Mba project - Energy management in commercial buildings of Kerala
200718TS146
1. Energy Conservation & Cost Reduction
BITS ZC423T: Project Work
By
Mohammed Ali. A
200718TS146
Project Work carried out at
Laser Shaving India Pvt Limited, Hyderabad
BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE
PILANI (RAJASTHAN)
April 2013
2. Energy Conservation & Cost Reduction
BITS ZC423T: Project Work
by
Mohammed Ali. A
200718TS146
Project Work carried out at
Laser Shaving India Pvt Limited, Hyderabad
Submitted in partial fulfillment of B.S. Engineering Technology degree
program
Under the Supervision of
Bhagath M
MAINTENANCE DEPARTMENT
Laser Shaving India Pvt Limited, Hyderabad
BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE
PILANI (RAJASTHAN)
April 2013
3. CERTIFICATE
This is to certify that the Project Work entitled Energy Conservation & Cost Reduction
submitted by Mohammed Ali. A having ID-No. 200718TS146 for the partial fulfillment of
the requirements of B.S. Engineering Technology degree of BITS, embodies the bonafide
work done by him under my supervision.
Signature of the Supervisor
Place: Hyderabad
Date: 02/04/2013
Bhagath M
Manager Maintenance
Laser Shaving India Pvt Limited
Hyderabad.
_____________________________
Name, Designation & Organization &Location
4. Abstract
Laser Shaving Manufacturing the Blades & Razors, In its Hyderabad Plant Total Connected
Electrical Load is 5 MW with CMD 2.7 MW. Blade manufacturing has several Processes and
every process consuming lots of Power. Currently there is no system to evaluate the efficiency of
Energy utilized. Heat Treatment furnaces and Air Compressors are the Main areas where huge
power is consuming.
This Project is to find out the ways to reduce the Energy cost in Laser Shaving India Limited.
Broad Academic Area of Work: Energy Management
6. Acknowledgement
I take this opportunity to express my profound gratitude and deep regards to my Mentor Bhagath M
and Additional Examiner Ramesh Babu for their exemplary guidance, monitoring and constant
encouragement throughout the course of this thesis. The blessing, help and guidance given by them time
to time shall carry me a long way in the journey of life on which I am about to embark.
I am obliged to staff members of LSIPL - Hyderabad, for the valuable information provided by them in
their respective fields. I am grateful for their cooperation during the period of my assignment.
I thank to entire team of BITS-PILANI UNIVERSITY for offering such a wonderful opportunity to
prepare functional project which would help us and our organization in near future.
----------------
Mohammed Ali. A
April 2013
7. Table of Content
CHAPTER 1 Introduction Page No
1.1 Company profile and background 1
1.2 Importance of Energy Conservation 2
1.3 Electrical Load details 3
1.4 Objective 6
1.5 Scope of work 6
CHAPTER 2 Power factor Correction
2.1 Understanding Power factor 7
2.2 How Capacitors Works 8
2.3 Current Powerfactor trend in LSIPL 9
2.4 Energy Wastage 11
2.5 Estimated Cost Savings 12
2.6 How to Improve Power factor 13
2.7 APFC – Automatic Power Factor Control 14
2.8 Harmonics 17
2.9 Benefits of Power factor 19
2.10 Benefits of APFC Panels 19
CHAPTER 3 Energy Efficient Motors
3.1 Defining Efficiency 21
3.2 Economic Comparison of Rewinding Vs Replacement 23
3.3 Importance of Energy Efficiency 25
3.4 Cost saving Calculations 27
3.5 Estimated savings in LSIPL 29
CHAPTER 4 Aqua Wash
4.1 Aqua Wash Process 32
4.2 Running cost Comparison Electricity Vs Diesel 32
CHAPTER 5 SUMMARY 35
CHAPTER 6 MONETARY BENEFITS AND FUTURE PLAN 36
CHAPTER 7 CONCLUSION 37
CHAPTER 8 REFERNCES 38
8. List of Pictures
Page No
Picture#1 KVA Demand Reduction by Capacitors 08
Picture#2 Current Reduction on Motors by Cpacitors 09
Picture#3 Capacitors Connected unsafely 10
Picture#4 APFC Panel 11
Picture#5 Epcos Capacitors 13
Picture#6 Capacitor Bank Wiring 15
Picture#7 Tuned Harmonic Filter 18
Picture #8 Blocking Inductor Harmonic Filter 19
Picture #9 Electrical Motor Losses 20
Picture #10 Example Motor Name Plate 22
Picture #11 Reconditioned 100Hp Motor 23
Picture#12 Siemens Energy Efficient Motor 24
Picture#13 94% Energy Efficient Motor Loss 25
Picture#14 Energy Audit kit 31
Picture#15 Hot Water Generator 33
Picture#16 Diesel Fired Boiler 34
9. List of Charts
Chart#1 Load Break-up 05
