ENERGY CONSERVATION IN ELECTRICATION DISTRIBUTION NETWORK IN AN INDUSTRY INTRODUCTION

Electrical energy is the most popular form of energy being used as the main driving force in industrial units due to its versatility, easy to use & less pollution. The electrical energy for industrial sector accounts for about 50% of total energy generated. Indian industries consume about 25% more electrical energy for the same level of production as compared to the advanced countries due to hesitation in technology upgradation, obsolete equipment, higher line losses, inadequate capacitive power compensation, poor quality of power supply, etc. In Industries, the distribution network losses vary between 7 & 18% of input energy. Energy conservation measures also require good maintenance practices. These practices also ensure improvement in reliability of the electrical distribution system. Therefore conscious implementation of energy conservation has the added benefit of improved reliability. The implementation of energy conservation measures in electrical distribution network will yield the energy saving of 5 10% of energy input with the pay back period of 1 2 years on the capital investment.

POWER FACTOR IMPROVEMENT FOR ENERGY CONSERVATION

In an alternating current (AC) inductive circuit, there is difference of phase between the voltage and the current. The real power is less than the product of voltage ( V ) and the current ( I ), called the apparent power. Power factor is defined as the ratio of the kilowatts of power divided by the kilovoltamperes drawn by a load or system, or the cosine of the electrical angle between the kilowatts and kilovolt-ampere. This definition of power factor is valid only if the voltages and currents are sinusoidal. When the voltage and/or currents are non sinusoidal, the power factor is reduced as a result of voltage and current harmonics in the system. The Power Triangle : The total power requirement of a load is made up of two components; namely, the resistive part and the reactive part. The resistive compressor of a load cannot be added directly to the reactive component since it is 90o out of phase with the other.

The pure resistive power is known as the watt, while the reactive power is referred to as the reactive volt amperes.

Apparent power KVA Resistive power kW= kVA. cos

Reactive (KVAR) KVA. Sin

Fig. 1, Vector diagram of power input without a power factor correction. Cos VAR = Angle between KVA and KW = Power factor

= Volt ampere reactive

Real Power ( KW ) = Apparent Power ( KVA ) x Cos Or Cos = Real power ( KW ) Apparent power ) KVA )

The Reactive power component also called as wattles power component represents the energy alternately stored or wasted in the magnetic or electric field and cannot be utilized by conversion to other forms. The power factor will be leading, if the current is leading the voltage and it is lagging when the current is lagging the voltage. A power factor of unity ( 100% ) denotes 100 percent utilisation of the total current for useful work whereas a power factor of 0.75 shows that only 75 percent of the current is performing useful work.

Effect of the Lower Power Factor : A low power factor causes poor system efficiency, as the total apparent power must be supplied by the source (store electricity boards). When the power-factor is low, the generator has to develop more reactive KVA, with the result load on the prime mover or turbines in a generating plant also increases but since the reactive KVA cannot be utilized, the cost of generation increases. For the same power to be transmitted over transmission lines or cables, it will have to carry more current at low power factors. Increased current increases the line losses and the voltage drop is also increased. Penalty charges are levied on industries in case their overall power factor is less than 0.9. KVA capacity of the transformers is decreased at low power-factor of the motors and the other equipments.

To summarise, due to low power factors the overall cost per unit increases and efficiency of the plant is decreased. Effect of Raised Power Factor: When the power factor is improved by installing power capacitors or synchronous motors, several savings are made: 1. A high power factor reduces the load on transformers and distribution equipment, that is, lower loading of transformers, switchgears, cables etc.

2.

A high power factor decreases the I2 R losses in transformers, distribution cable, and other equipments resulting in a direct saving of kilowatt-hour consumption.

3. A high power factor helps stablise the system voltage, that is, improvement in voltage conditions and apparatus performance. 4. A high power factor eliminates the penalty charge. Payable to State Electricity Board. 5. Increased capability of the power system, that is, additional load can be met without additional equipment. 6. Transformer size is based on KVA, and as the power factor approaches unity, the smaller the KVA and hence the size of transformer.

