OF EQUIPMENTS
TARIFFS AND ELECTRICITY BILLS
ENERGY AUDIT
ELECTRIC MOTORS AND PUMPS
LIGHTING
COMPRESSED AIR
REFRIGERATION
P.F. CONTROL
CASE STUDIES
ANNEXURE- 1 Energy Conservation Act
ANNEXURE- 2 BEE Star Labeling,
ANNEXURE- 3 Tips for Industries

1

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Commercial Energy Sources
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Non Commercial Energy Sources
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Renewable Sources of Energy

Non Renewable Sources of Energy

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Coal and Lignite *
Natural Gas *
Oil *
Nuclear Energy *
Hydro Electricity
* Non Renewable Sources of Energy

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Fire Wood
Agricultural Waste
Dung Cake

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Solar Energy
Wind Energy
Tidal Energy
Geothermal Energy
Wave Energy
Hydro Electricity

TYPE
OIL(MT)
GAS(MTOE)
COAL(MT)
INDIA WORLD
800
1100 139700 0.8
98000 1031610 9.00
HYDRO(MTOE) 30
138300
218
%
0.58
13.76
NUCLEAR 2
MT - MILLION TONS
596 0.34
MTOE – MILLION TONS OIL EQUIVALENT

OIL
COAL
GAS
20 YEARS
200 YEARS
25 YEARS
INDIA HAS LESS THAN 1% OF WORLD OIL & GAS
RESERVES AND 17% OF WORLD POPULATION

1.
India is importing 80% of oil, 15 to 20% of coal and Gas. This dependence will only increase in foreseeable future.
2.
Such heavy dependence on imported energy, poses serious questions about energy security and balance of payment. Rupee has already declined to rupee 68 /$.
3.
To meet challenge of climate change and environmental pollution, improving energy efficiency is a cost effective solution.
4. Present planning remains supply oriented. It must be oriented to demand management.
5. Major resources, financial and human; must be provided to demand management.
CONTD…….

6. Non commercial sources firewood, agriculture waste and dung cake still contribute about 33% of our energy needs. Their end use efficiency as well as supply management must form an integrated part of our energy policy. Energy efficient cook stoves, solar cookers , decentralized solar systems must form part of major policy initiative.
7. Education system must emphasize Energy Efficiency and Energy
Conservation and Moderate Life Style.

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AVOIDING WASTAGE OF ENERGY
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USE OF EFFICIENT EQUIPMENT
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MODERATION OF ENERGY USE

ENERGY CONSERVATION MEANS
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AVOIDING WASTAGE OF ENERGY
SWITCHING OFF IDLE LIGHTS,FANS
SWITCHING OFF IDLE AND REDUNDANT
EQUIPMENT
REDUCING WATER ,STEAM,COMPRESSED AIR
LEAKEAGES
EFFICIENT USE OF ENERGY
EFFICIENT EQUIPMENT AND PROCESSES
HIGH EFFICIENCY PUMPS,FANS,MOTORS,LIGHTS
EFFICIENT OPERATION AND MAINTENANCE
CLEANING OF EQUIPMENTS,WATER TREATMENT
ETC.
MODERATION OF ENERGY USE

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USE COMPRESSIORS , FANS, PUMPS WITH MINIMUM
PRESSURE, TEMPERATURE, FLOW
USE OF SMALL SIZE EQUIPMENT LIKE MOTORS, PUMPS,
REFRIGERATOR, T.V.SETS, VEHICLES
400 LIT. HIGH EFFICIENCY FRIDGE WILL CONSUME MORE
ENERGY THAN 165 LIT. MODEL
42 INCH T.V. WILL CONSUME 4 TIMES MORE POWER THAN
21 INCH T.V.
FAN POWER 50 WATTS
AIRCOOLER 200 WATTS
AIRCONDITIONER 1500 WATTS
CYCLING/WALKING IN PLACE OF 2/4 WHEELERS
TELEPHONE ,E-MAIL IN PLACE OF TRAVEL

1. ELECTRICITY, LPG, DIESEL, PETROL, COAL ARE
DIRECT USES OF ENERGY
2. WE USE LOT OF MATERIALS, TAKE FOOD, WEAR
CLOTHES. ALL THESE ACTIVITIES CONSUME
LOT OF ENERGY. CONSTRUCTION OF
BUILDINGS ALSO USE ENERGY
ENERGY CONSERVATION MEANS
REDUCING BOTH DIRECT AND
INDIRECT USES OF ENERGY

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ELECTRICITY IS GENERATED BY BURNING COAL,OIL,GAS
IN THERMAL POWER STATION
1 UNIT (KWH) OF ELECTRICITY REQUIRES 3 UNITS OF
PRIMARY FUELS LIKE COAL, OIL, GAS (EFFICIENCY – 30%)
HUGH TRANSMISSION & DISTRIBUTION NETWORK IS
REQUIRED TO BRING ELECTRICITY FROM POWER
STATIONS TO CONSUMERS
T & D LOSSES ARE ABOUT 25%
1 KWH (UNIT) SAVED BY CONSUMER LEADS TO SAVING OF
4 UNITS OF PRIMARY FUEL

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HYDRO ELECTRICITY, WIND, SOLAR BIOMAS ELECTRICITY
IS RENEWABLE AND NON POLLUTING
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SHARE OF HYDRO ELECTRICITY HAS DROPPED FROM 50%
TO ABOUT 15% NOW
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WIND POWER IS NOW COMPETITIVE WITH COAL/GAS/OIL
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SOLAR PV (PHOTOVOLTAIC) IS VERY EXPENSIVE
7-8 crores/MW Rs. 10-15/KWh

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SETTING UP POWER STATIONS IS VERY EXPENSIVE
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1 MW REQUIRES 4 CRORES TO 5 CRORES
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1 KW REQUIRES Rs. 40,000 TO 50,000
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WITH TRANSMISSION AND DISTRIBUTION TOTAL
INVESTMENT REQUIRED IS Rs. 60,000 TO Rs. 70,000 PER
KW
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1 KW DEMAND SAVED LEADS TO SAVINGS OF Rs. 60,000 to 70,000

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POWER STATIONS REQUIRE LEAD TIME OF 5 TO 7 YEARS
CONSERVATION PROJECTS CAN BE IMPLEMENTED IN SIX
MONTHS TO 1 YEAR
CAPITAL COSTS FOR CONSERVATION PROJECTS IS Rs.
2000 TO Rs. 10,000 PER KW
GENERATION OF ELECTRICITY LEAD TO ENVIRONMENTAL
POLLUTION
1 KWH LEADS TO 1KG OF CO2 FOR COAL
1 KWH LEADS TO 0.4 KG OF CO2 FOR GAS
1 KWH LEADS TO 0.65 KG OF CO2 FOR OIL
THIS LEADS TO GLOBAL WARMING
1 KWH GENERATION REQUIRES 4 TO 8 LITERS OF WATER

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SAVING OF ELECTRICITY LEADS TO SAVING OF
COAL,OIL,GAS
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SAVINGS OF COSTS TO CONSUMERS
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REDUCES COSTS OF SETTING UP EXPENSIVE POWER
STATIONS
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REDUCES ENVIRONMENTAL POLLUTION REDUCING
GLOBAL WARMING
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SAVES TIME FOR SETTING UP POWER STATION

