ENERGY CONSERVATION THE BEST ALTERNATIVE ENERGY AVAILABLE BY ENGR. MEHFOOZ QAZI June 15, 2007

SCOPE Power System peak demand is a key driver behind the need for new generation and transmission infrastructure. Energy costs are highly sensitive to peak demands. Energy Conservation is found to be least cost option to augment the gap between demand and supply.

Power System peak demand is a key driver behind the need for new generation and transmission infrastructure. Energy costs are highly sensitive to peak demands. Energy Conservation is found to be least cost option to augment the gap between demand and supply.

Our Objectives To encourage Energy Saving behavior in industrial plants and commercial buildings through technical assistance, education, awareness, information and studies. To establish a shared approach in the community by creating awareness among the masses regarding power crisis and joint efforts for its remedy. To introduce the changed culture of our organization. To restore customer confidence by helping them in reducing their energy bills To counter the persisted power crisis by reducing the system losses and over loading.

To encourage Energy Saving behavior in industrial plants and commercial buildings through technical assistance, education, awareness, information and studies.

To establish a shared approach in the community by creating awareness among the masses regarding power crisis and joint efforts for its remedy.

To introduce the changed culture of our organization.

To restore customer confidence by helping them in reducing their energy bills

To counter the persisted power crisis by reducing the system losses and over loading.

Two Step Program In order to achieve these objectives, a two step program have been implemented by Energy Conservation Department and all of the industrial and commercial facilities in the licensed area will be individually visited Step- I General Analysis Step- II Complete Energy Audit

In order to achieve these objectives, a two step program have been implemented by Energy Conservation Department and all of the industrial and commercial facilities in the licensed area will be individually visited

Step- I General Analysis

Step- II Complete Energy Audit

A three page Questionnaire form as set out in the Annexure 1 will be tick marked ( √) accordingly during the joint visit of the industrial and commercial facility and entries will be made up accordingly in the following key areas Plant Overview Power System Ventilation Strategy Lighting levels Ware house Motor Systems Air Compressor Systems Chillers Systems Boiler Systems Cooling Tower Systems Step- I General Analysis

A three page Questionnaire form as set out in the Annexure 1 will be tick marked ( √) accordingly during the joint visit of the industrial and commercial facility and entries will be made up accordingly in the following key areas

Plant Overview

Power System

Ventilation Strategy

Lighting levels

Ware house

Motor Systems

Air Compressor Systems

Chillers Systems

Boiler Systems

Cooling Tower Systems

Step- II Complete Energy Audit A complete energy audit facility is offered to the customer free of cost If the customer or its representative is interested or the Performa is handed over for self energy audit as set out in Annexure 2 and Annexure 3 as mentioned below: Chart –I For Non –motor inventory. Chart –II For Motor Inventory.

A complete energy audit facility is offered to the customer free of cost If the customer or its representative is interested or the Performa is handed over for self energy audit as set out in Annexure 2 and Annexure 3 as mentioned below:

Chart –I For Non –motor inventory.

Chart –II For Motor Inventory.

Recommendations Although each plant has a unique process, it is obvious that most plants have similar process equipment. Through these similarities, generalizations on recommendations can be made as under Technical General

Although each plant has a unique process, it is obvious that most plants have similar process equipment. Through these similarities, generalizations on recommendations can be made as under

Technical

General

Technical Install power factor correction capacitors Turn OFF equipment when not in use Begin a practice of monitoring electric demand Repair compressed air leaks Redirect air compressor intake to use outside air Lower air pressure in compressors Repair steam valve leakages Install water cooled chillers instead of replacing air cooled chillers Install Speed controllers on twisting machines Replace electromagnetic chokes of tube lights with energy efficient electronic ballasts. Reduce luminance to minimum required levels via delamping Install timers on lighting systems etc.

Install power factor correction capacitors

Turn OFF equipment when not in use

Begin a practice of monitoring electric demand

Repair compressed air leaks

Redirect air compressor intake to use outside air

Lower air pressure in compressors

Repair steam valve leakages

Install water cooled chillers instead of replacing air cooled chillers

Install Speed controllers on twisting machines

Replace electromagnetic chokes of tube lights with energy efficient electronic ballasts.

Reduce luminance to minimum required levels via delamping

Install timers on lighting systems etc.

General Form an Energy Audit team Objective of Energy team Employee Involvement.

Form an Energy Audit team

Objective of Energy team

Employee Involvement.

Some Interesting Facts During the last six months 130 industrial and commercial units have been visited in Korangi and SITE industrial areas and approximately 3.4MW Energy saving proposals were submitted in document to their respective top management along with detailed discussion . Each recommendation consists of the following four parts 1) Current Practice and Observation. 2) Recommended Action. 3) Anticipated Savings. 4) Simple Pay Back Period Out of which 27 industrial customers implemented in our recommendations and 1MW power saving was achieved successfully by improving power factor.

