Energy Intake by the industry
• Energy Losses (Between the Cup & Lip in industry)
• Voltage Regulation
in Stages upto Load End
• Power Factor
Regulation in Stages
• Compressed Air –
Cool Dry Air in Stages
• Energy Measured
• Measure Energy
Digitally & Accurately
from Entrance to Load End .
Energy Efficiency Benefits
• Reduced Energy bills – Visible Gains !
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Increased Productivity – Invisible Benefits
Improved Quality
Increased Profits
Increased Competitiveness
!!
• Ultimately, Machines’ Health Improves By :- Minimum Energy Input & Maximum Output
- This Prolongs the life of machines & Safety
- Important: We get more from machine even later
Energy usage Break-up in Foundry
Approximate power consumption of
Major Equipments ( Typical )
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Total Energy input
Melting Furnaces
Annealing Furnaces
Compressors
Sand plant
Other loads
lighting
100 %
60 %
17.14 %
11.48 %
2.55 %
6.52 %
2.28 %
ELECTRICAL DISTRIBUTION SYSTEM --
SINGLE LINE DIAGRAM
EB POWER
TRIVEATOR METER
Metering
11 KV/440V
Transformer
Effi.95-98%
M
ELECTRICAL
M
DG SET
Dist. loss
4 - 8%
M
M
M
M
Feeders,
Capacitors
C
C
Distribution
Panels
Motors
Effi.85-96%
FANS & BLOWERS
PUMPS
R & AC COMPRESSORS
LIGHTING, HEATING
MECHANICAL
C
Energy Balance in Induction Furnace
Material Grey Iron
Crucible Capacity
3200 Kg
Volts - 968 input
733 KW
Production capacity
1600 Kg /hr
660 Units / Ton
100 %
Input Energy
USEFUL HEAT 380
Coil I2R losses 130
units / ton
units / ton
58.5 %
20 %
Radiation losses 97.5
Conduction losses 34
units / ton
units / ton
15 %
5.2 %
Unaccounted loss 18.5
units / ton
1.3 %
Foundry furnace savings aspects
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Busbar losses - joints inpsect, overheating, discolor
Pneumatic ckt - demoist, lubricate, press regulate
Hydraulic ckt - oil level, filter, proper functioning
Refractory lining - to check before & after melt’
Transformer - ventilation, forced, oil temp, connect’
Water ckt - quality, temperature, pressure ratings
Water temp < 42 * C to prevent scale formation
CT - functioning and water In /Outlet temperature
monitoring etc., wooden fill > pvc fills practically.
Radiation losses in foundry
• Temperature - Energy loss - Energy loss
*C
btu/sqft/hr - kW /m2
•
555
8000
25.28
833
20,000
64.56
1115
52,000
161.4
1400
1,25,000
387.4
• Radiation – Line of sight phenomenon : Heat loss
proportional to difference of 4th power of hot & cold
• Practice to allow 100 –150 *C higher temp for melt
to take care of heat loss in sadle & during transit
• Each 1* extra temp > 1 to 2 kwh extra consume/ton
• Temperature monitor by pyro & T/Couple
Thermal Efficiency parameters of
Induction Furnace
• 3 to 10 %
• 18 to 22 %
• 4 to 6 %
• 2 to 4 %
Losses in the Electrical System in
connecting the bus bars
losses in Induction coil as well as the
water cooled leads
losses in keeping the lining hot
losses in radiation etc.
• 55 to 75 % Thus the Thermal Efficiency of
Induction Furnace varies in the range.
Flames leaping out of furnace
• Two identical furnaces taken for case study
• Gun metal to be melted was weighed & charged.
• One furnace was operated normally by the operators by
leaping out the flames outside.
• Other furnace was operated by confining the flame within
the furnace
• Time taken to melt the charge is the same for both the
furnaces; but the fuel consumption was only half.
Motors – range of Losses
Are we loading our motors efficiently ?