Chart#2 Initial & Life Time cost of Motors 24
Chart#3 15KW Motor Efficiency Pattern 26
List of Tables
Table#1 Power Transformer details 03
Table#2 Distribution Transformer 1 details 04
Table#3 Distribution Transformer 2 details 04
Table#4 Distribution Transformer 3 details 04
Table#5 Distribution Transformer 4 details 04
Table#6 Plant Load Break up 05
Table#7 Power factor & Units Consumption Data 10
Table#8 Specification of different Motors 26
Table#9 Monthly Energy Savings Calculation – Compressor Motors 29
Table#10 Monthly Energy Savings Calculation – Grinding Motors 30
Table#11 Over All Estimated Energy Savings 35
10. CHAPTER 1 Introduction
1.1. Company profile and Background
Laser shaving is the Malhotra group of Companies involved in Manufacturing and Exporting the
Traditional Double Edge Blades and Twin Track Systems. Laser shaving has manufacturing plant in
Hyderabad with Production Capacity of 1 crore Double Edge Blades per day.
Annually more than 4 Billion razor blades manufactured and sold worldwide vouch for Laser quality.
Laser Brands are available in quality conscious countries in America, Europe, and the Middle East,
amongst others.
Armed with impeccable credentials of quality and competitive price, Laser Razor Blades are reliable
aids to good grooming of consumers, World over.
LASER is totally self - reliant in technology using state of art manufacturing equipments. Ongoing
Research and development has enabled the Brand to earn sterling reputation in the World markets, while
reigning supreme at home, resulting in World Class Products
Laser products has enhanced the shaving experience for millions of men with its category that includes
flat blades, regular disposables, Rubberized long handle razors Triple blade systems and Disposables.
The Laser Range is in keeping with the latest trends in shaving and grooming products which include,
anti - perspirants, deodorants, after shave skin conditioners, Shave gel, after shave splashes and bath gel.
Nowadays Raw Material Cost, Labor Cost , Energy Costs are Going up year on year. Due to Stringent
demand for Electricity in India its costs high. Continuous Power Outages Lead to run the Plant by Diesel
Generators. In efficient and poor utilization of energy leads to high cost.
Hence Blade Manufacturing costs are also going up. Company cannot increase the Product cost. It will
lead to loose the market. MNC Companies are giving tough market competition by giving good quality
products with low price.
So it is essential to reduce the manufacturing cost to survive in industry. In this project we are going to
find out possible ways to reduce the energy cost which is going to help to reduce the manufacturing cost
of blade.
Energy Conservation not only going to save money, It’s going to help Environment also.
Energy saved Is Energy Produced.
Page 1
11. 1.2 Importance of Energy Conservation
India has made rapid strides towards economic self-reliance over the last few years. Impressive progress
has been made in the fields of industry, agriculture, communication, transport and other sectors
necessitating growing consumption of energy for developmental and economic activities. If India is to
achieve the targeted growth in GDP, it would need commensurate input of energy, mainly commercial
energy in the form of coal, oil, gas and electricity. However, India’s fossil fuel reserves are limited. The
known reserves of oil and natural gas may last hardly for 18 and 26 years respectively at the current
reserves to production ratio. India has huge proven coal reserves (84 billion tonnes), which may last for
about 200 years but the increasing ash content in Indian Coal as well as associated greenhouse gas
emissions are the major concern.
Energy being an important element of the infrastructure sector has to be ensured its availability on
sustainable basis. On the other hand, the demand for energy is growing manifold and the energy sources
are becoming scarce and costlier. Among the various strategies to be evolved for meeting energy
demand, efficient use of energy and its conservation emerges out to be the least cost option in any given
strategies, apart from being environmentally benign.
The steps to create sustainable energy system begin with the wise use of resources, energy efficiency is
the mantra that leads to sustainable energy management.