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AN EXAMPLE
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10 100WATTS BULB COSTS Rs. 100 LOAD = 1000 WATTS
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10 20 WATTS CFL COST Rs. 1500 LOAD = 200 WATTS
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AN EXTRA INVESTMENT OF Rs. (1500-100)Rs.1400 LEADS
TO SAVING OF (1000-200) 800 WATTS. THIS IS EQUAL TO
Rs. 1750 PER KW
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COMPARE THIS TO Rs. 60,000 TO Rs. 70,000 KW

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AN EXAMPLE
FOR 5 HRS/DAY, TOTAL HRS/YR = 5 X 365 =
1825 HRS.
ELECTRICITY CONSUMED BY ONE 100 WATTS
BULB
IS 1825X100 / 1000 = 182.5 KWH (UNIT)
ELECTRICITY CONSUMED BY 20 W CFL IS
1825X20/1000 = 36.5 KWH (UNIT)
SAVING IN ELECTRICITY 182.5 – 36.5 = 146
KWH
AT 5 Rs./KWH THIS IS 146X5 = Rs.730
EXTRA INVESTMENT Rs. 150 – 10 = Rs. 140
PAY BACK PERIOD = 2.3 MONTHS ( 160/730)

ENERGY EFFICIENT TUBE LIGH T
POWER CONSUMPTION OF T-5 WITH ELECTRONIC
BALLAST
POWER CONSUMPTION OF T-12 WITH NORMAL
BALLAST
POWER SAVING
30 WATTS
55 WATTS
25 WATTS
FOR 2000 HRS/ANNUM RUNNINGS UNIT SAVED= 25 *
2000 / 1000
PRICE DIFFERIENCE
= 50
=Rs.200
Rs.350
PAY BACK PERIOD
FOR 25WATTS DEMAND REDUCTION INVESMENT
21 MONTHS
Rs.350
FOR 1 KW DEMAND REDUCTION INVESTMENT 350 ÷ 25 *1000
=Rs.14,000
COMPARE THIS WITH Rs.50,000 to 70,000 for 1 KW
NEW CAPACITY

ENERGY EFFICIENT CEILING FANS
POWER CONSUMPTION OF NORMAL FANS
POWER CONSUMPTION OF EFFICIENT FANS
SAVING
FOR 5000 HRS RUNNING KWH SAVED IS
PRICE DIFFERENCE
PAY BACK PERIOD
FOR 25 WATT DEMAND REDUCTION ADDITIONAL
INVESTMENT
FOR 1 KW DEMAND REDUCTION INVESTMENT
COMPARE THIS WITH Rs. 50,000-70,000 PER KWFOR
NEW CAPACITY
75 WATTS
50WATTS
25 WATTS
125 KWH
=Rs.500
Rs.200
5 MONTHS
Rs.200
Rs.8000

Energy Consumption of Domestic Appliances
(Normal Appliance)
ITEM
BULB
TUBE
LIGHT
FANS
REFRIGAT
ORS
TOTAL
No. X Rating LOAD Hrs/annum kWh/ annum
3 X 40W 120 W 4 X 365 120*4*365/ 1000
=175.2 units
4 X 55W 220W 6 X 365 220*6*365/ 1000
=481.8 units
3 X 75W
1 X 150W
225W 15X 300
150W 8 X 365
715W
225*15*300/ 1000
=1012.5 units
150X8X365/1000
= 438 units
2119.5 kWh per annum
Avg.Monthly Consumption = 177 units

Energy Consumption of Domestic Appliances
(Energy Efficient Appliances)
Hrs/annum kWh / annum ITEAM
CFL
No. X
Rating
3 X 10(W)
Total
Load
30W
T-5
TUBE
LIGHT
EFFICIENT
FANS
4 X 30(W)
3 X 50(W)
REFRIGAT
OR
TOTAL
1 X 100W
120W
150W
100W
400W
4 X 365
6 X 365
15 X 300 150X15X300/1000
8 X 365
30X4X365/1000
120X6X365/1000
100X8X365/1000
UNITS
43.8
262.8
675
292
1281.6
Avg.Monthly Consumption = 107 units


 For sustainable development, adopt a moderate life style using less natural resources and using them efficiently
 Use of public transport in place of private transport
 Use of vegetarian diet in place of nonvegetarian diet
 Avoid use of energy intensive materials like plastics, metals

Energy Conservation Awareness Workshop For
Students of Final Year Engineering
(An Exclusive Program for Engineering Colleges in Gujarat)
Organized & Sponsored by
Gujarat Energy Development Agency
A Government of Gujarat Organization -

INTRODUCTION TO ELECTRICITY
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CONCEPT OF POWER FACTOR
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Electric motors, tube lights, transformers all work on principles of electromagnetic induction by faraday. To establish electromagnetic field in these device a type of current is required which is known as reactive current. For actually doing work, producing torque, heat, an active current is required. Total current flowing in line is vector sum of active and reactive currents.

INTRODUCTION TO ELECTRICITY
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CONCEPT OF POWER FACTOR
For better utilization of generators, transmission, distribution lines, it is necessary to restrict flow of reactive currents in these lines. Reduction of reactive current is known as power factor correction.
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Power Factor = Active Current/ Total Current
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(Total Current) 2 = (Active Current) 2 +(Reactive Current) 2
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P.F. = kW / kVA
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Power Factor correction is done by connecting capacitors.
They must be connected near loads. Like motors, tube lights etc.

INTRODUCTION TO ELECTRICITY
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POWER CONSUMED BY ELECTRICAL EQUIPMENT IS GIVEN
IN WATTS.
FOR SINGLE PHASE EQUIPMENT
POWER IN WATTS = VI COS
ø
WHERE
• V = VOLTAGE VOLTS ,
•
I = CURRENT AMPS
•
COS
ø
= P.F.
FOR THREE PHASE EQUIPMENT
POWER IN WATTS =
√
3 V I COS
ø

INTRODUCTION TO ELECTRICITY

ENERGY
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ELECTRICAL ENERGY IS MEASURED IN KWH(UNIT)
1 KWH = 1000 KWH
ONE LIGHT BULB OF 100 WATTS RUNNING FOR 10 HOURS
CONSUME 100 X 10 = 1000 WATT HOURS = 1 UNIT
FOR 230 VOLTS SUPPLY, BULB HAS P.F. = 1
CURRENT TAKEN FOR 100 WATT BULBS
100 = 230 X AMP X P.F.
= 230 X AMP X 1
AMP = 100/230 = 0.434 AMP

INTRODUCTION TO ELECTRICITY

ENERGY
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FOR 40W TUBE LIGHT TOTAL POWER TAKEN WITH CHOKE
40 + 15 = 55 WATTS P.F. = 0.5
55 = 230 X AMPS X 0.5
AMPS = 55 / 230 X 0.5 = 0.478 AMP
215 L REFRIGERATION MOTOR CONSUMES ABOUT 150
WATTS POWER FACTOR IS 0.7
150 WATTS = 230 V X AMPS X 0.7
AMPS = 150/230 X 0.7 = 0.93

INTRODUCTION TO ELECTRICITY-9
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ENERGY
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3 phase motors consume power as follows
POWER = √ 3 V I cosø
For a 5 hp (3.75 kw) 1 hp = 746 watts
At Full Load P.F. = 0.8 amps = 7.5
Power Input = _/3 x 415 x 7.5 x 0.8 = 4307 watts
Power Output = 3730 watt
Efficiency = output/input = 3730/4307 = 86.67%

