Energy Intake by the industry

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Energy Intake by the industry

• Energy Losses (Between the Cup Lip in industry)
  
• Voltage Regulation in Stages upto Load End
• Power Factor Regulation in Stages
• Compressed Air Cool Dry Air in Stages
• Energy Measured Digitally Accurately
• Measure Energy from Entrance to Load End .

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Energy Efficiency Benefits

• Reduced Energy bills Visible Gains !
• Increased Productivity Invisible Benefits !!
• Improved Quality
• Increased Profits
• Increased Competitiveness
• Ultimately, Machines Health Improves By -
• - Minimum Energy Input Maximum Output
• This Prolongs the life of machines Safety
• Important We get more from machine even later

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Energy usage Break-up in FoundryApproximate
power consumption of Major Equipments ( Typical )

• Total Energy input
• Melting Furnaces
• Annealing Furnaces
• Compressors
• Sand plant
• Other loads
• lighting

• 100
• 60
• 17.14
• 11.48
• 2.55
• 6.52
• 2.28

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Energy Balance in Induction Furnace
Material Grey Iron Crucible Capacity 3200 Kg
Volts - 968 input 733 KW Production capacity 1600 Kg /hr
Input Energy 660 Units / Ton 100
USEFUL HEAT 380 units / ton 58.5
Coil I2R losses 130 units / ton 20
Radiation losses 97.5 units / ton 15
Conduction losses 34 units / ton 5.2
Unaccounted loss 18.5 units / ton 1.3
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Foundry furnace savings aspects

• Busbar losses - joints inpsect, overheating,
  discolor
• Pneumatic ckt - demoist, lubricate, press
  regulate
• Hydraulic ckt - oil level, filter, proper
  functioning
• Refractory lining - to check before after melt
• Transformer - ventilation, forced, oil temp,
  connect
• Water ckt - quality, temperature, pressure
  ratings
• Water temp lt 42 C to prevent scale formation
• CT - functioning and water In /Outlet
  temperature monitoring etc., wooden fill gt pvc
  fills practically.

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Radiation losses in foundry

• Temperature - Energy loss - Energy loss
  C -
  btu/sqft/hr - kW /m2
• 555 8000 25.28 833 20,000 64.56 111
  5 52,000 161.4 1400 1,25,000 387.4
• Radiation Line of sight phenomenon Heat loss
  proportional to difference of 4th power of hot
  cold
• Practice to allow 100 150 C higher temp for
  melt to take care of heat loss in sadle during
  transit
• Each 1 extra temp gt 1 to 2 kwh extra consume/ton
• Temperature monitor by pyro T/Couple

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Thermal Efficiency parameters of Induction
Furnace

• 3 to 10 Losses in the Electrical System in
  connecting the bus bars
• 18 to 22 losses in Induction coil as well as
  the water cooled leads
• 4 to 6 losses in keeping the lining hot
• 2 to 4 losses in radiation etc.
• 55 to 75 Thus the Thermal Efficiency of
  Induction Furnace varies in the range.

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Flames leaping out of furnace

• Two identical furnaces taken for case study
• Gun metal to be melted was weighed charged.
• One furnace was operated normally by the
  operators by leaping out the flames outside.
• Other furnace was operated by confining the flame
  within the furnace
• Time taken to melt the charge is the same for
  both the furnaces but the fuel consumption was
  only half.

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Motors range of Losses
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Are we loading our motors efficiently ?
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Motor is a Consumable 7.5 hp replaced by 5 hp
new
Motor particulars 7.5 hp std motor 5 hp E E motor
Motor rating 5.5 KW 3.7 KW
Input voltage Volts 400 400
Full load speed rpm 1430 1450
Power factor 0.84 0.89
Measured current amps 8.6 7.16
Energy consumed / hr 5.0 units 4.4 units
Units consumed MORE 0.6 unit / hr nil
Units lost per day 14 units nil
Units lost per month 430 units
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The table below Compares the behavior of 5 H.P
motor at Higher than 400 voltscourtesy Muskan
Servo OEM study
Input Voltage Current KVA PF
400 7.5A 5.2 0.8
425 11 More 18 More 0.7
435 19 More 28 More 0.61
445 26 More 38 More 0.57
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Improved Power Factor Correction on typical 50HP
Motor gives significant results.
50 HP motor Without Cap 50 HP motor ( with Cap ) Change in parameters
37.3 KW 36.2 KW 3 Decrease
28 KVAR 15.1KVAR 46 Decrease
46.6 KVA 38.4 KVA 17 Decrease
0.8 PF 0.92 PF 15 improvement
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Thermal Imaging Tool to Predictive Maintenance
Management
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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
unbalance of 5 Say motor temp is 60 , then
this raises to 100 C.
Parameter Percent unbalance in voltage Percent unbalance in voltage Percent unbalance in voltage
Parameter 0.3 2 volt 2.3 10 volts 5.4 20 volts
Unbalance in current in 0.4 17.7 40
Increased Temp Rise C in motor 0 Say 60 C 30 60 30 90 40 60 40 100
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Hot spots motor bearing DE NDE
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CONDITION MONITORING Infra red gun readings
point to -

• 0 to 10 C high - Corrective measure to take
  during next maintenance period.
• 10 to 20 C high - Corrective measure required
  as scheduled Maintenance permits.
• 20 to 40 C high - Corrective measure required
  As Soon As Possible.
• 40C and high - Corrective measure
  required immediately.