On the energy demand and supply side, India is facing severe shortages. 70% of the total petroleum
product demand is being met by imports, imposing a heavy burden on foreign exchange. Country is also
facing Peak power and average energy shortages of 12% and 7% respectively.
Page 2
12. To provide power for all , additional capacity of 100,000 MW would be needed by 2013, requiring
approximately Rs.8000 billion investment. Further, the per capita energy consumption in India is too
low as compared to developed countries, which is just 4% of USA and 20% of the world average. The
per capita consumption is targeted to grow to about 1000 kWh per year by 2013 , thus imposing extra
demand on power system.
In a scenario where India tries to accelerate its development process and cope with increasing energy
demands, conservation and energy efficiency measures are to play a central role in our energy policy. A
national movement for energy conservation can significantly reduce the need for fresh investment in
energy supply systems in coming years. It is imperative that all-out efforts are made to realize this
potential. Energy conservation is an objective to which all the citizen in the country can contribute.
Whether a household or a factory, a small shop or a large commercial building, a farmer or a office
worker, every user and producer of energy can and must make this effort for his own benefit, as well as
that of the nation.
1.3 Electrical Load details
LSIPL Hyderabad Plant having total connected load of 5 MW and CMD 2.7 MW.
Power distribution system has 1 no of 33/11 KV Transformer and 4 no’s of 11KV/415V transformers.
Below is the detailed Load break-up and Transformer specifications
Table#1 Power Transformer
Page 3
13. Table#2 Distribution Transformer 1
Table#3 Distribution Transformer 2
Table#4 Distribution Transformer 3
Table#5 Distribution Transformer 4
Page 4
14. Table#6 Plant Load Breakup
Graph#1 Load Break up
This Plant has huge Inductive loads and some Resistive Loads also. All the Motor will fall on Inductive
Loads and Furnaces will come in Resistive Loads.
Page 5
15. 1.4 Objectives
Establish the system for Energy Management
Energy Cost Reduction
Reduce Specific Power Consumption
1.5 Scope of Work
Collecting the data of the current Energy Consumption & Utilization
Identify the Potential options to conserve the energy
Recommend / Implement Energy Conserving Options
Page 6
16. CHAPTER 2 Power factor Correction
2.1 Understanding Powerfactor
As with any equipment, an electrical system handles its job to some degree of Efficiency ranging from
poor to excellent. The measure of electrical efficiency is known as Power Factor.
The motors and other inductive equipment in a plant require two kinds of electric power. One type is
working power, measured by the kilowatt (kW). This is what actually powers the equipment and
performs useful work. Secondly, inductive equipment needs magnetizing power to produce the flux
necessary for the operation of inductive devices. The unit of measurement of magnetizing or reactive
power is the kilovar (kVAR). The working power (kW) and reactive power (kVAR) together make up
apparent power which is measured in kilovoltamperes (kVA).
Most AC power systems require both kW (kilowatts) and kVAR (kilovars). Capacitors installed near the
loads in a plant are the most economical and efficient way of supplying these kilovars. Low voltage
capacitors are traditionally a high reliability maintenance-free device.
On the spot delivery of magnetizing current provided by capacitors means that kilovars do not have to
be sent all the way from the utility generator to you. This relieves both you and your utility of the cost of
carrying this extra kilovar load. The utility charges you for this reactive power in the form of a direct, or
indirect power factor penalty charge. In addition, you'll gain system capacity, improve voltage and
reduce your power losses.
Page 7
17. 2.2 How Capacitors Works
Induction motors, transformers and many other electrical loads require magnetizing current (kVAR) as
well as actual power (kW). By representing these components of apparent power (kVA) as the sides of a
right triangle, we can determine the apparent power from the right triangle rule: kVA2 = kW2 + kVAR2.
To reduce the KVA required for any given load, you must shorten the line that represents the kVAR.
This is precisely what capacitors do.
By supplying KVAR right at the load, the capacitors relieve the utility of the burden of carrying the
extra KVAR. This makes the utility transmission/distribution system more efficient, reducing cost for
the utility and their customers. The ratio of actual power to apparent power is usually expressed in
percentage and is called power factor.
Picture#1 KVA demand reduction by Capacitors
In the illustration below, addition of the capacitor has improved line power factor and subtracted the
non-working current from the lines. This reactive current is Now supplied by the capacitors rather than
the utility.
