Electrical Energy Audit and Conservation

Unit 9: Energy saving opportunities [2]

9.1 Electrical system:

9.3.11. Sub- station and transformer

i. Locate the sub-station nearer to the load center to minimize the energy losses and
to improve then end voltage.
ii. Identify under loaded transformers and redistribute the load to achieve optimum
loading condition.
iii. Switch of transformers and re-adjust the load on holidays.
iv. Provide necessary circuit breakers and dis-connectors to the transformers and
adopt split bus system in sub station to allow flexibility of operation.
v. Provide all necessary instruments for monitoring the performance of individual
transformer.

9.3.21. Load management and power factor improvement

i. Incorporate a warning system in the maximum demand indicator so as to enable

immediate steps to be taken.
ii. Transfer the operation of high unit loads judiciously to lightly loaded shift hours to
reduce the maximum demand.
iii. Flatten the load curve and maintain a high load factor.
iv. Avoid idle running for machine.
v. Install capacitors with per-phase control to modulate the requirement of reactive
power.
vi. Maintain the peak load power factor between 0.94 to 0.98.

9.3.31. Distribution system

i. Minimize LT distribution by increasing the HT distribution system.

ii. Check cable size and ensure that cables of adequate current carrying capacity are
installed.
iii. Install separate distribution and switch boards for power and lights for individual
departments.
iv. Replace old paper cables having a high leakage factor with new PVC/XLP cables.
v. Balance the loads on all the three phases within  1% as voltage imbalance results
in higher losses.
vi. Install capacitors near the load points or at the sub distribution board.

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9.2 Electric Drive:

Definition:

 The system which is used for controlling the motion of an electrical machine, such type
of system is called an electrical drive. In other words, the drive which uses the electric
motor is called electrical drive.
 The electrical drive uses any of the prime movers like diesel or a petrol engine, gas or
steam turbines, steam engines, hydraulic motors and electrical motors as a primary source
of energy. This prime mover supplies the mechanical energy to the drive for motion
control.

Advantages of Electrical Drive

The following are the advantages of electrical drive.
1. The electric drive has very large range of torque, speed and power.
2. Their working is independent of the environmental condition.
3. The electric drives are free from pollution.
4. The electric drives operate on all the quadrants of speed torque plane.
5. The drive can easily be started and it does not require any refuelling.
6. The efficiency of the drives is high because fewer losses occur on it.

Disadvantages of Electrical Drive

The following are the disadvantages of electrical drive.
1. The application of the drive is limited because it cannot use in a place where the power
supply is not available.
2. It can cause noise pollution.
3. The initial cost of the system is high.
4. It has a poor dynamic response.
5. The output power obtained from the drive is low.
6. During the breakdown of conductors or short circuit, the system may get damaged due to
which several problems occur.
Application of Electric Drive

 It is used in a large number of industrial and domestic applications like transportation

systems, rolling mills, paper machines, textile mills, machine tools, fans, pumps, robots
and washing, etc.

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Motors consume nearly 85% of the power consumed by an industry. The potential saving of
electric motors is considerable at around 10-15%. The investment required on retrofit
modifications and replacement can normally be recovered within 3-4 years depending upon the
numbers of hours operation.

Check list for motors

i. Efficiency and power factor of the motor fall, if they are under loaded (<50%)
ii. Choose the motor size to match the load.
iii. Use a high efficiency motor instead of a standard induction motor when a motor is
required to produce constant and continuos torque or if the duty cycle is high.
iv. Replace rewound motors by standard motors where efficiency of rewound motor is
poor.
v. Do not use excessively tight belt.

Motor Drive Installations

i. Connect appropriate rated capacitors across motor terminals.

ii. Check voltage at points of use: At 90% of rated voltage, heating a work piece takes
25% extra time. Although total kWh required are the same, power used by supporting
equipment ( i.e., lighting, mixing, conveyors, exhaust etc.) are time based and their
kWh usage will be 25% above than normal. Hence use appropriate tap setting of
distribution transformer.
iii. Look out for oversize equipment.
iv. Lubricate moyors and drives regularly and provide proper lubrication.
v. Adopt proper maintenance practice to avoid friction losses such as misalignment of
equipment, frozen bearing and belt drag.

9.3 Lighting system:

Good lighting is required to improve the quality of work, to reduce human‟s / worker‟s
fatigue, to reduce accidents, to protect his eyes and nervous system. In industry it improves
production, and quality of products / work. To view economy of lighting system, cost of
initial installation cost, running cost, and effect on production / work are to be considered as
main parameters. The power consumption by the industrial lighting is nearly 2 to 10 % of
total power consumption, depending on type of industries

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9.3.1 Checklist of lighting system

i. Use as much natural lighting as possible by use of translucent roofing sheets.

ii. Use day lighting effectively by locating workstations requiring the most
illumination near the window.
iii. Avoid use of incandescent lamp. The power consumed by the GLS is 80% more
than the FTL lamps for the same lumen output.
iv. Use electronic ballast ( if good reliable make is available) in place of a copper
choke as the power saved will be about 80%.
v. Localized or task lighting schemes normally consume less energy than a general
lighting schemes unless a high proportion of the area is occupied by works area.
vi. Controls are very effective way of reducing lighting cost. Install switching for
effective control illumination.
vii. Install switching or dimmer controls to provide flexibility when spaces are used
for multiple purposes and require different amounts of illumination.
viii. Rule out use of GLS lamps for industrial lighting and install CFL lamps in
stairways, corridor and toilets etc.
ix. Propose to use 4 core cables fore street lighting and use staggered 3-phase
loading from pole to pole. Street light control by 33%, 66% and 100% turn
‘ON’ is possible according to the employee movement and shift demand in the
plant.

9.3.2 Management of lighting system

 Lighting has a considerable impact on our working and living spaces, either helping
fashion environments that create the right mood or causing discomfort or disruption
when we get it wrong.
 Lighting management systems help facilities management teams to ensure that the
lighting environment is always optimized to the needs of occupants, and caters to
their needs.
 Their advanced lighting control features improve the aesthetics and productivity in
living and working spaces, creating a human centric lighting (HCL) environment
 Since lighting accounts for 45% of the annual electricity used in office buildings,
this can mean saving up to 60% or more of your energy costs, contributing to
numerous credit categories for LEED® certification.
 The application of several features and technologies contribute towards reducing
consumption — such as dimming, motion sensing, daylight harvesting, ambient
light sensing, and much more. Intelligent software helps generate a real-time view
of lighting and power usage and helps maximize energy efficiency by remotely
adjusting shading, lighting, HVAC, and other equipment.

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