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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