20b.pdf
TRANSCRIPT
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ENERGY
CONSERVATION
P A SHAH
Associate TPEC. Consultant.
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Energy Conservation
Energy Conservation Act 2001.
Energy Management.
Energy Audit.
Demand Side Management.
Negawatt.
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Energy Conservation Act 2001
The Scope
Public awareness campaign.
Specialized technical advisory services.
Training and certifications of energy auditorsand managers.
Testing and certification of appliances.
Policy advisory services. Energy conservation fund.
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Energy Conservation Act
The Setting
Derivative of national policy.
Energy Efficiency action plan.
National plan for sustainable
development.
Environmental protection laws.
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ENERGY MANAGEMENT
It is an Art, Science and Engineering ofPlanning, Directing, Controlling the
Generation, Supply and Consumption of
Energy to:
MAXIMISE PRODUCTIVITY& COMFORTS.
MINIMISE THE ENERGY COST & POLLUTION
With CONSCIOUS, JUDICIOUS and EFFECTIVE
USE OF ENERGY.
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Energy Management includes
1. Supply side Management likereducing the auxiliary
consumption, T&D losses etc.2. Demand side management
includes customer side
reduction through energyefficiency.
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Energy Audit
It is the verification, monitoring andanalysis of use of Energy includingsubmission of technical as well asfinancial report containing
recommendations for improving energyefficiency with Cost Benefit Analysis andAction Plan to reduce energyconsumption.
Ref: EC Act 2001.
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Energy Audit Types
Phases:
Pre audit phase.
Audit phase.
Post Audit phase.
Preliminary Audit.
Detailed Audit.
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ENERGY ACCOUNTING,
MONITORING AND CONTROL
Energy audit is the systematic approach to carry out criticalexamination of each use of energy and to suggest the waysand means to improve the efficiency
The information of all important equipment of the plant are
required to carry out E. A. Electrical Consumption,
Operating hours
Production and Quality specification/ Variation
Electricity consumption per unit of production.
Electricity consumption per unit of time.
Production per unit of time.
Maxima and minima and normal values of equipment or processparameters like temp., pressure, flow etc.
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Integrated approach
Furnace running at rated capacity
Insulation improvement.
Scope of waste heat recovery
Min. opening of doors
Oil heating economics
Improvement in the lighting system
Upgrading with the latest technology.
Improvement in power factor
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ESCOs
Escos include :
Investment for energy audit and equipments
Financing arrangement
Purchase, installation, maintenance ofequipments
Training of O&M personnel.
Monitoring
Measurement & verification Guarantee of energy saving.
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Demand Side Management (DSM)
DSM is defined as the planning,implementation and monitoring of utilityactivities designed to influence the
use of electricity for mutual benefit of utilityand the customer.
DSM program fall into two categories, energyconservation and load management
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Demand Side Management (DSM)
Energy conservation encourages consumers to
use energy more efficiently, resulting reduced
energy consumption without sacrificing
comforts, convenience or productivity.
Load management shifts electricity loads from
one period to another but rarely reduces
electricity consumption.
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Why care about DSM?- Utility view
DSM can bring :
Less peak power demand reducing need for
outages or extensive peak power purchase Less dist. loss increasing available peak power
that can be sold
More off peak demand - generating more
revenue and profit.
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Demand Side Management
It can increase off peak demand &
revenue.
It can also improve power factor and
allow more generation capacity to be
sold.
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Demand Side Management
Load shapeLoad shapetargettingtargetting
Time of Day targeting. ItTime of Day targeting. Itreduces cost by shifting loadreduces cost by shifting load
from high cost to lower costfrom high cost to lower cost
Geographical targetingGeographical targeting ItIt
reduces cost, by encouragingreduces cost, by encouraging
load growth in area whereload growth in area wheredistribution infrastructure isdistribution infrastructure is
under utilized.under utilized.
Equipment targetingEquipment targeting ItIt
reduces cost by improvingreduces cost by improving
efficiency and p.f. for equipmentefficiency and p.f. for equipment
contributing to peak cost.contributing to peak cost.
