2012 IEEE International Conference on Power Electronics, Drives and Energy Systems

December16-19, 2012, Bengaluru, India

Energy Efficiency in Electrical Systems

D. Maheswaran

K. K. Jembu Kailas

Larsen & Toubro Limited, Chennai, India

dmaheswaran@lntecc.com

kkjk@lntecc.com

V. Rangaraj
raaj@lntecc.com

W. Adithya Kumar
aadi@lntecc.com

AbstractMitigating climate change and achieving stabilization

of greenhouse gas atmospheric concentrations the objective of
the United Nations Framework Convention on Climate Change
(UNFCCC) will require deep reductions in global Energyrelated Carbon Dioxide (CO2) emissions. G-8 leaders called for a
50% reduction in greenhouse gas (GHG) emissions before 2050
to avoid the most serious consequences of climate change.
Meeting this goal requires transforming the way energy is
produced, delivered, and consumed across all sectors of the
economy and regions of the world.
Energy efficiency offers seemingly glittering promises to allsavings for consumers and utilities, profits for shareholders,
improvements in industrial productivity, enhanced international
competitiveness and reduced environmental impacts. As global
energy demand continues to grow, actions to increase energy
efficiency will be essential. The technical opportunities are
myriad and potential savings real, but consumers and utilities
have so far been slow to invest in the most cost-effective, energyefficient technologies available. The energy efficiency of
buildings, electric equipment, and appliances in use falls far short
of what is technically attainable. Energy analysts have attributed
this efficiency gap to a variety of market, institutional and
technical constraints. Electric utility energy efficiency techniques
have great potential to narrow this gap and achieve significant
energy savings. This paper provides some of the recent trends in
energy efficiency technologies that have been successful and also
used widely worldwide. They are:
1)

Energy efficient motors

2)

Soft starters with energy saver

3)

Variable speed drives

4)

Energy efficient transformers

5)

Electronic ballast

6)

Occupancy sensors & Energy efficient lighting controls

7)

Energy efficient Lamps

This paper presents Case Studies of various energy efficient

techniques used in a Steel Plant resulting in considerable
Electrical energy savings varying from 10-15%. Electric motors
drive both core industrial processes, like presses or roll mills, and
auxiliary systems, like compressed air generation, ventilation or
water pumping. They are utilized throughout all industrial
branches, though the main applications vary. With only some
exceptions, electric motors are the main source for the provision
of mechanical energy in industry. In recent years, many studies

978-1-4673-4508-8/12/$31.00 2012 IEEE

identified large energy efficiency potentials in electric motors and

motor systems with many saving options showing very short
payback times and high cost-effectiveness.
Furthermore, almost all electricity in India is generated by
rotating electrical generators, and approximately half of that
generated is used to drive electrical motors. Hence, efficiency
improvements with electrical machines can have a very large
impact on energy consumption. The key challenges to increased
efficiency in systems driven by electrical machines lie in three
areas:
a.
To extend the application areas of variable-speed
electric drives through reduction of power electronic and control
costs
b.
Secondly, to integrate the drive and the driven load to
maximize system efficiency
c.
Finally, to increase the efficiency of the electrical
machine.
Lighting is a large and rapidly growing source of energy demand
and greenhouse gas emissions. At the same time the savings
potential of lighting energy is high, even with the current
technology, and there are new energy efficient lighting
technologies coming onto the market. Currently, more than 33
billion lamps operate worldwide, consuming more than 2650
TWh of energy annually, which is approximately 19% of the
global electricity consumption. The introduction of more energy
efficient lighting products and procedures can at the same
time provide better living and working environments and also
contribute in a cost-effective manner to the global reduction of
energy consumption and greenhouse gas emissions
KeywordsEnergy Efficiency;Energy efficient motors;variable
speed drives;energy efficient lighting controls.

I.

INTRODUCTION

Energy efficiency refers to the physical performance of

specific end uses or energy services such as lighting, heating,
cooling, and motor drive. Greater energy efficiency is achieved
by replacing, upgrading, or maintaining existing equipment to
reduce the amount of energy needed. Energy efficiency is
usually measured by the output quantity per unit of energy
input (miles per gallon or lumens per watt, for example).
Because energy is one of several factors of production (labor,
capital, and materials are others), energy efficiency
improvements contribute to greater energy productivity and
economic efficiency.