ELECTRICITY CONSUMPTION BY EQUIPMENT
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ELECTRIC BULBS
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BULBS COME IN RATINGS OF 25W, 40W, 60W, 100 WATTS
ENERGY CONSUMED IS GIVEN BY NUMBER OF HOURS
USED.
FOR 4 HRS/DAY USE FOR A 30 DAY MONTH
60 WATTS WILL CONSUME ELECTRICITY
4 X 30 X 60 = 7200 WATT HR = 7.2 KWH (UNIT)
FOR 6 HRS / DAY USE FOR A 30 DAY MONTH
100 WATTS BULB WILL CONSUME ELECTRICITY
6 X 30 X 100 = 18000 WATT HR = 18.0 KWH
HIGHER THE WATTS, HIGHER THE HOURS, HIGHER IS
CONSUMPTION

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ZERO WATT BULB CONSUMES 15 WATT
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FOR 30 DAYS, 9 HRS/DAY USE, ELECTRICITY CONSUMED
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30 X 15 X 9 = 4050 WATT HR = 4.05 UNITS
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A 3 WATT CFL WILL CONSUME
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30 X 3 X 9 = 810 WATT HR = 0.81 UNITS

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CFLs SAVE 80% ELECTRICITY
NORMAL BULBS LIFE IS 1000 HRS
CFLS’ LIFE IS 5000 HRS
BULB CFL
25 7
40 10
60 15
100 25
FOR 6 HRS / DAY 30 DAY MONTH 25 WATT CFL
CONSUMPTION
6 X 30 X 25 = 4500 WATT HR = 4.5 UNITS
COMPARE THIS WITH 18 UNITS FOR 100 WATT BULB

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NORMAL TUBELIGHTS (T-12) CONSUME 40
WATT. CHOKE OR BALLAST CONSUME 12 TO 15
WATTS. TOTAL CONSUMPTION IS 52 TO 55
WATTS
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SLIM TUBELIGHTS (T-8) CONSUME 36 WATTS.
CHOKE OR BALLAST CONSUME 12 TO 15 WATTS.
TOTAL CONSUMPTION IS 48 TO 50 WATTS.
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NEW T-5 TUBELIGHTS CONSUME 28 WATTS.
ELECTRIC BALLAST CONSUME 2 WATTS. TOTAL
T-5 CONSUMPTION IS 30 WATTS.

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1200 MM FAN AS PER BLS 374 (2002)
WILL CONSUME 50 WATTS
MOST OF THE WELL KNOWN BRANDS CONSUME BETWEEN
65 TO 85 WATTS
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CONSUMPTION FOR OTHER SIZES IS AS FOLLOWS:
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900 MM 42 WATTS
1200 MM 50 WATTS
1500 MM 63 WATTS
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FAN AT LOWER SPEED CONSUME LESS ELECTRICITY

FAN CONSUMPTION AT DIFFERENT SPEEDS
REGULATOR POSITION NORMAL ELECTRONIC
1 40 WATTS 15 WATTS
2 51 WATTS 34 WATTS
3 61 WATTS 40 WATTS
4 68 WATTS -
5 76 WATTS 76 WATTS

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165 – 180 litres refrigerators consume 35 to 40 units per month
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Consumption increases with age as air leaks through gaskets
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300 litres refrigerators consume 50 to 60 units per month
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Frost free refrigerators have heating coils to defrost. They consume 50% more energy
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Keep thermostat at highest possible temperature

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21” Colour TV consumes 100 watts
Larger sizes consume more electricity
Computer with 17” LCD screen consumes 70 - 80 watts
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Other equipments
Immersion Heater 1000 watts
Instant heater 3000 watts
Storage heater 1000 watts
Washing machine 150 watts
Air conditioner 1500 watts/ton
Air cooler 150 to 200 watts

40W Bulb 11W CFL Voltage T-8 Slim
FTL
190 V 26.03
---
210 V
230 V
250 V
29.11
32.20
34.30
35.26
40.50
45.85
9.40
10.21
11.40

EFFECT OF VOLTAGE on Fan (Wattage) Consumption
Voltage Normal
Regulator
(watts)
210 V 1 35.40
2 44.91
3 51.85
230 V 1 41.14
2 51.62
3 59.46
258 V 1 46.86
2 58.31
3 67.00
Electronic
Regulator
(watts)
9.97
27.94
52.50
12.57
33.66
59.32
15.58
39.07
66.69

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Different Tariffs are Applicable for different categories of consumers. Main categories are:
• Residential
• Commercial
• LT Industries
• HT Industries
For Residential , Commercial and LT
Industries Tariff consist of 2 part
• Fixed Charge depending on Connected Load
• Energy Charge depending on actual energy use

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RATE – RGP of MGVCL
FIXED CHARGES / MONTH:
Range of Connected Load: (Other than BPL Consumers)
(a) Up to & including 2 kW Rs. 15/- per month
(b) Above 2 to 4 kW Rs. 25/- per month
(c) Above 4 to 6 kW Rs. 45/- per month
(d) Above 6 kW Rs. 65/- per month

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For the total monthly consumption:
(other than BPL consumers)
(a) First 50 units 315 paise per Unit
(b) Next 50 units
(c) Next 150 units
360 paise per Unit
425 paise per Unit
(d) Above 250 units 520 paise per Unit

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RATE: NON-RGP (COMMERCIAL)
• This tariff is applicable to the services for the premises those are not covered in any other tariff categories and having aggregate load up to and including 40kW.
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FIXED CHARGES PER MONTH:
(a) First 10 kW connected load Rs.45/- per kW
(b) Next 30 kW connected load Rs.75/- per kW

1.
2.
For installation having Contracted
Load up to and including 10kW; for entire consumption during the month -
425 paise per Unit
For installation having Contracted
Load exceeding 10kW; for entire consumption during the month 455 paise per Unit

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Fixed Charge
Upto 40 kW of Demand: Rs. 85 kW/month
Next 20 kW of Demand: Rs. 120 kW/month
Above 60 kW of Demand:Rs. 185 kW/month
Energy Charges
Rs. 460/kWh
Reactive Energy Charge
10 paise per kVRh

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Demand charges vary from Rs. 120 per kVA/month to Rs. 350 per kVA/month
Energy Charges vary from 425 paise/kWh to 450 paise/kWh.
In addition Time of Use Charges are applicable for peak hour consumption.
PF has to be maintained at 0.9
For higher PF rebate is available. For lower
PF penalty has to be paid

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All consumers have to pay fuel surcharge depending on
of fuel compared to a
.
At present it varies from 110 paise / kWh to 150 paise/kWh

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Electricity Duty is applicable on
Demand and Energy Charges at following rate.
- Residential 15%
- Commercial 25%
- LT Industries 10%
- HT Industries 15 %

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It is essential to analyze Electricity Bills for
1 year for Commercial and Industrial users
The Bill Analysis should work out relation between production and electricity consumption. It is preferable to work out an index like kWh/metre of cloth, kWh/kg of yarn, kWh/Ton of cement, kWh /Ton of steel

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Each plant consist of production machines and utilities.
When production is reduced number of production machines and utilities must be reduced.
For energy efficiency it is always worthwhile running machines at full load rather than partial load

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LOAD FACTOR
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For large Industries it is worthwhile working out load factor every month to control maximum demand
L.F. = Average Demand for month
Peak Demand
Peak Demand is measured every half an hour.
Highest value in a month is taken as Peak Demand
Average Demand = KWH/Month
Running Hours
For continuous process industries L.F. Of 0.7 and above is achievable.