Motor is a Consumable = 7.5 hp replaced by 5 hp new
Motor particulars
Motor rating
Input voltage Volts
Full load speed rpm
Power factor
Measured current amps
Energy consumed / hr
Units consumed MORE
Units lost per day
Units lost per month
7.5 hp std motor 5 hp E E motor
5.5 KW
400
1430
0.84
8.6
5.0 units
0.6 unit / hr
14 units
430 units
3.7 KW
400
1450
0.89
7.16
4.4 units
nil
nil
The table below Compares the behavior of 5 H.P
motor at Higher than 400 volts
courtesy – Muskan Servo OEM study
Input
Voltage
Current
KVA
PF
400
7.5A
5.2
0.8
425
11% More
18% More
0.7
435
19% More
28% More
0.61
445
26% More
38% More
0.57
Improved Power Factor Correction on typical
50HP Motor gives significant results.
50 HP motor
Without Cap
37.3 KW
50 HP motor
( with Cap )
36.2 KW
% Change in
parameters
3% Decrease
28 KVAR
15.1KVAR
46% Decrease
46.6 KVA
38.4 KVA
17% Decrease
0.8 PF
0.92 PF
15% improvement
Thermal Imaging – Tool to Predictive
Maintenance – Management
Parameter
Unbalance in
current in %
Increased Temp
Rise *C in motor
Percent unbalance in voltage
0.3 = 2 volt 2.3 = 10 volts 5.4 = 20 volts
0.4
17.7
40
0*
30*
40*
Say 60 * C 60 + 30 = 90* 60 + 40= 100*
Effect of Voltage Unbalance
on the performance of 5 HP motor :is more detrimental to motor performance
and motor life than voltage variation.
Increased temp. rise is 40 *C for unbalance of 5 %
Say motor temp is 60 * , then this raises to 100 * C.
Hot spots motor bearing DE & NDE
CONDITION MONITORING
Infra red gun readings point to : • 0 to 10* C high : - Corrective measure to take
during next maintenance period.
• 10 to 20* C high : - Corrective measure required
as scheduled Maintenance permits.
• 20 to 40* C high : - Corrective measure required
As Soon As Possible.
• 40*C and high : -
Corrective measure
required immediately.
Compressed air what supplied & what used ?
CA system Air intake –
Rupee wise, Paisa Foolish
• Compr. Air intake Temp. 3*C raise, Power Up 1 %
• 100 scfm @ 7 bar Annual Comp Air use Rs. 6 Lacs
• Daily clean Pre Air Filter before Air intake Filter
• 160 Scfm Compr. @ 7 bar at 45*C air outlet pumps
1 Litre more water in air per hour than at 35 * C
Compressed Air systems – Are we Healthy ?
• Don’t crack drains manually all over.Auto-drain valve with
balancing pipes to be effective
• Regulate at start & Demarcate HP & LP air usage & shut off
the airlines when not in use
• Provide large air receiver near heavy consumer to
avoid shock load, fluctuations in system pressure
• Filter Lubricator Regulator at end usage point to be
inspected daily and oil maintained regularly.
• PLMS pipe line moisture separator to be active at start and
end of line, & at usage point.
CA usage Efficiency Example
• An open 6 mm pipe could consume about 70
CFM of air at 5.5 bar pressure which means
about entire compressed air generation of 20
HP air compressor. In contrast
• Energy Efficient Nozzles and jets
• consumes only 20 CFM air at 5.5 bar
pressure yet provides adequate thrust and air
volume for most applications.
Why we use air blow guns instead of blunt
nylon hose ?
• The flow through a leak is similar to an orifice in that the
flow is determined by the pressure immediately upstream of
the opening.
• The pressure drops in the line supplying air to the leak
based on line's ability to support rate of flow.
• For example, the air flow across a 1/4" orifice at 90
psig is 94 scfm
• but the flow through ten feet of 1/4" I.D. copper tube
at 90 psig will be less than 40 scfm because the
pressure will drop to 35 psig in the tube.