Efficient use of electricity and changes in the electric power

sector will play a vital role in any strategy for achieving a more
energy-efficient society. If the threat of global climate change
prompts concerted action to reduce carbon emissions,
maximizing energy efficiency will be an imperative and a
major overhaul of how energy services are provided and paid
for will be required on a more accelerated schedule.
Utilities & others have consistently found that there are
numerous cost-effective opportunities to use electricity more
efficiently and to avoid the costs and pollution associated with
new plant construction and still have the same energy services,
they are:

Improvements in the building services.

Improvements in the efficiency of electric equipment.

Lighting improvements.

Net efficiency gains from shifting energy sources from

fossil fuels to electricity (electrification).

Optimization of electricity use through better energy

management control systems, shifts in time of use, and
consumer behavior and preference changes.

Fig.2 shows major countries emitting CO2 in 2012

One third of the CO2 emissions in India are due to

Electricity generation & Heat as shown in Fig.3

A. Present Scenario in India

Demand for power in India has been increasing due to the
rising population, growing economy, and changing lifestyles
with Coal having the major capacity and major contribution on
CO2 emission as shown in Fig.1.

Fig.3 CO2 emissions Sources in India

B. National Electrical Policy

By the end of 2012,Indian National Electricity Policy
(2005) aims:
Fig.1 Break-up of installed generation capacity.

Per capita availability 1000 units

With the ever increasing demand for power, CO2 emissions

are following the increasing trend. As per the statistics taken in
September-2012, India alone contributes 6% of the total CO2
emissions in world with Europe, USA & China topping the list
as shown in Fig.2.

Installed capacity over 200,000 MW

Spinning reserves 5%

Minimum lifeline consumption of one unit per

household per day

Inter-regional transmission capacity 37,000 MW

Energy efficiency/conservation savings about 15%

Quality and reliable power supply.

II.

ENERGY EFFICIENT TECHNOLOGIES IN

ELECTRICAL SYSTEMS

As global energy demand continues to grow, actions to

increase energy efficiency will be essential. The technical
opportunities are myriad and potential savings real, but
consumers and utilities have so far been slow to invest in the
most cost-effective, energy-efficient technologies available.
The energy efficiency of buildings, electric equipment, and
appliances in use falls far short of what is technically
attainable. Energy analysts have attributed this efficiency gap
to a variety of market, institutional and technical constraints.
Electric utility energy efficiency techniques have great
potential to narrow this gap and achieve significant energy
savings. This paper provides some of the recent trends in
energy efficiency technologies that have been successful and
also used widely worldwide. They are:

This paper provides a detailed study considering a lower

bound of 0.75 kW and an upper bound of 200 kW into account
the standard power sizes and the new proposed International
Electro technical Commission (IEC) 60034 30 efficiency
classification standard on motor efficiency as shown in Fig.5.

Fig. 5 Efficiency classes for fourpole motors of standard IE3, IE2 and IE1
classes, and the new IE4 class

IE3 & IE4 Motors have high efficiency at any ambient

temperature. Hence these are costly than IE2 Motors. The
materials cost of the motor is increased by a few percent. While
trying to reduce copper losses, we end up increasing core loss.
Hence the starting current of motor is high (approx. 9.24 times
including IS tolerance), which increases fault levels and in turn
cable size.
However these disadvantages are overcome as the payback
period for the customer can be as little as six months for a
continuously loaded motor.
Thus energy-efficient electric motors reduce energy losses
through improved design, better materials, and improved
manufacturing techniques. Replacing a motor may be
justifiable solely on the electricity cost savings derived from an
energy-efficient replacement. This is true if the motor runs
continuously, power rates are high, the motor is oversized for
the application, or its nominal efficiency has been reduced by
damage or previous rewinds.
Economical benefits and energy savings are illustrated
through a Case Study in Chapter-III of this paper.