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Demand Side Management
Falls in 2 categories :
(1) Energy Conservation
It encourages the consumer to use energy moreefficiently, resulting in reduced energy consumption
without . Sacrificing comfort, convenience orproductivity.
(2) Load Management
It shifts electricity loads from one period to another
but rarely reduces electricity consumption. DSM programmes costs substantially less per kw (or kwh)
saved than it costs to generate a kwh from a new powerplant.
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Demand Side Management
The State and regional electricity system can
be categorized in 2 types from Supply Side
relations.
(1) D MW
(2) D
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Demand Side Management
Options :
Managerial or administrative options such as imposingdemand and energy cuts on the use of electricitynot likedby many
Staggering of weekly holidays and recess periods inindustries.
Shift water pumping for drinking water schemes, industrialuse and agricultural purposes to night off peak periods
Comprehensive energy audit by industrial consumers Co-generation
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Coincidence factor
This coincidence factor measures
fraction of the peak customer level saving
This factor is used to decrease the demand
reduction seen by the utility.
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What is DSM ?
Who can benefit from it?
Demand side management is a way to changecustomer demand by changing equipment efficiency& use pattern.
It benefits :
Electricity utility company (Profit management-Increase revenue, reduce cost & risk)
Customer (House hold -> Increase disposable
income, business -> Become more competitive) Business partners (sale more product & services)
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DSM options
Energy Efficient Motors (EEM)
Variable speed drives (VSD)
Good House keeping Measures (GHK)
Waste Heat Driven Vapor Absorption Refrigeration system (VARS)
Improvement in Electric Arc Furnace (EAF)
Time of Day tariff (TOD) High Efficiency Sodium Vapor Lamps (HPSV)
Compact Fluorescent Lamps (CFL)
Electronic Ballast (EB)
Efficient Pumps and fans (PUMP & FAN )
Power Factor Improvement (PF) Industrial Cogeneration (COGEN)
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Barriers to DSM Options
Those that are under control of the electric utility.
Those that result from cultural or awareness problem
Those related to the institution & infrastructure necessary forsuccessful implementation of DSM programmes.
Others : Lack of information
Non-availability of technology
Uncertain benefits
Lack of tech. expertise
No proven technology (reliability)
Late delivery an uncertainty
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DM E
Companies (ESCOs)
ESCOs have played a major role in DSM
implementation in United States and other Western
C
P C In a Performance Contract, the ESCOs identifies
and implements those measures at no initial cost to
the owner, maintains the measures for the life of thecontract, and guarantees the energy saving.
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Negawatt power
is a theoretical unit ofpower
representing an amount of energy
(measured in watts) saved.
The energy saved is a direct result of
energy conservation or increased
efficiency
http://en.wikipedia.org/wiki/Energyhttp://en.wikipedia.org/wiki/Watthttp://en.wikipedia.org/wiki/Energy_conservationhttp://en.wikipedia.org/wiki/Energy_conservationhttp://en.wikipedia.org/wiki/Watthttp://en.wikipedia.org/wiki/Energy -
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A negawatt is a watt of
electricity that is notused because of a
conservation measure,and is therefore
available for some otheruse.
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For example:
If you switch on a 13-wattcompact fluorescent light in place
of a 60-watt incandescent light
you have saved 47 watts. So you
could say, your new lamp has
added 47 negawatts to theelectrical supply on the grid.
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Power Factor
Improve power factor above 0.95 to get
rebate from utility.
Reduces KVA demand
Reduces electrical losses in the plant.
Reduces cable temperature.
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POWER FACTOR - USE OF CAPACITOR
Power factor is the coefficient of electricalactive work
Power Factor = KWH = COS
KVAH
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WHAT IS THE EFFECT OF P.F.
ON SYSTEM ?
A low p.f. means larger current (larger kva) for same work(kwh).
A low p.f. therefore will result in more loses in internaldistribution system and also in supply lines, and supplierhas to allocate more kva capacity.