ELECTRIC MOTORS
Electric Motors are used to drive equipment like Pumps, Compressors, blowers etc. in industries. It is important that the industrial users defines their need accurately to enable proper selection of Motors for specific applications. The important points to be considered when selecting a motor for any application, the following points should be considered. Process requirement: Flow, automatic / non-automatic control, Variable speed, etc. Technical aspects: Breakdown torque, start-up torque, duty / load cycle, and operating conditions. Electrical system requirement Availability, reliability, inventory and maintenance requirements. Price of motor The general observation in the industry is that motors of higher rating than is required for the given application are used. This may be because of over design by original equipment manufacturers and also under loading. Good knowledge of process parameters and a better understanding of the plant power system will help in reducing the over sizing of the motors without any loss of reliability. FACTORS AFFECTING PERFORMANCE The efficiency of an electric motor is the ratio of the mechanical energy delivered at the rotating shaft to the electrical energy input at its terminals. The efficiency with which this transformation takes place is determined by intrinsic losses are a function of the motor design parameters. Fig. (2) Shows the typical variation of efficiency, power factor, and in input current with load for an induction motor. The power load performance (in terms of efficiency and power factor) depends on the design parameters of the motor and varies for different makes of motors. For operating loads in the range of 60% to 100% of rated load, the reduction in motor efficiency is not very significant, but the power factor drops considerably. On further reducing the load, both power factor and efficiency decrease and the effect is very significant at very low loads. Intrinsic motor loses are no load losses (fixed losses) and load losses (variable losses). No load losses as the term implies, occur even when the motor is unloaded and are relatively constant over the entire load range. The fixed losses in a motor comprise of magnetic core losses and friction and windage losses. Load losses vary with the motor load and consist of stator and rotor I2 R losses and stray load losses.

Efficiency (%) and power factor (%) 90 - 80 - 70 - 60 - 50 - 40 - 30 - Stray load loss

Efficiency

Power factor

Total loss

I2R loss

20 - -10 - Core losses Friction and windage losses

75 100 125 Load (%) Fig. (2) Typical loss distribution and approximate efficiency and power factor Fig.(2), also shows the variation of different types of loses with variation in motor loading. Magnetic core losses or iron losses consist of eddy current and hysteresis losses in the stator and rotor magnetic structure. They are independent of load but depend on voltage, core steel material, and its physical geometry. Friction and windage losses are caused by friction in the bearings of the motor and the windage loss of the cooling far and other rotating parts. These losses are constant over the entire load range and the rated revolution per minute copper loses (I2 R losses) are caused by currents flowing through a resistive path and is a function of the square of the current. Motor performance is also affected considerably by service conditions such as voltage and frequency and voltage unbalance across the three phases. Voltage unbalance across the three phases. Voltage unbalance can be detrimental to motor performance and motor life. The table given below shows the effect of the voltage unbalance on the performance of a 5 HP motor. Another factor that affect the efficiency is the practice of rewinding of burnt-out motors. Through proper rewinding, motor efficiency can sometimes be maintained at previous levels. However, in a majority of instances, poor workmanship and poor rewinding practices result in efficiency losses.

25

50

EFFECT Unbalance in current ( %) Increased temperature rise O C

0.3 0.4 0.0

% unbalance 2.3 17.7 30.0

5.4 40 40

Effect of voltage unbalance on motor performance. ENERGY SAVING Energy consumption in motors can be reduced by the operational and retrofit improvements listed below. Operational improvements Operate at rated voltage and balanced supply Improved controls Regular maintenance Improved cooling

Retrofit improvements Replace oversized motors with those of lower rating Replace old and inefficient motors with new motors Replace existing motors with energy efficient motors Use of proper controls (e.g., variable speed drives, soft starters etc.)

Energy efficient motors Energy efficient motors ensure better performance, which is achieved by incorporating design improvements to reduce intrinsic motor losses. A check on motor losses is possible through several measures such as using low lots steel, increasing the active material using longer core length, using thinner laminations, reducing the air gap between the stator and rotor, using copper bars in the rotor instead of aluminiunm bars, by using superior bearings and a smaller fan, etc. As a result of these modifications, cost of energy efficient motors are also higher than those of standard motors. The advantages of an energy-efficient motor are: reduced power consumption lower temperature rise and increased service life, broader band of constant efficiency thereby enabling operation at lower loads without appreciable drop in efficiency, and improved power factor of operation

Energy-efficient motors are now available in India and their efficiency is higher by three to four per cent in comparison to standard motors. The power factor of these motors also improves along with the advantage of a fairly flat performance characteristic over a wide range (typically 50% - 100%) of load. These motors cost about 30% more than equivalent standard motors. Even so, the savings, which could be achieved at such improved efficiencies, justify the additional expenditure incurred on the motor. The economics, however, depend on the operating hours and the electricity tariff. Usually, motors operating for less than 2000 hours / annum are not good cases for replacement by energy-efficient motors. The selection of such motors should be based on several factors in addition to that of a standard motor. Electric power saving and life-cycle cost comparison with those of standard motors. Improved ability to perform under adverse conditions such as abnormal voltage (generally, energy-efficient motors have superior performance characteristics under abnormal voltage conditions) Lower operating temperature Lesser noise levels Ability to accelerate higher-inertia loads than standard motors

 In 1977, NEMA recommended a procedure for making a three-phase AC motors with a NEMA nominal efficiency which represents the average efficiency for a large population of motors of the same design. The nominal efficiency represents a value that should be used to compute the energy consumption of a motor or a group of motors. Full load efficiencies data of NEMA Design B Standard three-phase induction motors are reproduced in Table 1. For example a 3 horsepower electric motor, as shown in the Table, have an efficiency range of 74 to 83 per cent. At 74 percent efficiency the input power to the motor is 3024 Watt and at 83 percent efficiency the input power is 2696 Watt. Thus for the same output of 2238 W (3hp), the input power consumption can range from 2696 W to 3024 W, and so to say, there is an increase in energy consumption and the power cost of 12.2 percent, to operate the less efficient motor. For comparison purpose some typical average nominal efficiency values of energyefficient motors are shown in Table 2. These data are based on available published informations.

