ENERGY BALANCE in India

1. 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

2. 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

3. 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

4. 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.

5. 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.

6. 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;

7. 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

8. 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

9. 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

10. 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.

11. 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

12. 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 %

13. 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

14. 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.

15. 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.

16. 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.

17. 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

18. Energy Auditing

19. 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%

20. Conserve Energy & Serve Nation Thank You S.ASHOK, PCRA FACULTY, ENERGY CONSULTANT COIMBATORE . 0422 –2580472, 94437 20220. ID :ashoksvs@eth.net