Page 8
18. Picture#2 Current Reduction on Motors by Capacitors
2.3 Current Power factor Trend in LSIPL
Power factor will ranges from 0 – 1, for efficient utilization we should maintain power factor 1.
Practically we can achieve 0.99.
Currently PF is maintaining between 0.90 to 0.92, obviously it is very low powerfactor
Page 9
19. Table#7 Powerfactor and Unit Consumption data
Picture#3 Capacitors Connected unsafely to improve the Power factor
Page 10
20. Picture#4 APFC Panel
2.4 Energy Wastage
By the data we collected it is clearly show the low powerfactor. Huge Inductive loads will
always lead to low powerfactor.
KWH:
Kilo Watt Hour – Actual units consumed by the Machines
KWH = KVAH X PF
Page 11
21. KVAH:
Kilo Volt Ampere Hour – The unitswhich is going to calculate in energy Bill.
KVAH = KWH / PF
For Example If we have consumed 100 KWH units and our Power factor is 0.91, then our KVAH units
will 109.8
KVAH = 100 KWH / 0.91 = 109.8
So we have to pay 9.8 units extra, nearly 10% extra energy cost. Simply we are wasting 10% of
Electrical energy due to low Power factor.
2.5 Estimated Cost Saving
Daily average unit consumption 40,000 KWH Current Average Power factor 0.91
Payable units @0.91 pf = 40000/0.91 = 43956 KVAH units
Payable Units @0.99 Pf = 40000/0.99 = 40404 KVAH Units
Extra units Paid = 43956-40404 = 3552 KVAH Units
Cost per Unit = 4.32 Rs / KVAH ( in Andhra Pradesh )
Daily Savings = 3552 X 4.32 = 15344 Rs
Monthly Savings = 15344 X 30 = 4.6 Lacs Rs
Page 12
22. 2.6 How to Improve Powerfactor
Inductive loads will always lead to low power factor, to improve the same we have to compensate
Inductive with Reactive load such like Capacitors.
Calculation for Required Capacitive load to improve Power factor
Required Capacitive Load = KW*(Tanθ 1 – Tanθ 2)
Tanθ 1 – Current Powerfactor angle
Tanθ 2 – Required Power factor angle
For Example our Current power factor is 0.92 and we required 0.99, running load is 2000 KW
Then CosIn(0.92) = 23.07 and Tan (23.07) = 0.426
CosIn(0.99) = 8.11 and Tan (8.11) = 0.143
Tanθ 1 – Tanθ 2 = 0.426-0.143 = 0.283
KVAR = 2000 ( 0.283 ) = 566
By make it round we need 600 KVAR capacitive load to achive 0.99 power factor.
Picture#5 Epcos Capacitors in APFC Panel
Page 13
23. 2.7 APFC – Automatic Power factor Control Panels
By using APFC we can control the Power factor. APFC Panels will have capacitor banks and these
Capacitors will be controlled by the controller.
Reasons why APFC Panels are needed :
In industry most of the load is inductive in nature which results in lagging power factor that is why there
is loss and wastage of energy which results in high power bills and heavy penalties from electricity
boards. If the load is uneven it is very difficult to maintain unity power factor. To overcome this
difficulty APFC panel is used which maintains unity P.F.
Features And Applications :
High speed power factor correcting system are designed to compensate the reactive power of any load or
equipment requiring P.F. correction within a one cycle of operating frequency or time delay of 30 sec to
5 min after command signal from APFC controller.
Renders the distribution network more stable since there is no contactor switching causing high voltage
transients, spikes, harmonics and other disturbances by applying zero cross over voltage switching ON
and zero current switch OFF of the capacitors.
Prevents voltage drop and flickering reduces failures in highly sophisticated electronic equipments like
PLCs. computers and other control systems.
Helps in reducing maximum demand and RKVAH consumption hence substantial reduction in monthly
electricity tariff.
It is highly suitable for spot welding applications where the reactive energy is to be compensated for a
short period of 200 msec or less and for a number of times in a second.
Accurate power factor control even in the presence of harmonics.
Page 14
24. Picture#6 Capacitor Bank Wiring
Installation Recommendations (Where/What Type to Install)
After careful consideration of the advantages and disadvantages of the various
installation options below, care must be taken in sizing and placing power factor
correction capacitors. Leading power factor, greater than 100%, must be avoided.
The capacitors should only be on line when the load requires kVAR and
disconnected when the load is reduced.