TABLE1
FULL LOAD EFFICIENCIES OF NEMA DESIGN B STANDARD THREE-PHASE INDUCTION MOTORS
Horse power 1 1.5 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 Nominal Efficient Range% 68 78 68-80 72-81 74 83 78 85 80 87 81 88 83 89 84 89 85 90 86 90.5 87 91.5 88 92 88.5 92 89.5 92.5 90 93 90.5 93 91 93.5 91.5 94 91.5 94.5 Average Nominal Efficiency % 73 75 77 80 82 84 85 86 87.5 88 88.5 89.5 90 90.5 91 91.5 92 92.5 93` 93.5

TABLE2
FULL-LOAD NOMINAL EFFICIENCIES OF THREE-PHASE FOUR-POLE ENERGY EFFICIENT OPEN MOTORS
Horse power 1 5 10 20 25 50 75 100 150 200 Nominal Efficiency Range% 82 85.5 85.5 89.5 89.5 91.7 90.2 93.6 91.0 94.1 93.6 94.5 94.1 95.4 94./1 96.2 94.5 96.2 95.0 96.2 Average Nominal Efficiency % 83.5 87.9 90.6 92.1 92.6 94.1 94.8 95.1 95.3 95.5

REPLACEMENT OF UNDER LOADED MOTOR WITH LOWER CAPACITY MOTOR A CASE DUTY: Existing motor details Rating Full load current Full load speed Full load efficiency Full load power factor : : : : : 37 kW 65 amp 1470 rpm 90% 0.86

Existing motor operation Motor loading Peak current Efficiency Power factor : : : : 31% 30.7 amp 65% .53

Proposed option Standard Motor Rating : 22 kW Full load current : 40 amps Maximum loading : 53% Motor efficiency at given load : 78 Power factor at given load: 0.65

Associated energy savings Reduction in input power Annual energy saving Net investment in replacement Simple payback period : : : : 1.4 KW Rs.35784/Rs. 45000/15 months

Energy efficient motors Rating Full load current Maximum loading for same load Motor efficiency at given load Power factor at given load : : : : : 22 kW 40 amps 53 % 90 % 0.75

Associated energy saving Reduction in input power Annual energy saving Net investment in replacement Simple payback period : : : : 1.9 kW Rs. 48564/Rs. 58500/14 months

Efficiency (%) and power factor (%)

90 Efficiency

80 70 60 50 40 30 20 Stray load loss

Power factor

Total Loss

I2 loss

10 Core losses

0 0 25

Friction and windage losses

50

75

100

125

ENERGY SAVING USING VARIABLE SPEED DRIVES The motor popular applications of VVVF drives are fans and pumps where the loads vary depending upon the flow rate. The other application is where eddy current drives are used. The parameters involved are: Process Fan side Drive side - flow rate, load cycle - Torque, speed and power - Torque, speed, current power and motor details

Power Torque x speed

Torque (speed)2 Power consumed (speed)3

From the above it is observed that as the speed decreases, the power consumption also decreases but in a cubic manner. How Drives saves energy? To maintain the set flow rate bases on the inputs the flow rate may vary as pr the process demands. Flow control is achieved by follow: Conventional method Pumps - Valve control ( Open / close) Fans - Dampers / vanes ( Open / close) In this case the flow control is achieved by diverting / resisting a part of the fluid flow. The pumping rate does not decrease 1:1 for a decrease in flow rate. Electrically the following takes place Motor speed does not change. Hence the mechanical losses (windage and frictional losses) do not change Motor load varies depending on the resistance to the fluid flow. Hence, the energy spent by the mot does not decrease proportional to the decrease in flow rate. The exact load curves for various methods of control brings out this point.

Using variable speed drives Motor speed varies depending upon flow rate required. Pumping rate = Discharge rate No diversion / resistance to flow on the delivery side. Hence there is no wandage of energy on unproductive flow. The savings

VFDs reduces the speed of the motor and hence mechanical losses decrease. As power is (speed)3, the power consumed decreases drastically for speed variations. Hence considerable energy savings are realized more so at partial loads. There is no unproductive diversion / resistance to the fluid flow. Improved power factor 0.93 to 0.96) reduces the system losses Case study In the air pressurization system of plant substation the pressure inside the substation was originally controlled by outlet damper. By using a VVVF controller the pressure control was achieved and the associated energy savings are as given below:Power drawn without variable speed Power drawn with variable speed drive Savings in Kw Savings / year Cost of VSD unit Single pay back period = Kw = = = = = 16 months