General Observations from Electricity Bills of last 12 months
Present Contract Demand
Average Billing Demand
Average Actual Max Demand
Total Electrical Consumption
Purchase Elect Billed Amount
Minimum Electricity Consumption in the month
Feb-2012
Maximum Electricity Consumption in the month
Dec-2011
Monthly Average Electricity Consumption
/Month
Monthly Average Power Bill Amount
Average Net Unit Cost
Average Power Factor maintained
4500 KVA
3825 KVA
3855 KVA
2,60,64,255 kWh
16,73,00,735/-
18,13,200 kWh
24,80,475 kWh
21,72.019 kWh
1,39,41,728/month
6.43/kWh
0.994

Table 1

 Details of last two years & month wise production along with respective Power consumption is shown here under

Based on the figure of power & production, the specific
Power consumption is calculated for energy performance evaluation, which are shown in the following tables
Table 2: Annual Specific Power Consumption Last Two Years
(Jan-Dec)
Year
2010
2011
Total
Avg
Total
Production
(Kpcs)
345.798
444.279
790077
395039
Consumptions
(Kwh)
26932.679
31210.589
58143.268
29071.634
Specific Power
Consumption
(Kwh/Kpcs)
77.89
70.25
74.07

Energy Conservation Awareness Workshop For
Students of Final Year Engineering
(An Exclusive Program for Engineering Colleges in Gujarat)
Organized & Sponsored by
Gujarat Energy Development Agency
A Government of Gujarat Organization -


ENERGY AUDIT IS A SYSTAMETIC STUDY OF ENERGY
INPUTS, ENERGY CONVERSION AND OUTPUTS OF ENERGY
CONSUMING EQUIPMENTS.

GOAL OF ENERGY AUDIT IS TO IMPROVE ENERGY
PRODUCTIVITY I.E. TO REDUCE ENERGY CONSUMPTION
PER UNIT PRODUCT.

IT IS NECESSARY TO REMEMBER THAT BOTH ENERGY
INPUT AND OUTPUT OF ENERGY USING EQUIPMENTS MUST
BE STUDIED.

SYSTEMS APPROACH

It is also necessary to study all links in a chain from energy input to output.

For Water Pumping - the following needs to be studied.
• Electric Motor
• Pump
• Pipe line
• Valves
• Leakages in system
• Quantity of water required
• Scope of Variable Speed Drive
• Many plants have reduced water requirement and reduced energy use.

SYSTEMS APPROACH IN COMPRESSED AIR SYSTEMS

Similarly for compressed air system, energy audit will study.

Scope of reducing compressed air use

Reducing compressed air pressure

Reduce leakage

Efficient motor, efficient compressor

Variable speed drives

SYSTEMS APPROACH IN
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Reduce need for Refrigeration Air
Conditioning
Increase Temperature Setting
Reduce Heat Ingress
Larger Heat Exchangers
Energy Storage
Use of Absorption Chillers (Using Heat For
Refrigeration)
Efficient Motor, Compressor and Drive
Transmission
69

SYSTEMS APPROACH IN LIGHTING

FOR LIGHTING AUDIT , LOOK AT FOLLOWING :
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EFFICIENT LIGHT SOURCE
USE OF DAY LIGHT
TASK LIGHTING
PROVIDING LIGHT WHERE AND WHEN REQUIRED
LIGHTING CONTROLS LIKE, SWITCHES, DIMMERS,
OCCUPANCY SENSORS
VOLTAGE CONTROL


ENERGY AUDIT HAS FOLLOWING STEPS

MONITORING AND CONTROL

REDUCTION OF LOSSES

MAINTENANCE

MORE EFFICIENT EQUIPMENTS

MORE EFFICIENT PROCESSES






It is necessary to put energy meters on all important equipment. It is also necessary to put instruments for measurement of flow, temperature, pressure etc.
Plant equipments can be divided into two categories
Production equipment like, machine tools, reactors, furnaces
Utility equipment like pumps, fans, compressors
Both these types of equipment need to be monitored.

MONITORING AND CONTROL

Monitoring of energy accounts on a shift daily, weekly, monthly basis immediately gives an indication of plant energy efficiency

Production has dropped but energy use is not dropping means production machines utilities are not used properly. Compressor, pumps, furnaces can be switched off when not required. Use all equipment at full capacities. One equipment at full load is to be preferred to two equipment at half load

Monitoring itself can give 2% to 5% energy saving



All electric equipment have high efficiencies, ranging from 99.9% for circuit breakers to 85% to 90% for motors.
Total distribution losses in a plant in cables etc will be in range of 2% to
4% nothing much need to be done about this.


Major losses are in compressed air leakage(10% to 50%) water and steam leakage heat loss through radiation, heat ingress in refrigeration and air-conditioned spaces. These have to be minimized
COMPRESSED AIR LEAKAGE 7BAR(100PSIG)
HOLE DIA.
AIR LEAKAGE KW LOSS COST OF LOSS/YR
8000 hrs.&@ Rs.5/kWh
1/32”
1/8”
1/4”
1.62CFM
26CFM
104CFM
0.275
4.42
17.68
11,000
1,76,800
7,07,200

HOLE DIA
3MM
6 MM
7 KG/CM 2
22.5 KG/HR.
20 KG/CM 2
59 KG/HR

STEAM LEAKAGE PREVENTION IS MOST
IMPORTANT.
76


All equipments including pipelines should be properly lagged. All flanges should also be lagged. This is the cheapest energy conservation opportunity. The following table shows effect of insulation.
BARE
25 MM INSULATION
50 MM INSULATION
75 MM
100 MM
150 MM PIPE AT 300 0 C – AMBIENT 30 0 C
HEAT LOSS KCAL/M/HR REMARK
3415
505
307
232
191
With increasing thickness cost goes up but savings increase marginaly economic thickness of insulation can be studied.
77









Minimize end use like water, compressed air
Minimize idle running
Operate equipment at best efficiency
Avoid partial load running of motors, pumps etc
Operate most efficient equipment
Different compressors, pumps, refrigeration equipment have different efficiencies monitor it and use the best
Improved maintenance
Cleaning of filters, lighting fixtures, condensers is essential







High efficiency motors
High efficiency pumps
High efficiency chillers
Technology has improved efficiency by 5% to 15%
T-5 tube lights, electronic ballasts
Select and look for best - on basis of Life
Cycle Cost (LCC)






New process technologies are developed to reduce energy use
Dry process in place of wetprocess for cement
Membrane process in place of mercury cell for caustic soda
Low pressure technology for polypropylene, oxygen and other chemicals
Saving 10% to 75%

COAL
COST HEAT VALUE COST FOR
1000KCAL
Rs.2000/TON 4000KCAL/KG.
0.50 Rs.
OIL
GAS
Rs.40/KG
Rs.30/M 3
.
10000KCAL/KG 4.00 Rs.
9000KCAL/M 3 3.33 RS.
ELECTRICITY Rs.6/KWH 860KCAL/KWH 6.97Rs.
ELECTRICITY IS MOST EXPENSIVE FOR HEATING

Energy Conservation Awareness Workshop For
Students of Final Year Engineering
(An Exclusive Program for Engineering Colleges in Gujarat)
Organized & Sponsored by
Gujarat Energy Development Agency
A Government of Gujarat Organization -







About 50% of electricity in is used for pumping of water in residences, industry and agriculture
Opportunities for saving electricity in pump systems
Proper size of motor and pumps
Operation of motor and pumps
High efficiency motor and pump
Most important point is to minimize use of water

IMPORTANCE OF RUNNING COST
Motor Rating (kW)
Efficiency
Power Input (kW)
Running Hours/Year
7.5
0.86
8.72
6000
7.5
0.88
8.52
6000 kWh/Year 52320 51120
Rs/year (Rs.5/kWh) 261600 255600
Running Cost (10yr.) 2616000 2556000
First Cost 20000 23000
First Cost As % Of
Running Cost
0.8
0.8


Even a 7.5kw (10hp) motor consumes electricity worth Rs. 26 lakhs in 10 yrs

A small difference in efficiency (88%-
86%) leads to saving of rs.5000/yr

Extra cost (Rs.3000) is recovered in 7 months

Running cost accounts for 99% of total life cycle cost.