Some Interesting Facts

During the last six months 130 industrial and commercial units have been visited in Korangi and SITE industrial areas and approximately 3.4MW Energy saving proposals were submitted in document to their respective top management along with detailed discussion . Each recommendation consists of the following four parts

1) Current Practice and Observation.

2) Recommended Action.

3) Anticipated Savings.

4) Simple Pay Back Period

Out of which 27 industrial customers implemented in our recommendations and 1MW power saving was achieved successfully by improving power factor.

Other Benefits of Power Factor Power factor improvement will serve the mutual savings of customers and the utility at the same time by controlling the reactive load on the distribution system and reducing the operating costs of processed items of that particular industry. The other benefits of power factor improvement are It will increase the power system capacity and will help us to eliminate the persisted power crisis in our beloved city. It will decrease the system voltage fluctuations and provide the quality power to achieve the consistent product quality.

Power factor improvement will serve the mutual savings of customers and the utility at the same time by controlling the reactive load on the distribution system and reducing the operating costs of processed items of that particular industry. The other benefits of power factor improvement are

It will increase the power system capacity and will help us to eliminate the persisted power crisis in our beloved city.

It will decrease the system voltage fluctuations and provide the quality power to achieve the consistent product quality.

Other Benefits of Power Factor It will increase the efficiency and the life of electric motors/ machinery installed at your plant. It will reduce power losses, resulting in effective power consumption. It will reduce the Per unit cost of electricity consumed at every plant.

It will increase the efficiency and the life of electric motors/ machinery installed at your plant.

It will reduce power losses, resulting in effective power consumption.

It will reduce the Per unit cost of electricity consumed at every plant.

As a result of Power Factor correction from Cos Ø1 =0.65 to Cos Ø2 =0.9 51.3 : 184.6 = 0.28 ( 28% more active power can be utilized) M/S Trans Asia at Plot No: 9/3 Sec 17 Korangi 41 kW 74 Amperes 51.3 kVA Relief to the Generation/Distribution System (Saving) 192 133.3 120 0.9 Proposed 266 184.6 120 0.65 Existing Proposed Saving (kVA * 0.8) Current/Phase (kVA/( √ 3 * V)) Apparent Power (kW* 1/Cos ø)kVA Active Power (kW) Power Factor (Cos ø ) Description

Control on Reactive Load There have been a lot of opportunities to save substantial amount of electrical energy by improving the power factor of all the industries. Out of approximately 5000 large industrial and commercial registered customers of KESC more 1800 customers (including various government agencies) are paying regularly the penalty having low power factor. There has been no law except Power Factor penalty below 0.9 power factor of the cumulative reactive load generated throughout the month. Small industrial customers having loads below than 40 kW are on the other hand. If this reactive load is to be controlled, by changing the law substantial amount of energy can easily be saved.

There have been a lot of opportunities to save substantial amount of electrical energy by improving the power factor of all the industries. Out of approximately 5000 large industrial and commercial registered customers of KESC more 1800 customers (including various government agencies) are paying regularly the penalty having low power factor. There has been no law except Power Factor penalty below 0.9 power factor of the cumulative reactive load generated throughout the month. Small industrial customers having loads below than 40 kW are on the other hand. If this reactive load is to be controlled, by changing the law substantial amount of energy can easily be saved.

REACTIVE LOAD DETAILS Only by improving the power factor of these 1800 customers we may easily save more than 2 MW 33.6 48.4 0.77 2.08 82.1 100.1 12.6 604.0 1,746 May-07 26.1 47.8 0.8 2.37 74.0 99.7 14.1 592.3 1,925 Apr-07 23.1 39.7 0.79 2.77 62.9 82.7 14.1 509.1 1,910 Mar-07 43.8 37.8 0.69 2.90 81.7 78.9 13.6 467.0 1,880 Feb-07 36.3 41.3 0.73 3.00 77.7 85.4 15.2 504.7 1,850 Jan-07 Saving of kVArh/PM At 0.9 PF kVArh Approx. PF % of bill paid as penalty Reactive Power Active Power Total PF Penalty billed Total amount billed of these customers (Millions) Total no of customers who were charged PF Penalty Month

Replacing standard Fluorescent lighting with efficient Electronic ballasts: Recommendation submitted to M/S Chief Fabrics at SITE Karachi The plant is lit with 100, 4-foot fluorescent fixtures approximately, with electromagnetic chokes. Recommended Action: Energy efficient electronic ballasts are recommended for all the plant’s lighting fixtures. The electromagnetic chokes may be replaced with electronic ballasts. These chokes consume 52 watts per fixture as per our observation, out of which more than 30% power is dissipated by the heat losses in the choke. It is recommended that energy efficient electronic ballasts with different ratings may be replaced.