Fig. 4 Energy Efficient Technologies

A. Energy Efficient Motors

It is estimated that Electrical Motor-Driven Systems
account for between 43% and 46% of all global electricity
consumption.

B. Soft Starter with energy savers

When starting, AC Induction motor develops more torque
than is required at full speed. This stress is transferred to the
mechanical transmission system resulting in excessive wear
and premature failure of chains, belts, gears, mechanical seals,
etc. Additionally, rapid acceleration also has a massive impact
on electricity supply charges with high inrush currents drawing
+600% of the normal run current.
Soft starter provides a reliable and economical solution to
these problems by delivering a controlled release of power to
the motor, thereby providing smooth, step less acceleration and
deceleration. Motor life will be extended as damage to
windings and bearings is reduced.

However, as the % loading increases, the % savings

decrease. Energy savings are of appreciable quantity only if the
time period is more than 5yrs.
C. Variable speed drives
When discussing energy savings and variable frequency
drives (VFD) the attention often focuses on a centrifugal fan or
pump application. However, one should not overlook other
applications which also have large potential energy savings and
energy recovery. Applications involving regeneration, power
factor correction, common bus applications or a combination of
the three can also quickly achieve a significant reduction in
energy use.
In variable torque applications, the torque required varies
with the square of the speed, and the horsepower required
varies with the cube of the speed, resulting in a large reduction
of horsepower for even a small reduction in speed. The motor
will consume only 12.5% as much energy at 50% speed than at
100% speed as shown in Fig. 6. The following laws illustrate
these relationships:

Flow is proportional to speed

Torque is proportional to (speed)2

Power is proportional to (speed)

transformers have increased efficiencies even at low loads 98.5% efficiency at 35% load.
E. Electronic Ballast
The conventional ballasts make use of the spike caused by
sudden physical disruption of current in an inductive circuit to
produce the high voltage required for starting the lamp and
then rely on reactive voltage drop in the ballast to reduce the
voltage applied across the lamp.
One of the major advantages of electronic ballast is the
enormous energy savings it provides. This is achieved in two
ways. The first is its amazingly low internal core loss, quite
unlike old fashioned magnetic ballasts. And second is
increased light output due to the excitation of the lamp with
high frequency. If the period of frequency of excitation is
smaller than the light retention time constant for the gas in the
lamp, the gas will stay ionized and, therefore, produce light
continuously. This phenomenon along with continued
persistence of the phosphors at high frequency will improve
light output from 8-12%. This is possible only with high
frequency electronic ballast
F. Occupancy sensors & enery efficient lighting control &
Lamps
These sensors switch lighting ON when occupancy is detected,
and OFF again after a set time period, when no occupancy
movement detected. They are designed to override manual
switches and to prevent a situation where lighting is left on in
unoccupied spaces. With this type of system it is important to
incorporate a built-in time delay, since occupants often remain
still or quiet for short periods and do not appreciate being
plunged into darkness if not constantly moving around.
CFL have taken over from incandescent bulbs and the present
trend is LEDs which save more energy while providing the
same lux levels.
Proposed activities:
1.

Timer circuits for external locations viz. Coal yard,

Coke / Ferrous Stock houses etc are to be provided.

2.

Connecting photo sensitive devices to the lighting

panels which are operated manually.

Fig. 6 Power savings using VFD

3.

Reducing operating voltage by adjusting lighting

transformer tap( where-ever possible )

D. Energy efficient Transformers

Most energy loss in dry-type transformers occurs through
heat or vibration from the core. The strategy developed to
make power available to all by 2012 includes promotion of
energy efficient products and its conservation in the country,
which is found to be the least cost option to augment the gap
between demand and supply. The new amorphous core
transformers with high efficiency minimize these losses.

4.

Replacement of incandescent lamps by CFL and

energy efficient lamps like LEDs.

5.

For street lighting applications, implementation of

Solar cells & LEDs will result in higher energy
saving.

6.

To change the timer setting of O&S building

Centralized AC so as to switch it OFF earlier during
evening peak.

The expected reduction in energy loss over conventional (Si

Fe core) transformers is roughly around 70%, which is quite
significant. By using this amorphous core with unique
physical and magnetic properties- these new types of

III.

