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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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

  • 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

  • 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 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.


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

  • 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;


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

  • 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

  • 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

  • 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

  • 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 – savingsparameters existing’ new pump

  • Motor rating hp7.55

  • Suction pipe mm 6575

  • Delivery pipe mm 5075

  • Piping materialGI White PVC

  • Foot valve localISI

  • Discharge LPS3.685.03

  • Input power KW 6.184.35

  • Increase in discharge --36 %

  • Input power reduction30 %--

  • Saving in Energy --48 %


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

  • 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

  • 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 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 ?

  • 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 Auditing


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

Thank You

S.ASHOK,

PCRA FACULTY,

ENERGY CONSULTANT

COIMBATORE .

0422 –2580472, 94437 20220.

ID :[email protected]


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