A higher p.f. will result in substantial energy
conservation. A low p.f. is caused by induction loads andrunning induction load at reduced capacity.
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Capacitors for induction motors
MOTORMOTOR
HPHP
KVAR Rating for speed (RPM)KVAR Rating for speed (RPM)
30003000 15001500 10001000 750750
2.52.5 11 11 1.51.5 2255 22 22 2.52.5 3.53.5
7.57.5 2.52.5 33 3.53.5 4.54.5
1010 33 44 4.54.5 5.55.51515 44 55 66 7.57.5
2020 55 66 77 99
2525 66 77 99 10.510.5
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MOTORMOTORHPHP
KVAR Rating for speed (RPM)KVAR Rating for speed (RPM)
30003000 15001500 10001000 750750
3030 77 88 1010 12124040 99 1010 1313 15.515.5
5050 1111 12.512.5 1616 1818
7575 1616 1717 2121 2323100100 2121 2323 2626 2828
Capacitors for induction motors
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Motors
RetrofitsRetrofits Approx. SavingsApprox. Savings
If load < 50% connect with starIf load < 50% connect with star
windingwinding
33%33%
Replacement of motor byReplacement of motor by
smaller size energy efficientsmaller size energy efficientmotors if motor load
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Motors
Stopping idle running; Matching motors with the driven load
Improving drive transmission efficiency
Use of high efficiency motors Improvement in the motor systems.
Oversize motor need more investment,running cost, KVA demand, cable losses,Switchgears, Space requirement andinstallation cost.
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Motors
Motor selection may be carried out with load
requirement, duty cycle, motor speed and with the
environmental considerations.
Options available for energy conservation are : Soft starters
Programmable logic circuits (PLC)
High Efficiency Motor(HEM)
Avoiding rewinding of motors more than 2-3 times
Use of variable speed drive
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Importance of motor running cost
Motor rating (KW) 7.5 7.5 37 37
Efficiency 0.86 0.88 0.92 0.93
Power I/P (KW) 8.72 8.52 40.22 39.78
Running Hours 6000 6000 6000 6000
Energy I/P (Kwh) 52,320 2,04,480 9,65,280 9,54,720
Running cost (Rs.) per
annum (@ Rs.,4.00/Kwh)
20,92,800 20,44,800 96,52,800 95,47,200
First Cost (Rs.) 20,000 20,000 1,00,000 1,00,000
First Cost as % of running
cost for 10 Years
0.95 0.97 1.03 1.04
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Importance of motor running cost
Even a small motor of 7.5 KW consumes at full load, electricity worthRs.20 lakhs in 10 years similarly, a 37 KW motor consumers about Rs.1Crore worth of electricity in 10 Years.
The first cost is only around 1% to 2% of the running cost for 10 Years;hence running costs are predominant in life cycle costing.
Even a small difference in efficiency can make a significant difference inrunning cost.
When economically justified, motors may be replaced, even if these have
been recently installed.
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INCREASED COSTS DUE TO OVERSIZED MOTOR
F.L.F.L. 60%60% 40%40%
MotorMotor loadload requirementrequirement (KW)(KW)
requirementrequirement (KW)(KW)
1515 1515 1515
MotorMotor ratingrating (KW)(KW) 1515 3030 5555
MotorMotor efficiencyefficiency ((%%)) 8989 8989 8484
InputInput PowerPower (KW)(KW) 16.8516.85 16.8516.85 17.8517.85
InputInput energyenergy (KWH)(KWH) (For (For
60006000 hourshours // annum)annum)
101100101100 101100101100 107100107100
MotorMotor PowerPower FactorFactor 0.890.89 0.750.75 0.500.50
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INCREASED COSTS DUE TO OVERSIZED MOTOR
F.L.F.L. 60%60% 40%40%
InputInput KVAKVA 18.9318.93 22.4422.44 33.7033.70EnergyEnergy DifferenceDifference (Kwh)(Kwh) -- ---- 60006000
InvestmentInvestment (Rs(Rs..)) 40,00040,000 80,00080,000 1,50,0001,50,000
IncreaseIncrease inin investmentinvestment (Rs(Rs..)) ------ 40,00040,000 110,000110,000
IncreaseIncrease inin runningrunning costcost (Rs(Rs..)) ------ ------ 24,00024,000
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COMPRESSED AIR
Compressed Air is obtained from Compressor which is rated inCFM Compressed air used for pneumatic tools,instrumentation, power hammers, spray painting.