Page 15
25. OPTION A - Install directly at the single speed induction motor terminals (on the
secondary of the overload relay).
ADVANTAGES:
Can be switched on or off with the motors, eliminating the need for
Separate switching devices or over current protection. Also, only energized
when the motor is running.
Since kVAR is located where it is required, line losses and voltage drops
are minimized; while system capacity is maximized.
DISADVANTAGES:
Installation costs are higher when a large number of individual motors need
correction.
Overload relay settings must be changed to account for lower motor current draw.
PRODUCT:
Usually the best location for individual capacitors.
OPTION B - Install between the contactor and the overload relay.
l With this option the overload relay can be set for nameplate full load
current of motor. Otherwise the same as Option A.
PRODUCT:
Usually the best location for individual capacitors.
OPTION C - Install between the upstream circuit breaker and the contactor.
ADVANTAGES:
l Larger, more cost effective capacitor banks can be installed as they supply
kVAR to several motors. This is recommended for jogging motors, multispeed
motors and reversing applications.
Page 16
26. DISADVANTAGES:
l Since capacitors are not switched with the motors, overcorrection can occur
if all motors are not running.*
l Since reactive current must be carried a greater distance, there are higher
line losses and larger voltage drops.
OPTION D - Install at the main distribution bus.
ADVANTAGES:
Lower installation cost, since you install fewer banks in large kVAR
blocks.
DISADVANTAGES:
Overcorrection can occur under lightly loaded conditions.
A separate disconnect switch and over current protection is required.
2.8 Harmonics
System harmonics should be considered when applying power factor correction
capacitors. Although capacitors do not generate harmonics, under certain
conditions they can amplify existing harmonics. Harmonics are generated when
non-linear loads are applied to power systems. These non-linear loads include:
adjustable speed drives, programmable controllers, induction furnaces, computers,
and uninterruptible power supplies. Capacitors can be used successfully with nonlinear
loads when harmonic resonant conditions are avoided.
To minimize the occurrence of harmonic resonance, the resonant harmonic of the
system including the capacitor should be estimated. The resonant frequency can be
calculated by:
where
h = calculated system harmonic
kVAsc = short circuit power of the system
kVAR = rating of the capacitor
Page 17
27. Harmonic values of 5, 7, 11, and 1 3 should be avoided as they correspond to the
characteristic harmonics of non-linear loads. The harmonic value of 3 should also
be avoided as it coincides with harmonics produced during transformer
energization and/or operation of the transformer above rated voltage.
Once identified the resonant harmonics can be avoided in several ways.
1. Change the applied kVAR to avoid unwanted harmonics.
Although this is the least expensive way to avoid resonant harmonics, it is
not always successful because typically some portion of the applied kVAR
is switched on and off as load conditions require. The calculation of system
harmonics should be repeated for each level of compensation. Adjusting
the size of the capacitor(s) may be necessary to avoid the harmonic values.
2. Add harmonic filters.
In order to filter harmonics at a specific site, tuned harmonic filters can be applied. A capacitor is
connected in series with an inductor such that the resonant frequency of the filter equals the harmonic to
be eliminated. Tuned filters should never be applied without a detailed analysis of the system. The
currents expected to flow in the filter are difficult to predict and are a complex function of the system
and load characteristics.
Picture#7 Tuned Harmonic Filter
3. Add blocking inductors.
Inductors added to the lines feeding the capacitor can be sized to block higher than 4th harmonic
currents. This method protects the capacitor from the harmonics but does not eliminate the harmonics
from the system. A system study is required to determine correct ratings for the capacitor and inductors.
Page 18
28. Picture#8 Blocking Inductor Harmonic Filter
2.9 Benefits of Power factor
1. Energy cost reduction by reducing payable units
2. Beside unit charges we can save on demand charges also ( 60,000 Rs / Month )
3. We can load up to 2673 KW without any penalties. In January LSIPL paid 65400 Rs as
penalty for loaded 2547 KW.
4. Load reduction in DG. Capacitors will be automatically switched of when DG is running.
5. Increased Voltage
6. Reduced current flow will help to avoid system over heating and cable loss
2.10 Benefits of APFC Panel
1. Accurately we can maintain the power factor
2. Power quality will be maintained by Harmonics filter
3. Improved Plant Safety – Capacitors are potential blast hazards
Page 19
29. CHAPTER 3 Energy Efficient Motors
Motors are Rotating Equipment converting Electrical Energy into Mechanical Energy. When
converting Energy some losses will be there.