Saving Calculations : Annual Savings = Rs. 60830/= (Note: The cheapest type of ballasts available in the local market are not recommended.) Approximate Implementation Cost: The average cost of electronic ballast fixture = Rs.500/= approx. 100 fixtures * 500 =Rs. 50,000/= Expected Simple Pay Back; Payback = 50000 / 60830 = 9 Months. 60830 10138 1.6 Annual Savings 136853 22809 7920 660 22 0.8 3.6 0.036 100 T/L Proposed 197683 32947 7920 660 22 0.8 5.2 0.04 100 T/L Existing Annual Elect. Cost (Rs) Annual kWh Hrs/yrs Hrs/month Hrs/ Day LF Operating load (kW) Rated power (kW) Qty Description Lighting

Energy Saver V/S Ordinary Bulb . Rs. 2664 Cost Savings by using CFL 696 3360 Total Cost = Bulb + Energy 576 3200 Energy cost (Domestic) (@ Rs.4 /unit) average 656 Units -- Energy Savings by using CFL 8000 x18 = 144 Units 1000 8000 x 100 = 800 Units 1000 Energy consumed for 8000 hrs operation 1 x120 =120 8 x 20 = 160 Cost of lamps (Rupees) 1 8 No. of lamps required for 8000 hrs operation 8000 hrs 1000 Hrs Operating life Good Quality 18 Watt CFL 100 Watt Ordinary Incandescent Lamp

ENERGY CONSERVATION ACT IN INDIA India passed the Energy Conservation Act in 2001 in order to avoid suffering from massive electricity shortfalls banning electrical appliance manufacturers from dumping outdated or energy inefficient products in the market. Energy Conservation potential for the economy has been assessed as 23% with maximum potential in industrial and agriculture sector.The strategy developed to make power available to all by 2012 estimates nearly 25000MW capacity of power creation through the adoption of energy efficiency techniques.

India passed the Energy Conservation Act in 2001 in order to avoid suffering from massive electricity shortfalls banning electrical appliance manufacturers from dumping outdated or energy inefficient products in the market.

Energy Conservation potential for the economy has been assessed as 23% with maximum potential in industrial and agriculture sector.The strategy developed to make power available to all by 2012 estimates nearly 25000MW capacity of power creation through the adoption of energy efficiency techniques.

Developed Nations In the western countries most of the power utilities have adopted the energy conservation programs supported by their governments. For example The provincial Govt of Ontario’s state (The largest populated state of Canada) observed that their summer peak demand has increased due to increased air-conditioning. In order to handle this situation their provincial Govt committed to reduce energy demand in the province by five percent. A five percent reduction of Ontario's 26000 MW summer peak comprises of1300 MW. For that the Govt signed an agreement of 39.5 billion dollars with Hydro One Networks Inc. (a third party) with the name of Conservation and Demand Management Plan with a consulting firm M/S Hydro One Networks Inc and Hydro One Brampton Networks Inc in 2005 in the name of Conservation and Demand Management Plan.

In the western countries most of the power utilities have adopted the energy conservation programs supported by their governments.

For example The provincial Govt of Ontario’s state (The largest populated state of Canada) observed that their summer peak demand has increased due to increased air-conditioning. In order to handle this situation their provincial Govt committed to reduce energy demand in the province by five percent. A five percent reduction of Ontario's 26000 MW summer peak comprises of1300 MW. For that the Govt signed an agreement of 39.5 billion dollars with Hydro One Networks Inc. (a third party) with the name of Conservation and Demand Management Plan with a consulting firm M/S Hydro One Networks Inc and Hydro One Brampton Networks Inc in 2005 in the name of Conservation and Demand Management Plan.

Developed Nations The plan was includes Load Management through smart metering CFL Promotion Real time monitoring Power factor correction free of cost Technology demonstration Communication/ Education programs Research and plannings.

The plan was includes Load Management through smart metering

CFL Promotion

Real time monitoring

Power factor correction free of cost

Technology demonstration

Communication/ Education programs

Research and plannings.

Conclusion We have power generation through crude oil imported after paying heavy taxes with a big gap between demand and supply that compels us to follow the forced load management during summer peak since last year. Which does not allow us to waste energy at any cost. Therefore Energy Conservation is vital for all the third world countries including pakistan for our economic development and energy independence.

We have power generation through crude oil imported after paying heavy taxes with a big gap between demand and supply that compels us to follow the forced load management during summer peak since last year. Which does not allow us to waste energy at any cost. Therefore Energy Conservation is vital for all the third world countries including pakistan for our economic development and energy independence.