Give importance to running cost

It is worthwhile to refer to latest BIS standars. In market motor pumps are available with efficiencies higher than standards.
IS 12615-2011 ENERGY EFFICIENT MOTOR
IS 7538-1910 MOTORS FOR AGRICULTURE PUMP
IS 9238-1995 MOTOR FOR SUBMERSIBLE PUMP
IS 6595-2002 CENTRIFUGAL PUMS
IS 8034-2002 SUBMERSIBLE PUMP
IS 9079 MONOBLOCK PUMP
BEE STAR LABEL PRODUCTS MUST BE USED








It can be seen from above
Motor efficiency is constant upto 50% load
Pump efficiency goes on dropping with flow. At
50%flow efficiency drop by 20%
Selection of proper size of pump is much more important than proper size of motor
Motor no load current is 20%-40%of full load current. No load power is only 5% of full load power.
Pump power at no load is 25%-35%
Pump can not run on 0 flow, motor can run on no load with out any problem








Oversize motors and pumps lead to following problems
High initial investment
High running cost due to low efficiency
High maximum demand due to poor power factor
High installation cost
High rewinding cost
Replace with proper size and high efficiency




Motor and pump efficiencies are being increased with better materials, better manufacturing technologies and reduction of losses
For motor following table gives necessary information
For pumps refer to standard given earlier
STANDARD
IS 7538-1996
(AGRICULTURE
MOTORS)
IS 12615-2004
EE MOTORS
AMERICAN
STARNDARD
NEMA-MG-1-2003
PREMIUM EFFICIENCY
2.2 KW/ 3 HP
4 POLE
3.7 KW /5HP
4 POLE
7.5KW/ 10 HP
4 POLE
79% 83% 85%
86.4%
89.5%
88.3%
89.5%
90.1%
91.7%








ALL PLANT EQUIPMENTS ARE DESIGENED FOR MAXIMUM
OUTPUT
WORST AMBIENT CONDITION
IT IS POSSIBLE TO SAVE ENERGY BY FOLLOWING
AT LOW LOADS LOW AMBIENHT TEMPS NO OF PUMPS CAN
BE REDUCED FLOW CAN ALSO BE REDUCED
MOTORS MUST BE CLEANED REGULARLY
PUMP IMPELLERS MUST BE CHECKED FOR WEAR AND TEAR
REGULAR MAINTAINANCE OF COOLING TOWERS,HEAT
EXCHANGERS IMPROVE EFFICIENCIES
PROPER WATER TREATMENT ALSO IMPROVE EFFICIENCY


VALVES ARE ROUTINELY USED TO REDUCE
PRESSURE AND FLOW AS PUMPS ARE OVER SIZES
THROTTLING LOSSES CAN BE

30%-70%






TO REDUCE THROTTING LOSSES
TRIM IMPELLER
SMALLER IMPELLER
SMALLER PUMP
VARIABLE SPEED DRIVE

VARIABLE SPEED DRIVES
VARIABLE ASPEED DRIVE WITH INVERTOR IS THE BEST OPTION
THROTTLING CONTROL
FLOW LPM
SYSTEM PRESSURE
PUMP PRESSURE
PUMP EFFICIENCY
PUMP INPUT
MOTOR LOAD
MOTOR EFFICIENCY
MOTOR INPUT
12,000
23.5
23.5
86.0
53.58 KW
97.41%
90%
59.53
STARTER EFFICIENCY 99.8
INPUT KW 55.65
6,000
13.35
29.5
69.0
41.92KW
76.20
89%
47.10
99.8
47.2

VARIABLE SPEED CONTROL
FLOW LPF 12,000
SYSTEM / PUMP
PRESSURE
PUMP EFFICIENCY
PUMP INPUT KW
MOTOR RPM
MOTOR LOAD
23.5
86.0
53.58
1450
97.4%
MOTOR EFFICIENCY
MOTOR INPUT KW
93.7
57.18
CONVERTOR EFFICIENCY 97.0
INPUT KW 58.95
SAVING KW
SAVING %
0.7
1.12
6,000
13.35
78
16.78
1000
30.5%
90
18.64
84.0
20.83
26.37
55.8
HIGH EFFICIENCY
MOTOR
VARIABLE
SPEED DRIVE

IS 12615-2011
Energy Efficient Induction Motors
Three Phase Squirrel Cage

IS 12615 is now revised to bring IS
In Line With International Standards
IEC 60034-30-2008

Also Testing Method as Per
IEC 60034-2-1:2007 And
IEEE 112B----IS 15999:2011

IS 12615-2011




IE1 - Only for VFD drive
IE2 –High Efficiency
IE3 –Premium Efficiency
IE4 -Super Premium Efficiency


IE2 Mandatory 30th June 2011
IE3 – 31 st Jan 2014






IS & IEC Standards Used To Take Stray
Losses As 0.5% of Input.
American Standards Prefer Determining
Stray Losses by Tests.
Determination Of Stray Loss is Time
Consuming and Difficult.
IEC & IS Standards are now aligned with American Standards

IEC 60034-2-1 IEEE-112
1KW - 2.5% 1.8% -100K
10KW -2% 1.5% -375KW
100KW -1.5% 1.2% -2000KW
1000KW-1%
OTHERS.
0.90% -
10000KW-0.5%
IS – 15999 -2011 Similar to IEC







High Efficiency Motors IE2 is Mandatory
With New Test Method
Test With Higher Stray losses.
Existing Machine Designs Have To Improve
Substantially to Achieve this Standard
IS 12615-2011 IE2 , IE3 Motors Available in Market
Premium Efficiency Mandatory in USA
Starting Currents are Higher for these
Motors

ISO 50001
2011 –06-15
Energy Management System – Requirements with
Guidance for use
The purpose of this International Standard is to enable organizations to establish the systems and processes necessary to improve energy performance, including energy efficiency, use and consumption.
This international standard is applicable to all types and sizes of organizations irrespective of geographical, cultural or social conditions.