We all know that to get a motor to do work we need to supply a source of electrical power. In an ideal
world ALL of the power that is put in would be seen at the output.
However, all real systems have losses
Picture#9 Electrical Motor Losses
Page 20
30. 3.1 Defining Efficiency
'Efficiency is the percentage of the power input that reaches the load:
Where:
η is a decimal value; if multiplied by 100 will give the efficiency as a percentage
Pout is the output power
Pin is the input power.
The efficiency rating of an induction motor accounts for the losses in both the stator and the rotor.
in the ideal world an electric motor would be 100% efficient.
in the real world it is more realistic to expect 50% efficiency.
low efficiency means higher running costs.
not all electric motors are created equal. Some are more efficient than others.
All motors have a metal nameplate fixed to their body (right).
The nameplate gives a number of the motors characteristics including:
Brand
kW or hp (horse power)
Hz (frequency)
Amps
Ambient temperature
Efficiency (%)
Voltage (Star / Delta)
RPM
cos φ (power factor)
Page 21
31. Picture#10 Example Motor name plate
Manufacturers also publish Motor Efficiency tables (below) and carefully label each of their motors with
data that enables the purchaser to match a motor to its end use and enable the selection of a high
efficiency motor.
The prevailing view among facility managers is that it is cheaper to repair failed motors above 15
horsepower (hp) than to replace them. While this is usually true in terms of first cost, when all the
relevant factors are considered, replacement with an energy-efficient motor makes economic sense in
many situations.
One such factor is the efficiency degradation that is typical when motors are repaired. Field surveys
confirm that typical motor repair practice reduces motor efficiency by up to 5 percent. Rewinding a
motor can preserve and, in rare cases, slightly improve its efficiency, if skillfully done. However, in the
rewinding process the motor efficiency can be degraded, greatly increasing operating cost and energy
consumption. The magnitude of this problem can vary widely from one rewind shop to another, and can
only be properly identified when efficiency measurements are taken before and after rewinding. Quality
assurance programs developed by the motor repair industry aim to improve field practice so that a motor
will emerge from a repair shop with as small an impact on efficiency as possible.
Given federal regulations that went into effect in 1997, mandating minimum efficiency levels for the
most common motors, it's likely that even the least-efficient replacement motor will be more efficient
than the original motor when it was brand new. Moreover, motors are often oversized for the function
they perform, meaning that they operate below the full-load efficiency stated on their nameplate, and
thus can be replaced by smaller and less costly motors. These factors often combine to create
opportunities for significant efficiency improvements and resulting energy cost savings by replacing
rather than repairing motors when they fail. Thus the best economic decision for a given motor is not
always as straightforward as it might seem.
Page 22
32. LSIPL having nearly 1 MW load of Re wound Motors, these motors will consume huge powers due to
low efficiency, by replacing these motors with energy efficient motors we can save huge amount in
running cost.
3.2 Economic Comparison of Rewinding Versus Replacement
Most analyses of the comparative economics of rewinds versus replacement consider only a few
parameters, including first cost, the difference in nameplate efficiency between the failed motor and a
potential replacement, duty factor, electricity price, and demand charges.
A more comprehensive analysis should consider the following:
• Life-cycle cost, cost of saved energy, or, at least, a simple payback analysis
• Actual vs. nameplate efficiency of the existing motor (actual efficiency may have been degraded by
prior repairs)
• Motor capacity vs. peak loading
• Expected lifetime of repaired motor vs. that of a replacement
New energy-efficient motors typically cost about two to three times as much as a repair job in motors up
to 200 hp. The cost-effectiveness of rewinds tends to improve at larger motor sizes because labor
requirements for rewinding increase more slowly with motor size than do materials requirements for
new motors.
Picture#11 Reconditioned 100HP Motor
Page 23
33. Energy cost for a 15 years usage at Rs 4.5 kWH is staggering 14.10 lacs as compared to buying cost of
Rs 7215/- . Also the energy KWH rate is likely to only go up in future. If we compare initial purchase
price of the motor with the cost of energy it uses over it working lifetime, the initial cost represents
less than two percent of its lifetime cost in most of the cases .
