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Industrial energy-saving
1. Industrial Energy Efficiency & Management
Small & Medium Enterprises Development Authority (SMEDA)
Energy Professionals Consultative Seminar
February 10, 2010
2. SMEDA Energy Efficiency Programme
•
International Collaborations;
–
German International Cooperation (GIZ)
–
Japan International Cooperation Agency (JICA)
–
United Nations Industrial Development Organization (UNIDO)
–
World Bank
•
Objectives
–
Minimizing losses in Energy Usage
–
Develop systems to efficiently manage energy related issues
–
Capacity development of industry staff to make industry self-
sustained
•
Beneficiaries
–
62 industrial units (15~20% achieved average savings)
–
25 workshops on Energy Efficiency and Management
3. SMEDA Energy Efficiency Programme
•
Projects
–
Establishing Demo Projects through Energy Audits (2006~2008)
• 6 Demo Projects established in Textile Spinning & Processing
• Partner organization: GIZ
–
Implementation of Energy Management System (EnMS) (2008 ~ 2011)
• EnMS has been implemented in 25 textile mills
• Partner organization: GIZ, APTMA
–
Energy Manager Training Programme
• Two batches of Energy Managers have been trained
• Partner Organizations: GIZ, JICA, APTMA, UMT
–
Development of Energy Service Companies (ESCOs)
• Local Energy Consultants will be trained in Feb.~Mar. 2011
• Partner Organization: GIZ
–
Replication of EnMS to 3 Industrial Sectors (2011)
• Steel Re-rolling, Food & Beverages, Glass Manufacturing
• Partner Organization: GIZ
4. SMEDA Energy Efficiency Programme
–
Energy Audits by Japanese Expert from JICA (June 2010 ~ Jan. 2011)
• 4 detailed energy audits by Japanese Expert Mr. Morihito Takayama
• Partner Organization: JICA
–
Energy Efficiency Management Programme (EEMP) (2011~2014)
• Target Sectors: 3 (Foundry, Light Engineering, Edible Oil)
• Implementation of EnMS in 45 SMEs
• Training of 450 Industrial Professionals
• Partner Organization: JICA
–
Energy Audits in SME Clusters
• Detailed Energy Audits in 25 SMEs through Local Consultants
• Power Looms, Marble, Jute, Auto Parts, Furniture
• Partner Organizations: Relevant Chambers & Associations
–
Gas Appliance Efficiency Improvement Programme
• Survey of Gas Appliance Manufacturers in Lahore & Gujranwala
• Efficiency Improvement mechanism will be developed based on survey
report
• Partner Organization: World Bank
6. Power Distribution System & Power Quality
•
Cable Sizing
–
Voltage drop on distribution
cables must be below 5%
•
Phase Balancing
–
Allowable Max. Current
Imbalance = 5%
–
Allowable Max. Voltage
Imbalance = 1%
•
Improve Power Factor
–
Optimum value is 0.95
–
Capacitor Banks should be
checked regularly
–
Capacitor power loss should not
be more than 10W/1kVAr
•
MDI Penalty
–
Load Shifting to reduce MDI
Location Phase Current A Imbalance
Unit #1
Phase-1 48
24.3%
Phase-2 75
Phase-3 58
Unit#2
Phase-1 82
27.8%
Phase-2 71
Phase-3 113.5
7. Electric Motors & Drives
•
Switch it off
–
Manual switching off, Time
switch, Load sensing
–
Requires Soft Starters
•
Slow it down
–
Install Variable Frequency
Drives to save energy in Low/No
Load Operation
8. Electric Motors & Drives
•
Reducing motor load
–
Bush worn out
–
Cracked Main Connecting Rod
–
Condition after replacements
• Peak Load < 110kW
•
Star/Delta Operation
–
Wood Cutter (NC)
–
Running Peak Load < 30%
•
Process Optimization
–
Marble Cutter
–
30% energy saved by reducing
Idle Operation
300
310
320
330
340
350
360
370
380
390
400
0
50
100
150
200
250
300
12:31:20
12:32:18
12:32:43
12:33:16
12:33:40
12:34:17
12:34:54
12:35:15
12:35:52
12:37:05
12:37:41
12:38:09
12:38:45
12:39:13
12:39:33
12:40:21
12:40:54
12:41:19
12:42:00
12:42:21
12:42:53
12:43:27
12:43:55
12:44:44
12:45:16
12:45:49
A,kW
FP2000TMain Motor (112kW) Consumption
A
kW
V
Over
Loaded
kW vs TIME
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
13:07:46
13:07:50
13:07:55
13:07:59
13:08:03
13:08:07
13:08:11
13:08:15
13:08:19
13:08:24
13:08:28
13:08:32
13:08:36
13:08:40
13:08:44
13:08:48
13:08:52
13:08:57
13:09:01
13:09:05
13:09:09
13:09:13
13:09:17
13:09:21
13:09:26
13:09:30
13:09:34
13:09:38
13:09:42
13:09:46
13:09:50
13:09:55
13:09:59
TIME
kW
Idle
Over
Loaded
Idle Idle
OK
9. Electric Motors & Drives
•
In-efficient use of Vacuum Pumps in a furniture factory
•
Demand pressure for the job = 9 bar
•
Loss of Pump # 01 = 4.5 x 4000 x 10 = 180,000Rs.