INCANDESCLENT
BULB
FLUORESCENT TUBE
COMPACT
FLUORESCENT
HIGH PRESSURE
MERCURY VAPOUR
HIGH PRESSURE
SODIUM VAPOUR
METAL HALIDE
LED LAMPS
Rating Efficien cy
Lumen/
Watt
8 TO17 15W TO
500W
18W TO
65W
40 TO 70
50TO 75 5W TO
25W
80W TO
1000W
70W TO
1000W
70W TO
250W
MILLIWATS
TO WATTS
40 TO 50
60 TO 90
70 TO 80
10 TO 30
CRI
(Colour
Renderin g Index)
100
65 TO 80
70 TO 80
50
40
80
> 80%
Life
Hours
1000
5000
8000
8000 TO
10000
12000
10000
50000 TO
100000

GENERAL
LIGHTING
20 TO 50 LUX
INTERIOR
LIGHTING
50 TO 200
OUTDOORSTORES
YARDS,BOILER HOUSE
WAREHOUSES,DINING
HALLS,LOBBY
OFFICE
LIGHTING
150 TO 250 OFFICE WORK
READING ROOM
WORKSHOP
ASSEMBLY
DRAWING
300 TO 500
TASK LIGHTING
INSPECTIONDRAWING
FACILITY
500 AND ABOVE VISUALLY DIFFICULT
TASK


USE OF DAYLIGHT

EFFICIENT LIGHT SOURCES

TASK LIGHTING

VOLTAGE CONTROL

SENSORS, DIMMERS ,CONTROL DEVICES




In industries use of glass or polycarbonate sheets has reduced lighting consumption during daytime
In offices lighting use can be minimized near windows. Dimmers with sensors can do this automatically
Large complexes provide central atrium with FRP sheets








Replace incandescent bulb with CFL
Replace standard fluorescent tube light with tri-phosphorous tube lights
Replace electro-magnetic ballast with electronic ballast
Replace T–12, T–8 with T-5
Replace Mercury Vapor with Metal Halide
Lamps High Pressure Sodium Vapor lamps
Replace Halogen Lamps with Induction Lamps
Replace normal streetlights with LED Lamps





Task lighting means provide illumination for a given task at that point only when required
For factories provide CFLs on machine tools provide intensive lighting at inspection benches only
For offices provide CFL for reading on a table keeping low overall lighting levels
Engineering, textile industries have reduced fixtures heights to reduce number of lamps and provide better lighting







Lighting feeder voltage rises during night time from 415v to 460/470v.This leads to wasteful energy consumption
For single phase, keep voltage 190-210
For three phase, keep voltage 390-410
Separate lighting transformers with taps to be used
Energy saving 10%-20%
Light output does decrease

Voltage GLS
Watts
T 8
Watts
210
230
250
35
40
46
29
32
34
CFL
Watts
Fan Electronic regulator
(Watts)
16 Step 1- ….. 10
Step 5 –…..52
18 Step 1- ….. 12
Step 5 – …..60
20 Step 1- ….. 16
Step 5 – …..67
Fan Normal
Regulator
(Watts)
Step 1- ….. 35
Step 5 –….. 52
Step 1- ….. 41
Step 5 –….. 60
Step 1- ….. 47
Step 5 –….. 67


Dimmers available for incandescent as well as fluorescent tubes

Provide multiple switches so that individual ,machine, table lighting can be controlled

Occupancy sensors can
lights, AC when rooms not occupied.









ELECTRONIC BALLAST CONSUMES ONLY 1 TO 2
WATTS COMPARED TO 10 TO 16 WATTS OF
NORMAL BALLAST
NORMAL TUBE + CHOKE - 50 TO 55WATTS
SLIM TUBE WITH ELECTRONIC CHOKE - 32 TO
38 WATTS
ELECTRONIC BALLAST OPERATION 30 TO 50KHZ
T- 12 TUBELIGHT DIA 12/8 INCH 40W
T - 8 TUBELIGHT DIA 8/8 INCH 36W
T - 5 TUBELIGHT DIA 5/8 INCH 28W
SUPER REFLECTIVE ALUMINIUM COATING
ALLOW FEWER TUBES





COMPRESSED AIR IS VERY INEFFICIENT
AND EXPENSIVE UTILITY
ONLY 10% TO 15% INPUT ENERGY IS
AVAILABLE TO DO WORK. REST IS
WASTED AS HEAT
AFTER DISTRIBUTION LOSSES LEAKAGES
ACTUAL WORK DONE BY COMPRESSED
AIR IS ONLY 5% OR SO
100 CFM AT 7 BAR(100LBS/INCH 2 )
REQUIRE 16 TO 17 KW







Reciprocating & Screw Compressors have similar efficiencies
Centrifugal Compressors most efficient
Centrifugal compressor expensive and available in large sizes > 1000cfm
Reciprocating Compressors requires maintenance
Screw Compressors preferred are as base load machines
No-load power of reciprocating and screw compressors range between 20 to 40%.
PRESSURE RECIPROCATING SCREW CENTRIFUGAL
7 BAR
3BAR
16.0KW
10.0KW
17.0KW
10.5KW
14.0KW
8.5KW
Above Power is for 100 CFM Capacity


Alternative to compressed air
- Minimize compressed air leakage
- Regular compressor maintenance
- Proper type of air drier
- Minimize air pressure


Vacuum cleaning in place of compressed air

Minimize air pressure if at all used in cleaning. 2 bar in place of 7 bar

Mechanical transport of material in place of pneumatic transport implemented in cement, paper chips, chemicals savings 80%

Electrical tools in place of pneumatic tools. If necessary use 200hz supply (for high speed)

COMPRESSED AIR LEKAGE
AT 3BAR(45PSIG)
HOLE DIA AIR LEKAGE
CFM
POWER
LOST
(KW)
1/64”
1/8”
0.211
13.5
1/4” 54.1
AT 7BAR(100PSIG)
1/64”
1/8”
1/4”
0.406
26
104
0.0207
1.323
5.3
0.069
4.42
17.68
ANNUAL
COST
8000HRS.
5RS./KWH
826
52867
211860
2758
176623
706493










OBSERVE LOADING,UNLOADING TIME WHEN NO
ACTUAL USE
LEAKAGE= Q*ON TIME/ON+OFF TIME
Q – CAPACITY CFM
CAN BE DONE WITH DIFFERENT SECTIONS
TO BE DONE EVERY MONTH
LEAKAGE FROM FLANGES ,JOINTS, VALVES, PIPES
TO BE PLUGGED BY NOTTING NOISE
BETTER TO OUTSOURCE
5% TO 10% ACCEPTABLE
20% TO 50% ACTUAL











Carry capacity test with receiver by P
Initial Pressure TO P
2
Final Pressure
1
Q = P
2
-P
1
/Pa*Vr / t
Q = CFM CAPACITY
P
2
= Final Pressure in bar
P
1
= Initial Pressure in bar
Pa= Atmospheric Pressure, 1 BAR
Vr = Receiver Volume, mtr 3 /ft 3 t = Time in minutes
DO THIS EVERY SIX MONTHS
Replace worn out parts, provide proper oil grease

Pressure
Dew Point
REFRIGERATION -20 O C
1 st
Cost
Power
Consumption
1000m 3 /Kw
LOW 2.9KW
DESSICANT BY
COMPRESSED
AIR PURGING
HEAT OF
COMPRESSION
-20 O C
-40 O C
LOW 20.7KW
HIGH 0.8KW


Air amplifier takes outside air uses small amount of compressed air

VFDs are used for capacity control of reciprocating and screw compressors

20% to 30% saving







CHILLED WATER, BRINE FOR PROCESSES
ICE PLANTS
AIR CONDITIONING
HUMIDIFICATION – MOISTURE REMOVAL
VAPOUR COMPRESSION SYSTEM RUNS ON
ELECTRICITY
VAPOUR ABSOBPTION SYSTEM RUNS ON
HEAT




RECIPROCATING - UPTO 200TR
SCREW - 100 To 750 TR
CENTRIFUGAL - 200 TR Or MORE

1TON OF Refrigeration is removal of heat at a rate of 3023 kcal/hr or 12000 BTU/hr


LITHIUM BROMIDE AND WATER SYSTEM
FOR TEMP UPTO 6 0 C

WATER(ABSORBENT) AND
AMMONIA(REFRIGERENT) FOR TEMP.
SYSTEM LESS THAN 0 0 C.