Energy conservations is required since it is round the clockservice. Hence switch off the compressor when not required.
Reduce misuse of air for personal cleaning and cooling. Identify invisible leakages by carefully observing on a holiday
when other sounds are not there.
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Change worn out seals and gaskets.
Use higher efficiency compressors andmotors.
Eliminate 'V' belts.
Use steam turbines in place of motors
wherever applicable. Use direct drive if feasible.
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While selecting higher efficiency compressor, check life cyclecost, part load efficiency, oil consumption and maintenancecost.
Use multistage compressors instead of single stage.
Use large inter coolers to improve system efficiency.
Reduce distribution loss by adopting short length of pipes,minimum bends, minimum charges in sections, corrosionfree piping & ducting.
Maximum velocity of air 6 meters/sec.
Locate the compressors near load centres
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Generally reduce the pressure of air.
Consider carefully real pressure needs of each equipment.
Avoid misuse of high pressure air for low pressure highvolume jobs. Install blowers in such cases.
Stop misuse of personal cooling and if necessary install fans. Stop the compressor during recess hours like lunch time or
shift change etc.
Use electronic soft starter cum energy saver for low load
operation.
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Compressors
RetrofitsRetrofits Approx. SavingsApprox. Savings
Use of flat belts instead of V beltsUse of flat belts instead of V belts 3%3%--11%11%
Measuring and minimizing the leakagesMeasuring and minimizing the leakages
by better seals, valves andby better seals, valves and
housekeepinghousekeeping
10%10% -- 50%50%
Stopping of compressors during recessStopping of compressors during recess
hours.hours.
6.25%6.25%
Use of no load energy saverUse of no load energy saver 33--11%11%
Use of direct driveUse of direct drive Up to 15%Up to 15%
Reduction in compressors outletReduction in compressors outlet
pressure by 10%pressure by 10%
4%4%
Use of blower instead of compressor forUse of blower instead of compressor for
high volume low pressure flows.high volume low pressure flows.
90%90%
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Air Compressors
Check :
Inter cooler
Cool intake
Minimizing no load electrical consumption Leakages
Optimum pressures
Distribution losses
Substitution of compressed air.
Recovery of waste heat
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Furnaces
Check up flue gases, analyze them.
Reduce furnace heat losses through refractory
and through door openings.
Find out possibility of waste heat recovery.
C
Whether furnace is loaded optimally?
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Lighting
Lighting measurements Lux, Kwh
Use of natural day lighting
Task lighting
Reduction of lighting feeder voltage
Low loss electromagnetic chokes and tubes
Use of electronic ballast
Use of timer & Occupancy sensor
Use of FRP Sheets
Manual Controls individual or group switches
Use of high efficiency luminaries.
Clean the luminaries periodically.
R f i i d
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Refrigeration and
Air Conditioning
Reduce need for refrigeration
Increase temperature setting
Reduce heat ingress
Better heat exchanger designs & Maintenance
Better monitoring and control techniques
Energy storage (Peak, off peak, TOD)
Inter fuel substitution (VAS) Dry transmission Electric Motors
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Air conditioner
Remove all the obstacles in front ofit.
Remove the deposited dust on thegrill.
Check the thermostat, clean it.
Switch off the A.C. half an hourbefore leaving the room.
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Air conditioner
If direct sun light comes on the heatexchanger of a.c., it will consume 10-
15% more electricity. Insulate the ceiling, walls with the
help of wood, fiber, etc.