Graph#2 Initial & Life time Cost of Motors
Picture#12 Siemens Energy Efficient Motor
Page 24
34. 3.3 IMPORTANCE OF ENERGY EFFICIENCY
Growing cost of energy calls for power saving at each possible step of manufacturing. Electric motor
driven systems used in industrial processes consume more than 70 percent of electricity used in industry,
hence best possible technology is being applied for achieving highest possible efficiency values. The
efficiency of an electric motor is determined by the amount of useful power it produces compared to the
amount of energy required to operate it. The figure below illustrates how Energy efficient motors
effectively turns 1000 units of electrical power into mechanical power.
Picture#13 94% Efficient Motor Loss
Page 25
35. Graph#3 15KW Motor Efficiency Pattern
Table#8 Specification of different Motors
Page 26
36. 3.4 Cost Saving Calculation
Example: 1
A Siemens 2 pole 11kW motor has an efficiency of 91% at full load.
What is its running cost based on 4000 hours a year at 5 Rs per kWh?
Calculation:
First, let’s calculate the losses
11 kW x 9% (Note: 100% - 91% = 9% = 0.9).
11 kW x 0.09 = 0.99 kW (this is the total of the losses).
Therefore the total power that must be supplied to the motor will be:
11 kWh + .99 kWh = 11.99 kWh (rounded to 12 kWh).
Total power used in the year:
12 kWh x 4000h = 48,000 kWh or 48 MWh.
Total cost of running the motor in ONE year:
12 kWh x 4000h x 5 = 2,40,000 Rs a year.
What would the running costs be for one year if the motor’s efficiency was only 81%:
11 kWh x 0.19 = 2.09 kWh (losses: 100% – 81% = 19%)
11 kWh + 2.09 kWh = 13.09 kWh
Total running cost in ONE year:
13.09 x 4000 x 5 = 261800 Rs a year
So yearly savings will be 21800 Rs in one 11 KW energy efficient Motor.
Page 27
37. Example 2
Kw - output of motor in kw
E1 - efficiency of standard motor
E2 - efficiency of energy efficient motor
Kw Kw
X = -------- _ --------
E1 E2
Savings=X * working hours * working days * tariff
Calculation
3.7kW 4 pole motor in frame ND112M
Std motor eff 2: 85% eff1 88.3%
Price eff2 : Rs 7215/- eff1: Rs 9380/-
Working hours 16 per days, working days 300 in a year , power
rate Rs 4.5 per KWH
X=0.1626
RS Savings=0.1626X16X300X4.5
=3514 /- RS per year
Extra investment RS 2615/-
Payback period=9 months
Page 28
38. 3.5 Estimated Savings in LSIPL
Below is the estimated savings in LSIP by replacing old Motors with Energy efficient Motors.
Table#9 Monthly Energy Saving Calculation in Compressor Motors
Energy Savings in Compressor Motors
Compressor IR 8 IR 6 IR 7 Elgi 4
Motor Rated Output KW 91 88 88 75
Running KW @75% Loading 68.25 66 66 56.25
Current Efficiency 0.84 0.84 0.84 0.84
Required Efficiency 0.93 0.93 0.93 0.93
X 7.863 7.604 7.604 6.480
Run Hour 22 22 22 22
Days 28 28 28 28
Unit rate 6 6 6 6
Savings per Motor / Month 29061.29 28103.23 28103.23 23951.61
Monthly Savings in Compressors 109219.35
Cost of New Energy Efficient 100HP Motor is 1.6 lacs. Pay back period is 7 Month
Page 29
39. Table#10 Monthly Energy Saving Calculation in Grinding Machines
Energy Savings in Grinding Machine Motors
Motor Rated Output KW 3 2 1 0.5
Running KW @75% Loading 2.25 1.5 0.75 0.375
Current Efficiency 0.78 0.78 0.78 0.78
Required Efficiency 0.93 0.93 0.93 0.93
X 0.465 0.310 0.155 0.078
Run Hour 22 22 22 22
Days 28 28 28 28
Unit rate 6 6 6 6
Savings per Motor / Month 1719.6 1146.4 573.2 286.6
No of Motors / Machine 4 5 4 8
Monthly Savings 6878.41 5732.01 2292.80 2292.80
Monthly Savings / Gr. Machine 17196.03
Monthly Energy Cost savings per Grinding Machine is 17196 Rs. Total 15 Grinding Machines in
LSIPL. Total Monthly Savings in all Grinding machines will be 2.6 lacs Rs.
