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ENERGY BALANCE in India

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ENERGY BALANCE in India. Energy used more 1unit of electricity. Decreasing Fuels & Industry Consuming More Thermal plants generate @ 35% Efficiency Transmission & Distribution Losses at 33 % 4 units of Primary Fuel gives one EB unit. Energy Efficiency Benefits.

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slide1

ENERGY BALANCE in India

  • Energy used more
  • 1unit of electricity
  • Decreasing Fuels & Industry Consuming More
  • Thermal plants generate @ 35% Efficiency
  • Transmission & Distribution Losses at 33 %
  • 4 units of Primary Fuel gives one EB unit
energy efficiency benefits
Energy Efficiency Benefits
  • Reduced Energy bills – Your Visible Gains !
  • Please Look Not for Visible Gains, But for
  • Hidden long term profits after payback period !
  • Increased Productivity – Invisible Benefits !!
  • Improved Quality in product & Increased Profits
pillars of successful energy management
Pillars of Successful Energy Management
  • Key ingredient- top management support is First
  • Well chartered strategy plan
  • Effective Monitoring system
  • Adequate technical capability for
  • Analyzing and Implementing Energy Saving options
  • Good communication downwards from senior management is the first vital step
energy intake by textile mill energy stages between cup lip in industry
Energy Intake by Textile MillEnergy Stages Between Cup & Lip in industry
  • Voltage Regulation in Stages upto Load End
  • Power Factor correction & Improve in Stages
  • Compressed Air - Cool Dry Air in Stages
  • Steam - Dry Saturated state at load
  • Lighting - Regulated voltage for soft load
  • Regulated, Balanced, Filtered, slightly Lagging,
  • Metered and Sustain-released in stages to the loads.
slide5

Effect of Voltage Unbalanceon 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 5 % unbalance.

motor check points in maintenance
Motor check points in maintenance
  • condition based lubrication - Scheduling
  • quality & quantity of Greasing
  • check active ventilation by fan
  • casing temperature, Keep clean.
  • remove cooling off passages blockage
  • alignment of motor and load;
slide7

Case study of high efficiency motorsDifferent makes of motors are compared for 20 hp rating ring frame motor in textile industry 10 % difference between high effy & low Effy motors

mlm mla is important
MLM & MLA is Important
  • Condition based monitoring than Breakdowns
  • Predictive Preventive Maintenance
  • MLM – micro level monitoring of parameters
  • MLA – macro level Analysis of altering parameters
ca system air intake rupee wise paisa foolish
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 loss examples
Compressed Air loss - Examples
  • Leakage @ ½”dia hole in CA 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.
humidification effect on mill
Humidification effect on mill
  • Less water, more air yields more humidity to mill
  • Nozzles to operate at rated Pressure and Flow
  • Hour meter on water pump,water meter online.
  • High Efficiency GRP fan on Supply & Exhaust fans
  • nozzles jetting, plugged, pissing or oozing
  • Ring main method instead of the present Radial system
pumping system savings parameters existing new pump
Pumping system – savingsparameters existing’ new pump
  • Motor rating hp 7.5 5
  • Suction pipe mm 65 75
  • Delivery pipe mm 50 75
  • Piping material GI White PVC
  • Foot valve local ISI
  • Discharge LPS 3.68 5.03
  • Input power KW 6.18 4.35
  • Increase in discharge -- 36 %
  • Input power reduction 30 % --
  • Saving in Energy -- 48 %
boiler efficiency improves by
Boiler efficiency improves by :
  • 22 * C reduction in flue gas temp > effy UP by 1 %
  • 6 * C raise in feed water temp leads to 1 % fuel saving
  • 20* C raise in pre-heated combustion air >1 % fuel saving
  • 5 % excess air reduction improves boiler Effy by 1 %
  • 1TPH of steam @ 7000 hrs pa cost Rs. 35 lakhs pa
  • One inch steam trap failed ( open) cost Rs. 8 lakhs pa
minute steam parameters
MINUTE STEAM PARAMETERS
  • A few Air vents reduce cycle time in start up.
  • A separator directly increases machine output by removing condensate and so boosting heat transfer.
  • A sight glass helps one to daily monitor Trap – and directly increases drying machine speed.
  • Invest in Pressure Reduction valve PRV at the load ends and it pays back in few months.
steam house keeping values
STEAM – HOUSE KEEPING VALUES
  • A weekly brushing of boiler tubes save 2% fuel bill.
  • A Deaerator head reduces dissolved oxygen and so reduces corrosion (=leaks!) of pipes and fittings.
  • Wet steam is highly corrosive & please avoid
  • Automatic Blow down Control costs < Rs.1 lakh pays for itself in months & improves steam quality.
  • Float traps the payback is days.
steam pressure vs latent heat
Steam Pressure Vs Latent Heat
  • Steam has high Latent Heat at low pressure.
  • Latent heat at 1 kg/cm2 526 Kcal/Kg.
  • Latent Heat at 7 kg/cm2 490 Kcal/Kg.
  • Latent Heat is 7.5% less at Higher pressure

OR

  • 7.5% more steam is used at higher pressure.
  • Always advisable to reduce steam pressure near equipment and not in Boiler – House.
energy audit why
ENERGY AUDIT – WHY ?
  • To reduce cost of production and overheads.
  • To identify areas of excess consumption of energy in Production & Utilities - ref Industry standards
  • To suggest ways for minimizing waste energy consumption using good maintenance practices
  • To increase levels of efficiency of energy consumption with good operating parameter, retrofit
energy audit indicates you
Energy Audit Indicates you
  • What to do,
  • where to start,
  • at what cost and
  • for what benefits
  • Indicative saving potential to achieve
  • Good House-keeping yields 5-10%
  • Minor Investment gives 10-15%
  • Reasonable Investment pays back 20-25%
conserve energy serve nation
Conserve Energy & Serve Nation

Thank You

S.ASHOK,

PCRA FACULTY,

ENERGY CONSULTANT

COIMBATORE .

0422 –2580472, 94437 20220.

ID :[email protected]

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