Li h i
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Lighting
Lighting measurements Lux, kwh Use of natural day lighting
Task lighting
Reduction of lighting feeder voltage
Low loss electromagnetic chokes and tubes Use of electronic ballast
Use of timer & Occupancy sensor
Use of FRP sheets
Manual controls- individual or group switches Use of high efficiency luminaries
Clean the luminaries periodically
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PUMPS AND FANS
Normally centrifugal pumps are used to lift liquid or water fromone place to other.
Radial fans are used to move air/gas continuously against
moderate pressures. Impellers of both pumps and fans are driven by AC Induction
motors, with speed to give constant flow.
Variable flow may also be required in specific applications.
Variation of impeller speed gives variable flow
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Flow is proportional to speed. Fan pressure is proportional to square of speed. Fan power is proportional to cube of speed.
If speed is reduced by 5% flow reduces by 5% and pressure isreduced by 25%.
Scope for energy saving in pipes is substantial since normallyduring project design, pumps are over sized.
By the speed control of pumps/fan motors, Energy saving ispossible and also has other advantages like:
During start up acceleration time of motor is controlled, hence Peak load (Max.Demand) can be reduced. Life of pump increases. Reduction of fan speed reduces noise level.
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When parallel pumps work into a common pipe system each pump
can be switched on or off depending on flow requires.
To improve the efficiency in pumping system, following steps have
to be taken.
a Use of pump with high efficiency.
b Use of pipes, valves and other hardware with
minimum frictional loss.
c Proper matching of system characteristics.
d Use of variable speed drive.
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The usual pump equation is as follows: H.P. = Gallon/minute x head(ft) x specific gravity
--------------------------------------------------
(3960 x efficiency)
H.P. = Pressure in inches of water x flow (Cusecft./minute)/6356 x efficiency)
Hydraulic pressure is generally measured by a pressure gaugeconsisting of essentially of a bourdon tube and a suitablemeans for converting the deflection of bourdon tube intomotion a pointer along a scale.
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Advantages of variable speed drives for pumps and fans.
(a) Improved pump seal and bearing life.
(b) Increased motor life.
(c) Increased life of rotating components like
couplings, gear etc. (d) Reduced Noise and Vibration level.
(e) Extended operating range before surge line.
(f) Reduced maintenance costs.
Stop leakage from pipes, valves taps and storage tanksimmediately.
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Stop over flow and spillage of water from storage tanksby providing suitable float valves.
Recycle treated water as far as possible.
Avoid unnecessary water cooling and ensure that the
most effective heat transfer takes place. Reduce water pumping cost, create the maximum heat at
the pump suction and eliminate pressure restrictions.
Remove redundant pipes.
Check on system characteristics & impeller size.
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Consider replacement of undersized lines &valves
Consider whether recycles can be reduced
Switch off pumps when not required Minimize unnecessary flow of cooling water.
Check a scope for cascade cooling system.
Check on cooling water flow rate.
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Air movement for comfort of personnel or cooling of machinery (asman coolers for eg.)
Ventilation of stale/toxic air (as in mines)
Combustion of fuels
De-areation
Transporting gases and mixing them etc.
The requirement of fans to move/ventilate air is determined by thevolume of space (in cubic feet or cubic meters) to be ventilated.
The fan capacity in cubic feet per minute (cfm) is then determined. Apoint to note here is that when a manufacturer rates the capacity of afan at a certain cfm, the actual delivery of the fan will only be around65 to 75% of the rated capacity.
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In industry, fans are generally used for one or more of the followingpurpose :
The horse-power of a fan changes directly as the cube of the speed (RPM),Pressure changes directly as the square of the speed while volume of airdelivered changes in direct proportion to the speed of the fan.
Controls : Fans are controlled by
a. Varying the speed of the drive unit (turbine, motor fluid drive,variable pitch sheaves etc.)
MINIMIZE HEAT LOSSES
(1) Refractory lining-undertake proper repair and replacement.
(2) Furnace openings (lids, slagging doors etc.) - keep open for minimumtime, and ensure satisfactory scaling whom shut.
(3) Metal - transfer system use well-designed and insulatedladles/launders, and design system for minimum transfer time.
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(4) Metal temperature-maintain minimum temperature
consistent with production of sound castings.