Total Motor Replacement Cost per Grinding Machine is 1.8 lacs. Pay back period 11 Month
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41. Chapter 4 Aqua Wash
4.1 Aqua Wash Process
Aqua wash is the Machine used to clean the Blades in LSIPL. Detergent water is the cleaning media
used in this. In this water is required to heat up to 80 deg Celsius. Immersion type water heaters are used
to heat up the waters.
Total 115KW of Electrical Water heaters required to achieve this temp. Below is the Monthly Electrical
Energy savings calculation if we will run the Machine with Diesel fueled Boilers to heat the water
instead of Electrical Heaters.
4.2 Running Cost Comparison Electricity Vs Diesel
Aqua Wash Calculation
Water Flow 1800 L/hr for one Machine
Initial Temperature 25 deg C
Required Temp 80 deg C
Delta T 55 deg C
Required Kcal/hr 99000 Kcal/hr for one Machine
Required Electrical Load to get 99000 Kcal 115 KW
Required Diesel to get 99000 Kcal 11 L
Running Cost
For 115 KW With Diesel
Cost of Electricity per Hour 690.6977
Cost of Diesel per
Hour 605.1903
Cost of Electricity per day 16576.74 Cost of Diesel per Day 14524.57
Cost of Electricity per Month 497302.3
Cost of Diesel per
Month 435737
Monthly Savings by Running Boiler for Aqua wash Instead of Electrical Water Heaters
Savings in Rs/Month 61565.3
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42. Note:
Electricity Unit cost Considered as Rs 6 per Unit
Diesel Cost Considered Rs 53 per liter
Machine Run time considered 24 hours & 30 days
Picture#15 Hot Water Generator (Diesel Fueled)
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43. Picture#16 Diesel Fired Hot Water Generator
Cost of Hot water Generator – 4 Lacs Rs
Savings per Month – 61000
Payback period – 7 Months
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44. Chapter 5 Summary
By analyzing total electrical load and power consuming trends, following potential energy saving
options are identified. Required investments, estimated monthly savings and pay back periods are as
follow.
Table#11 Estimated Energy Savings
Sl.No Activity
Estimated
Monthly
Savings (Rs)
Required
Investments
(Rs)
Pay Back
Period
(Months)
1 Improving Power factor by Installing APFC panels 460000 1600000 3.5
2 Replacing IR 6 Compressor Motor 28000 160000 5.7
3 Replacing IR 7 Compressor Motor 28000 160000 5.7
4 Replacing IR 8 Compressor Motor 29000 180000 6.2
5 Replacing Elgi4 Compressor Motor 24000 140000 5.8
6 Replacing Grinding Motors 17000 180000 10.6
7
Using Diesel Fired Hot water Generator in Aqua
wash 61000 400000 6.6
Total Estimated Monthly Savings 647000 Rs
Total Estimated Yearly Savings 7764000 Rs
Total Required Investments 2820000 Rs
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45. CHAPTER 6 Monetary Benefits and Future Plan
Total 647000 Rs Monthly savings estimated
During this Project 5 % Energy cost saved by improving power factor from 0.92 to 0.97 by
compensating Reactive load with detuned Reactors (APFC Panel)
Future Plan:
1. Install further 3 APFC panels to achieve the 100 savings on power factor
2. Install digital Meters in all LT Panels to measure the power factor
3. Implement SCADA system for Energy Monitoring
4. Purchasing the Portable Energy Audit kit
5. Replacing all re wound / low efficient Motors
6. Conduct Energy Audit Every year
7. Find out Energy Loss in HT Furnaces
8. Use Hot Water generators in Aqua Wash Instead of Electrical Water Heaters
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46. Chapter 7 Conclusion
To conclude I can proudly say that with this project activity has been successful in reducing energy
cost, the success of this project is solely due to the dedicated efforts put in by the circle members
and the encouragement and guidance given by our superiors. We thank them whole-heartedly for
helping us to achieve our targets.
Finally, we thank you for going through this project Activity report.
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47. Chapter 8 References
1. How to write your Thesis
Compiled by Kim Kastens, Stephanie Pfirman, Martin Stute, Bill Hahn, Dallas Abbott, and
Chris Scholz
2. Plant Single Line Diagram
3. Internet articles about Energy Conservation
4. Ministry of Power’s article on Energy Conservation – 2005
5. Crompton Greeves Energy Efficient Motor Manual
6. Thermax Boilers Technical Sheet
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