SAVES 90% POWER BUT HEAT INPUT IS
QUITE SIGNIFICANT

OVERALL ECONOMICS DEPEND ON
COSTOF HEAT SUPPLIED










COP = COEFFICIENT OF PERFORMANCE
= REFRIGERATION EFFECT/WORK DONE
VALUE- 4.0 TO 6.0 VAPOUR COMPRESSION
1.0 FOR VAPOUR ABSORPTION
SPECIFIC POWER CONSUMPTION
KW/TON 0.6 TO 1.0 FOR CHILLED WATER AT 8 0 C
EER= ENERGY EFFICIENCY RATIO
EER = BUT/HR REFRIGERATION EFFECT/WATTS
9 TO 13 FOR AIR CONDITIONER

EVAPORATOR
TEMP.
EFFECT OF TEMPERATURE
CONDENSER
TEMP.
+5 0 C TR
+40 0
143
POWER 102
0 0 C
KW/TR 0.72
TR 118
POWER 96.8
KW/TR 0.82
-5 0 C TR 96
POWER 89.6
KW/TR 0.93
OPERATE AT HIGHEST POSSIBLE EVAPORATOR TEMP.
+50 0
127
117
0.93
104
108.9
1.05
84
99.4
1.19
OPERATE AT LOWEST CONDENSER TEMP.


Optimum temperature setting

Each 1 0 c temp increase in air condition space reduces power by 2% to 3%

Set AC temperature at 27 0 to 30 0

Use fans for circulation

For cold storage better and equal air distribution allows higher temp.

Better heat exchangers









PROVIDE AIR CONDITIONING IN USED AREA
PROVIDE FALSE CEILING
REDUCE OUTSIDE HEAT BY INSULATION,SUN
CONTROL FILMS ETC.
FOR VEGETABLES 5 0 C REQUIRED
FOR ICECREAMES -30 0 C REQUIRED
SEGREGATE SUCH LOAD
KEEP MOTORS,HEATING DEVICES OUTSIDE
CONDITIONED SPACE
AIR CURTAINS,AUTOMATIC DOOR CLOSURES


Larger heat exchanger, condenser and evaporators allow higher evaporator temp and lower condenser temp

Regularly clean all heat exchanger

Provide proper water treatment

Performance can drop by 50% in absence of cleaning and water treatment


THERMAL STORAGE TO TAKE ADVANTAGE
OF CHEAP POWER AT NIGHT

TARIIFF AS WELL AS TEMP. FAVOURABLE

HEAT RECOVERY SYSTEMS

HEAT PIPES,HEAT WHEELS VARIABLE
SPEED DRIVES HEAT PUMPS




Electric equipments like motors, furnaces, welding transformers, tube lights
All draw reactive current from power supply. This current affects heating of lines, cables, conductors and hence their utilization.
A 3 phase circuit of 415 V and 10 amps can carry different amounts of power for different PF.
V
415
415
415
I
10
10
10
P.F.
0.5
0.7
1.0
POWER = √ 3 VI COSǾ
3590 WATTS
5025 WATTS
7179 WATTS
FOR POWER SYSTEM OPERATION, HIGHEST PF IS DESIRED







MANDATORY P.F. FOR H.T. CONSUMERS
WAS 0.8 EARLIER IS 0.9 NOW
INCENTIVE AVAILABLE FOR P.F. HIGHER
THAN 0.95
REBATE OF 1% IN ENERGY AND DEMAND
FOR 1% RISE IN P.F. ABOVE 95%
PENALTY OF 1% FOR P.F. BELOW 90%
REBATE REMOVED FROM JUNE 2006


P.F.
Is improved by connection of capacitors near load centers like motors, tube lights.

Please see table for selection

Connect capacitors near motors

Automatic PF Correction required in few cases of fluctuating loads like induction furnaces, welding, etc.

REACTIVE KVAR REQUIRED TO ACHIEVE
VARIOUS P.F. VALUES (kVAr per kW)
OLD P.F.
DESIRED NEW POWER FACTOR
0.90 0.95 0.96 0.97 0.98 0.99 0.999
0.80 0.266 0.421 0.458 0.499 0.547 0.608 0.705
0.85 0.135 0.291 0.328 0.369 0.417 0.477 0.575
0.90 0.000 0.156 0.193 0.234 0.281 0.342 0.440
0.91 -
0.92 -
0.93 -
0.94 -
0.95 -
0.96 -
0.97 -
0.98 -
0.99 -
0.000 0.037 0.078 0.126 0.186 0.284
-
-
-
-
0.126 0.164 0.205 0.253 0.313 0.411
0.097 0.134 0.175 0.223 0.284 0.381
0.067 0.103 0.145 0.192 0.253 0.350
0.034 0.071 0.112 0.160 0.220 0.318
0.000 0.041 0.089 0.149 0.247
-
-
-
0.000 0.048 0.108 0.206
-
-
0.000 0.061 0.158
0.000 0.098


P.F. IMPROVEMENT REDUCES KVA
DEMAND

KVA = KW/P.F

P.F. IMPROVEMENT REDUCES
DISTRIBUTION LOSSES

PF IMROVEMENT WILL BE REQUIRED

IN FUTURE BY RESIDENTIAL,COMMERCIAL
CONSUMERS










POWER SYSTEMS GET PEAK LOADS IN MORNING AND
EVENING
PEAK LOADS ALSO COME IN SUMMER DUE TO FANS,
COOLERS, AIR CONDITIONING.
SINCE 1 MW REQUIRE 4 CRORE TO 6 CRORE INVESTMENT,
UTILITIES REQUIRE CONSANT DEMAND
FOR OPTIMUM CAPACITY USE LARGE CONSUMERS GIVEN
INCENTIVE TO SHIFT LOAD TO NIGHT FROM PEAK PERIOD
FOR GUJARAT
75 PAISE/KWH 7.0 TO 11 A.M.
EXTRA 18.0 TO 22 HRS.
75 PAISE/KWH 10 P.M. TO 6 P.M
REBATE FOR MORE THAN 33% CONSUMPTION

Energy Conservation Awareness Workshop For
Students of Final Year Engineering
(An Exclusive Program for Engineering Colleges in Gujarat)
Organized & Sponsored by
Gujarat Energy Development Agency
A Government of Gujarat Organization -

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Preheat combustion air with waste heat (22 0C reduction in flue gas temperature increases boiler efficiency by 1%).
Use variable speed drives on large boiler combustion air fans with variable flows.
Burn wastes if permitted.
Insulate exposed heated oil tanks.
Clean burners, nozzles, strainers, etc.
Inspect oil heaters for proper oil temperature.
Close burner air and/or stack dampers when the burner is off to minimize heat loss up the stack.

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Improve oxygen trim control (e.g. -- limit excess air to less than 10% on clean fuels). (5% reduction in excess air increases boiler efficiency by 1% or: 1% reduction of residual oxygen in stack gas increases boiler efficiency by 1%.)
Automate/optimize boiler blowdown. Recover boiler blowdown heat.
Use boiler blowdown to help warm the back-up boiler.
Optimize deaerator venting.
Inspect door gaskets.
Inspect for scale and sediment on the water side
(A 1 mm thick scale (deposit) on the water side could increase fuel consumption by 5 to 8%).
Inspect for soot, flyash, and slag on the fire side (A 3 mm thick soot deposition on the heat transfer surface can cause an increase in fuel consumption to the tune of 2.5%.)