•
Pump # 01 has been disconnected
Vacuum Pump
#
Vacuum
Pressure (bar)
Power kW
Total
Generated
Vacuum
Pressure (bar)
01 4 4.5
11
02 10 6.0
10. Electric Motors & Drives
7hp, 36inch fan
6642.85
4329.15
7030.64
988.80
0.00
1000.00
2000.00
3000.00
4000.00
5000.00
6000.00
7000.00
8000.00
2 Return 5 Return 15 Return 6 Return
m3/KWH
116319.4589 7030.64 988.80 16.54465268 41.724 25.17935
ACTUAL POWER CONSUMPTION (4mo avge) 120165.1 KWH/yr
POTENTIAL POWER SAVING (4mo avge) 72516.52 KWH/yr
POTENTIAL % POWER SAVING 60.35%
SAVING IN RUPEES @ Avge. Rs 6/KWh 427847.5 Rs.
Total Power
Consumption
at Max. output
KWh
Total
Actual
Power
Consumpt
Power
Saving/Ho
ur KWh7hp,
36inch
Total Flow
Rate m3/h
Maximum
output
m3/KWh
Minimum
output
m3/KWh
12. Electric Motors & Drives
•
Total Cooling Towers = 3
•
Total Power Consumption = 25.6 kW
•
Annual Power Consumption = 184,126 kWh/yr
•
Total Power Cost = 1,841,260 Rs/yr
•
Cooling requirements vary throughout the year
–
During 3 extreme winter months, difference is about 40 deg
–
Day-Night difference is 10+ deg. (even in extreme summer)
•
15~20% Energy can be saved by regulating water flow using VFD
•
Approx. Total Cost of VFDs = 220,000 Rs.
Approx. Total Saving Potential ≈ 276,188 Rs/yr
Pay Back ≈ 10 months
This is based on Manual VFD, but its better to install Automatic VFD with
Temperature Sensor
13. Compressed Air System
Case-1
•
Compressor capacity = 200hp + 85hp
•
Actual Consumption = 185hp + 82hp
•
Load Time (during Zero Demand) = 45%
•
Total leakage = (185+82 hp) x 45% = 120.15hp (equiv.)
= 89.63 kW
•
Annual Leakage = 89.63kW x 7200hr/yr x 10Rs/kWh
= 6,453,360 Rs/yr
After Improvement
•
Load Time (during Zero Demand) = 32%
•
Total leakage = (185+82 hp) x 32% = 85.44hp (equiv.)
= 63.73 kW
•
Annual Leakage = 63.73kW x 7200hr/yr x 10Rs/kWh
= 4,588,560 Rs/yr
•
Annual Savings = 1,864,800 Rs/yr
14. Compressed Air System
•
Total Annual hrs = 4200hrs (1554 hrs Off load & 2646 hrs On load)
•
All compressors were of 30kW rating
•
Total Energy Consumption = 4,432,960 Rs/yr
•
Peak Pressure Setting = 9bar
•
Required peak pressure = 7bar (7% additional energy for every bar)
–
Loss = (137.67 x 2646 + 50.85 x 1554) x 14% x 10Rs/kWh = 620,614 Rs/yr
•
Leakage test was run with 1 (#501) compressor running
–
Q = 4.53 m³/min
–
T = ON Time = continuous
–
t = OFF Time = 0 sec.
–
So Leakage = 35kW/h x 4200hr/yr x 10Rs/kWh = 1,470,000Rs/yr
–
Leakage Points identified = 14
•
Total Loss = 2,090,614 Rs/yr (47.2%)
Sr. Loaded kW Off Load kW On-Load Hours Off Load
Hours
Off Load kWh Off Load Loss
Rs.
499 32.20 11.25 3255 2816 31,680 316,800
500 33.87 11.4 5156 2169 24,726 247,260
501 35 11.10 4386 2702 29,992 299,920
507 36.60 17.1 357 86 1470 14,700
137.67 50.85 131,54 7,773 (37%) 878,680
Case-2
15. Compressed Air System
After Improvement
•
Pressure Reduced to 8 bars at compressors
•
Cleaning points set at 2.5 bars
•
All leakages repaired
•
2 screw compressors are used at 20% low-load operation
•
New consumption = 2,410,210 Rs./yr
•
Saving = 2,022,750 Rs./yr = 45.6%
16. Welding Plants
•
No. of Welding Plants = 4
•
Off-load working of welding plants is
generally 70~80% (including Arc-to-
Arc delay and Job-to-Job delay)
•
Transformer consumes power during
Off-load in form of losses
•
Switch designed and installed on
plant to eliminate the Off-load Loss
•
For 8hrs shift, at 70% Off-load
–
Savings for 4 plants = 11,760 Rs/yr
•
Shift from Variable Current
Transformer type welding plants to
Inverter type Welding plants saving
30~35% energy in On-Load state
–
Saving Potential = 35,251 Rs/yr
•
Total Saving Potential in Electric Arc
Welding
= 47,011 Rs/yr
Welding units
Current
On-load
(I)
Voltage
On-load
(V)
On-load
cosФ
On-load
kW
Voltage
Off-
load (V)
Current
Off-
load (I)
Off-
load
cosФ
Off-
load
kW
0.175391.7 402.90.354 4.08
single phase
160A/400V
29.39 3.93 0.111