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Compressed air what supplied what used ?
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CA system Air intake Rupee wise, Paisa Foolish

• Compr. Air intake Temp. 3C raise, Power Up 1
• 100 scfm _at_ 7 bar Annual Comp Air use Rs. 6 Lacs
• Daily clean Pre Air Filter before Air intake
  Filter
• 160 Scfm Compr. _at_ 7 bar at 45C air outlet pumps
• 1 Litre more water in air per hour than at 35
  C

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Compressed Air systems Are we Healthy ?

• Dont crack drains manually all over.Auto-drain
  valve with balancing pipes to be effective
• Regulate at start Demarcate HP LP air usage
  shut off the airlines when not in use
• Provide large air receiver near heavy consumer to
  avoid shock load, fluctuations in
  system pressure
• Filter Lubricator Regulator at end usage point to
  be inspected daily and oil maintained regularly.
• PLMS pipe line moisture separator to be active
  at start and end of line, at usage point.

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CA usage Efficiency Example

• An open 6 mm pipe could consume about 70 CFM of
  air at 5.5 bar pressure which means about entire
  compressed air generation of 20 HP air
  compressor. In contrast
• Energy Efficient Nozzles and jets
• consumes only 20 CFM air at 5.5 bar pressure yet
  provides adequate thrust and air volume for most
  applications.

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Why we use air blow guns instead of blunt nylon
hose ?

• The flow through a leak is similar to an orifice
  in that the flow is determined by the pressure
  immediately upstream of the opening.
• The pressure drops in the line supplying air to
  the leak based on line's ability to support rate
  of flow.
• For example, the air flow across a 1/4" orifice
  at 90 psig is 94 scfm
• but the flow through ten feet of 1/4" I.D. copper
  tube at 90 psig will be less than 40 scfm because
  the pressure will drop to 35 psig in the tube.

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Compressor takes excess power due to inadequate
maintenance
Worn-out piston ring, gland packing 2 3 higher power
Worn, broken, leaking valves 5 6 higher power
Worn, improperly aligned bearings 1 3 higher power
Dirty, non recommended lube oil 1 higher
Clogged suction filter 2 3 higher power
Low, high temp. cooling water flow 1 higher power per 4 C higher water temp up to certain limit
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CA system efficiency improves by

• Reduction of 1 Kg/cm2 air pressure (8 Kg/cm2 to
  7 Kg/cm2) results in 7 input power savings
• Using solenoid ball valves wherever required
• Installation of after coolers and dryers
• Carrying out pump up test, leakage test,
  specific power consumption determination
  regularly
• Ensuring proper air /water cooling of compressor
• 1mm scale build-up on condenser tubes increases
  energy consumption by 40 

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Compressed Air loss - Examples

• Leakage _at_ ½dia hole in Compressed Air line _at_ 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.

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we must know what we consume where

• Preliminary energy audit is a relatively quick
  exercise
• to Establish energy consumption in the
  organization
• Estimate the scope for saving
• Identify the most likely ( easiest areas for
  attention.)
• Identify early ( no-/ low-cost) improvement
  savings
• Set a reference point / Bench mark within the
  machine
• Identify areas for more detailed
  study/measurement
• Preliminary audit uses existing, and easily
  obtained data.

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Energy Audit shows where we stand

• What to do,
• where to start,
• at what cost and
• for what benefits
• First step is start with Preliminary Audit with
  existing Datas.
• Second step is Detailed Audit Generate more
  Parameters.
• Indicative saving potential to achieve
• Good House-keeping yields 5 - 10
• Minor Investment gives 10 -
  15
• Reasonable Investment pays back
  20 - 25

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Shock, Relief Delight

• The three stages of accepting results of an
  energy study or audit of process utility are
• Shock, Relief and, finally, Delight !
• The general wrong opinions about Maintenance has
  been
• "Maintenance is a necessary evil"
• "Nothing can be done to improve maintenance
  costs
• Please remove the opinions now Remember
• Where Safety (Conservation) Fails, Pollution
  Starts.
• Maintenance is a Tool to Productivity
• Utility to process is like Medicine in bottle to
  our body.
• Shake bottle before use shake our body after
  intake for quick better results of medicine.

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FIVE COST REDUCTION MEASURES OF ENERGY
CONSERVATION

• Identify inefficient energy use
• Upgrade machinery process in context of
  energy efficiency
• Improve maintenance practice
• Promote employee awareness and
• Conservation in domestic consumption.

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Tube light variation in Light output Power
output

• Particulars 10 low-360 volt 10 high 450
  volts
• Light output Decreases by 9 Increases by
  8
• Power input Decreases by 15 Increases by 8
• Take the case of your transformer without OLTC
• Low High voltages are 400 to 450 volts in day
  night
• Lighting wants safe regulated working 360 volts
  only
• Priority is towards Energy Savings in Lighting
• More priority is in Safety in lighting voltages
• Tube light life increases and inventory comes
  down
• Not only for tube lights but also for ballasts
  also.

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Conserve Energy Serve Nation

• www.pcra.org
• www.energymanagertraining.com
• Please go through the Govt. Website
• and you will find mine more articles on
  Industry
• Thank You S.ASHOK,
• PCRA Faculty
• BEE certified Energy Auditor
• COIMBATORE 05.
• cell - 9 4 4 3 7 - 2 0 2 2
  0
• ID - ashok.anbesivam_at_gmail.c
  om
• Pl visit my site WWW.energymeasuretosave.c
  om