Note : Keep the heat in the furnace, and maintain
transfer losses as low as possible.
IMPROVE FURNACE UTILIZATION
All melting furnaces-increase in holding-periods or reductionin power levels results in decreased utilization and increasedenergy consumption.
1 Batch melting - minimize tapping time and frequency.
2 Charge materials-select suitable size, density andcondition.
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3 Charge and molten - metal handling system - design andoperate efficiently.
4 Slagging practice - minimize production of slag, anddeslagging time and frequency.
5 Holding periods - reduce to minimum, facilitated by high
throughput and multi- shift operation.
FURNACE LOADING CONCEPT
Specific energy consumption figures
Depends on loading
Fixed energy consumption (30 to 50 %)
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furnace wall heating
wall heat losses
support structure heating
sec = unit consumed = f.e. + v.e.
production production
Do not accept maximum capacity at face value
verification required
space availability support structure
heater/burner capacity
other items
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CHECK LIST - INDUSTRIAL LIGHTING
Are internal lights left on unnecessarily? This can be a largeopportunity for financial saving with modern control systems, alsoare staff property motivated to "Switch Off"?
Are the most efficient types of lamp/tube being used? Many recentadvances towards more efficient lamps have been made; do notautomatically buy the same replacements. The tungsten filamentbulb must now be ruled out for any relatively continuous use. Fitslimline tubes as replacements in order switch-start fluorescentfittings.
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Consider using high frequency control gear and ballaststo operate standard fluorescent tubes to obtain higherefficiencies of light output against electrical out put. Thisshould particularly be considered when fittings needreplacing or a new building is being equipped.
Consider replacing MBF /U mercury lamps, by moreefficient low/high pressure sodium lamps usingconversion controls now available to convert presentlamp holders.
Are external car park and security lights left onunnecessarily? Use time-of-year clocks or photocellcontrols.
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Are the light fittings themselves giving the best output? Dust
and dirt fouling can seriously reduce output, so clean
regularly. The fitting may give the wrong distribution of light
for the particular room or type of work.
Are the illumination levels the most suitable? Too high a level
wastes energy, too low a level may increase mistakes, slow
down work speeds or even cause accidents.
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Are correct colours used on walls, ceilings, furnishings andmachines, to give a reasonable reflection of light but avoidglare, to give reasonable contrast with material beingprocessed?
Are the lighting switches properly positioned? How far doessomeone have to walk to turn the lights over theirworkstation on or off? Too far and they will be left on even ifdaylight gives sufficient illumination.
Are the number of lights per switch excessive? If some people
are absent, can the lights over their work stations be turnedoff? Often this cannot be done as the switch also controls thelights over other stations where staff need light.
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Have you investigated possible installation of any of theautomatic control systems? These can give very large savingsin suitable cases. They can be activated by light sensors orpersonnel sensors.
When high lighting levels are genuinely required, have youchosen good fittings which emit a high proportion of lampoutput, but do not cause excessive glare which can createeyestrain or complaints?
Do you have a regular cleaning programme for lamps,
reflector and glass panels in lighting systems to minimize lossof illumination? Frequency depends on quality ofatmosphere.
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Have you borrowed (or purchased) a simple light meter(Similar to what photographers/film cameramen use) tocheck for correct illumination level at work stations sothat, where necessary, lighting can be re-arranged locally
reinforced. Such a meter will also help decide onintervals between cleaning since it will indicate gradualloss of outputs due to dust etc.
Have you considered reducing lighting levels in little usedareas, corridors, stores, etc? (One can remove chokes ortubes as an immediate measure.
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Electricity saving tips
Electricity consumption details
Electricity using equipments list
Monitoring of Electricity consumption
Monthly expenses of electricity.
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Electricity saving tips
Analysis of electricity expenses
Wastage of electricity
Steps to save electricity
Saving calculation Use common sense of saving
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Reduce, Reuse, Recycle
Finite planet cannot support infiniteproduction of goods and services
To protect environment, the message for the
21st century is :
Reduce
Reuse
Recycle
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Thank You