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Optimize boiler water treatment.
Add an economizer to preheat boiler feedwater using exhaust heat.
Recycle steam condensate.
Study part-load characteristics and cycling costs to determine the most-efficient mode for operating multiple boilers.
Consider multiple or modular boiler units instead of one or two large boilers.
Establish a boiler efficiency-maintenance program.
Start with an energy audit and follow-up, then make a boiler efficiency-maintenance program a part of your continuous energy management program.

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Fix steam leaks and condensate leaks (A 3 mm diameter hole on a pipe line carrying 7 kg/cm2 steam would waste 33 kilo litres of fuel oil per year).
Accumulate work orders for repair of steam leaks that can't be fixed during the heating season due to system shutdown requirements. Tag each such leak with a durable tag with a good description.
Use back pressure steam turbines to produce lower steam pressures.
Use more-efficient steam desuperheating methods.
Ensure process temperatures are correctly controlled.
Maintain lowest acceptable process steam pressures.
Reduce hot water wastage to drain .

Remove or blank off all redundant steam piping.
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Ensure condensate is returned or re-used in the process
(6 0C raise in feed water temperature by economiser/condensate recovery corresponds to a 1% saving in fuel consumption, in boiler).
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Preheat boiler feed-water.
Recover boiler blowdown.
Check operation of steam traps.
Remove air from indirect steam using equipment
(0.25 mm thick air film offers the same resistance to heat transfer as a 330 mm thick copper wall.)

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Inspect steam traps regularly and repair malfunctioning traps promptly.
Consider recovery of vent steam (e.g. -- on large flash tanks).
Use waste steam for water heating.
Use an absorption chiller to condense exhaust steam before returning the condensate to the boiler.
Use electric pumps instead of steam ejectors when cost benefits permit
Establish a steam efficiency-maintenance program.
Start with an energy audit and follow-up, then make a steam efficiency-maintenance program a part of your continuous energy management program.

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Check against infiltration of air: Use doors or air curtains.
Monitor O2 /CO2/CO and control excess air to the optimum level.
Improve burner design, combustion control and instrumentation.
Ensure that the furnace combustion chamber is under slight positive pressure.
Use ceramic fibres in the case of batch operations.
Match the load to the furnace capacity.
Retrofit with heat recovery device.
Investigate cycle times and reduce.
Provide temperature controllers.
Ensure that flame does not touch the stock.

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Repair damaged insulation (A bare steam pipe of 150 mm diameter and 100 m length, carrying saturated steam at 8 kg/cm2 would waste 25,000 litres furnace oil in a year.)
Insulate any hot or cold metal or insulation.
Replace wet insulation.
Use an infrared gun to check for cold wall areas during cold weather or hot wall areas during hot weather.
Ensure that all insulated surfaces are cladded with aluminum
Insulate all flanges, valves and couplings
Insulate open tanks
(70% heat losses can be reduced by floating a layer of 45 mm diameter polypropylene (plastic) balls on the surface of 90 0C hot liquid/condensate).

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Recover heat from flue gas, engine cooling water, engine exhaust, low pressure waste steam, drying oven exhaust, boiler blowdown, etc.
Recover heat from incinerator off-gas.
Use waste heat for fuel oil heating, boiler feed-water heating, outside air heating, etc.
Use chiller waste heat to preheat hot water.
Use heat pumps.
Use absorption refrigeration.
Use thermal wheels, run-around systems, heat pipe systems, and air-to-air exchangers.

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Seal exterior cracks/openings/gaps with caulk, gasketing, weather stripping, etc.
Consider new thermal doors, thermal windows, roofing insulation, etc.
Install windbreaks near exterior doors.
Replace single-pane glass with insulating glass.
Consider covering some window and skylight areas with insulated wall panels inside the building.
If visibility is not required but light is required, consider replacing exterior windows with insulated glass block.
Consider tinted glass, reflective glass, coatings, awnings, overhangs, draperies, blinds, and shades for sunlit exterior windows.

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Use landscaping to advantage.
Add vestibules or revolving doors to primary exterior personnel doors.
Consider automatic doors, air curtains, strip doors, etc. at high-traffic passages between conditioned and nonconditioned spaces. Use self-closing doors if possible.
Use intermediate doors in stairways and vertical passages to minimize building stack effect.
Use dock seals at shipping and receiving doors.
Bring cleaning personnel in during the working day or as soon after as possible to minimize lighting and HVAC costs.

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Recycle water, particularly for uses with less-critical quality requirements.
Recycle water, especially if sewer costs are based on water consumption.
Balance closed systems to minimize flows and reduce pump power requirements.
Eliminate once-through cooling with water.
Use the least expensive type of water that will satisfy the requirement.
Fix water leaks.
Test for underground water leaks. (It's easy to do over a holiday shutdown.)
Check water overflow pipes for proper operating level.
Automate blowdown to minimize it.
Provide proper tools for wash down -- especially self-closing nozzles.
Install efficient irrigation.

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Reduce flows at water sampling stations.
Eliminate continuous overflow at water tanks.
Promptly repair leaking toilets and faucets.
Use water restrictors on faucets, showers, etc.
Use self-closing type faucets in restrooms.
Use the lowest possible hot water temperature.
Do not use a central heating system hot water boiler to provide service hot water during the cooling season -- install a smaller, more-efficient system for the cooling season service hot water.
Consider the installation of a thermal solar system for warm water.
If water must be heated electrically, consider accumulation in a large insulated storage tank to minimize heating at on-peak electric rates

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Use multiple, distributed, small water heaters to minimize thermal losses in large piping systems.
Use freeze protection valves rather than manual bleeding of lines.
Consider leased and mobile water treatment systems, especially for de-ionized water.
Seal sumps to prevent seepage inward from necessitating extra sump pump operation.
Install pretreatment to reduce TOC and BOD surcharges.
Verify the water meter readings. (You'd be amazed how long a meter reading can be estimated after the meter breaks or the meter pit fills with water!)
Verify the sewer flows if the sewer bills are based on them

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Optimize loading
Use waste heat to generate steam/hot water /power an absorption chiller or preheat process or utility feeds.
Use jacket and head cooling water for process needs
Clean air filters regularly
Insulate exhaust pipes to reduce DG set room temperatures
Use cheaper heavy fuel oil for capacities more than 1MW

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Meter any un-metered utilities. Know what is normal efficient use. Track down causes of deviations.
Shut down spare, idling, or unneeded equipment.
Make sure that all of the utilities to redundant areas are turned off -- including utilities like compressed air and cooling water.
Install automatic control to efficiently coordinate multiple air compressors, chillers, cooling tower cells, boilers, etc.
Renegotiate utilities contracts to reflect current loads and variations.
Consider buying utilities from neighbors, particularly to handle peaks.

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Leased space often has low-bid inefficient equipment.
Consider upgrades if your lease will continue for several more years.
Adjust fluid temperatures within acceptable limits to minimize undesirable heat transfer in long pipelines.
Minimize use of flow bypasses and minimize bypass flow rates.
Provide restriction orifices in purges (nitrogen, steam, etc.).
Eliminate unnecessary flow measurement orifices.
Consider alternatives to high pressure drops across valves.
Turn off winter heat tracing that is on in summer