Compressor takes excess power
due to inadequate maintenance
Worn-out piston ring, gland packing 2 – 3 % higher power
Worn, broken, leaking valves
5 –6 % higher power
Worn, improperly aligned bearings
1 – 3 % higher power
Dirty, non recommended lube oil
1 % higher
Clogged suction filter
2 – 3 % higher power
Low, high temp. cooling water flow
1 % higher power per 4
*C higher water temp
up to certain limit
CA system efficiency improves by :
• Reduction of 1 Kg/cm2 air pressure (8 Kg/cm2 to 7
Kg/cm2) results in 7% input power savings
• Using solenoid ball valves wherever required
• Installation of after coolers and dryers
• Carrying out pump – up test, leakage test, specific
power consumption determination regularly
• Ensuring proper air /water cooling of compressor
• 1mm scale build-up on condenser tubes increases energy
consumption by 40%
Compressed Air loss - Examples
• Leakage @ ½”dia hole in Compressed Air line @ 7 Kgsc
can drain almost Rs.2500/- per day
• Hour meter on Compressor Load/ Unload Status
• Compressor works like Submersible pump in air.
• Cool Compressor delivers more air.
• Continuously run Compressor delivers less than an
intermittently run Compressor.
“ we must know what we consume where ”
Preliminary energy audit is a relatively quick exercise
• to Establish energy consumption in the organization
• Estimate the scope for saving
• Identify the most likely ( & easiest areas for attention.)
• Identify early ( no-/ low-cost) improvement & savings
• Set a reference point / Bench mark within the machine
• Identify areas for more detailed study/measurement
• Preliminary audit uses existing, and easily obtained data.
Energy Audit shows where we stand
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What to do,
where to start,
at what cost and
for what benefits
• First step is start with Preliminary Audit with existing Datas.
• Second step is Detailed Audit & Generate more Parameters.
• Indicative saving potential to achieve
• Good House-keeping yields
• Minor Investment gives
• Reasonable Investment pays back
5 - 10%
10 - 15%
20 - 25%
Shock, Relief & Delight
• The three stages of accepting results of an energy study or
audit of process & utility are
•
Shock, Relief and, finally, Delight !
• The general wrong opinions about Maintenance has been
• "Maintenance is a necessary evil"
• "Nothing can be done to improve maintenance costs”
• Please remove the opinions & now Remember:
• Where Safety (Conservation) Fails, Pollution Starts.
• Maintenance is a Tool to Productivity
• Utility to process is like Medicine in bottle to our body.
• Shake bottle before use & shake our body after intake
for quick & better results of medicine.
FIVE COST REDUCTION MEASURES
OF ENERGY CONSERVATION
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Identify inefficient energy use
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Upgrade machinery & process in
context of energy efficiency
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Improve maintenance practice
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Promote employee awareness and
•
Conservation in domestic consumption.
Tube light– variation in Light output & Power output
• Particulars
• Light output
• Power input
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10% low-360 volt 10% high – 450 volts
Decreases by 9 %
Increases by 8 %
Decreases by 15 % Increases by 8 %
Take the case of your transformer without OLTC
Low & High voltages are 400 to 450 volts in day & night
Lighting wants safe regulated working 360 volts only
Priority is towards Energy Savings in Lighting
More priority is in Safety in lighting voltages
Tube light life increases and inventory comes down
Not only for tube lights but also for ballasts also.
Conserve Energy & Serve Nation
• www.pcra.org
• www.energymanagertraining.com
• Please go through the Govt. Website
• and you will find mine & more articles on Industry
•
Thank You
S.ASHOK,
PCRA Faculty
BEE certified Energy Auditor
COIMBATORE – 05.
cell : - 9 4 4 3 7 - 2 0 2 2 0
ID :- ashok.anbesivam@gmail.com
Pl visit my site
WWW.energymeasuretosave.com