CASE STUDY

C. Comparison between Fan and Pump

The following case studies have been performed for a steel

plant especially for rolling mills with data collected over a
period of 2 years.
The following table (Table. I) provides a glimpse energy
efficient technologies & suitability along with payback period
for equipment where there was scope of energy savings.

Parameter

FAN (6.6kV)

PUMP (6.6kV)

Power factor improvement

0.97

0.97

Motor efficiency

96.5%

97%

Reduction

280kW

219kW

Average running time per year

5000 hrs.

3200 hrs.

Energy saving (MWh/year)

1400

700.8

Area

Energy
efficient
Technology

Suitability

Payback

Motors

Energy efficient Motors

Very Good

1-1.5yrs

Table. IV Energy Savings with VFD

D. Energy Savings with Soft Starters

Soft starters
Mill motor

VFD

Very Good

6-8months

Water Pumps

VFD

Very Good

6-8months

Blower pump

VFD

Very Good

6-8months

10

58

Lighting

Energy efficient control

Good

1.5-2yrs

20

37

30

20

40

11

50

60

4.5

70

80

90

1.5

Table. I Energy efficient technologies in rolling mills

Energy savings provided here are only for a Fan and Pump.
However, the same philosophy has been followed for other
motors like conveyors & Mill motors.
A. Status without VFD
Parameter

Measurement
FAN (6.6kV)

PUMP (6.6kV)

Motor Rating

1760

775

Total air flow at full load

650TPH

Flow

10000m3/hr

Fan Speed

600RPM

560RPM

Current

182A

88A

Peak Power Consumption

1760kW

775kW

Table. II Energy without VFD

B. Running with VFD

Parameter

Measurement
FAN (6.6kV)

PUMP (6.6kV)

Motor Rating

1760

775

Total air flow at full load

650TPH

Flow

10000m3/hr

Fan Speed

580RPM

490RPM

Current

145A

45A

Peak Power Consumption

1480kW

556kW

Table. III Status with VFD

% Loading

% Savings

Table. V %Energy Savings with Soft Starters

E. Energy Savings with energy efficient Transformers

In this case study we considered a iron-steel industry with
average electricity loading of 60 MW. About 30 MW of the
loading is used at higher voltages (mainly high-voltage motors)
and are therefore not distributed by distribution transformers.
The electricity consumption is relatively constant during 24
hours a day, 7 days a week.
The transformer rating is between 630 kVA and 4000 kVA.
There are about 20 transformers. 10 transformers (50%) are
1250 kVA; 25% of the transformers 1600 kVA and 25% other
ratings. Almost all transformers are dry-type transformers
because of problems in the past with PCB in oil. Most of the
transformers have been replaced with Amorphous Core
transformers. We evaluated the energy saving between the
normal dry-transformers and the amorphous core dry type
transformers for the ratings 1250 and 1600 kVA compared
with the actual present transformers.
If the life cycle of the already existing dry type
transformers is exceeded, amorphous core transformer with
high efficiency and low losses can replace these existing dry
type transformers.

Transformer

Unit

Dry type
transformer

Amorphous
Core Dry type
transformer

rating

kVA

1250

1250

no-load loss

2400

2200

-200

load loss

13568

11712

-1856

Annual losses

kWh/
a

71241

62618

-8623

CO2 emission @
0,4 kg/kWh

ton/a

28,5

25,0

-3,5

Pay back (years)

Difference

2.5

The intent of this paper is to bring out the salient energy

efficient technologies prevailing today. This should not be
considered as a guideline for the energy saving for electrical
systems. Depending upon the system requirement and usage,
the appropriate and most suitable energy efficient methodology
can be adopted which doesnt affect the system performance.
REFERENCES
[1]

[2]

Table. VI Energy Savings with Energy efficient Transformer

[3]

F. Energy efficient lighting controls, Ballasts & Lamps

[4]

The Combination of Occupancy Sensors & lighting

controls resulted in a saving of 27,275kWh per year.
No.
Lamps

of

Wattage
(kW)

kWhr
(1day)

Annual
kWhr

Original
system

1524

42.786

213.93

51,344

After
implement
ation
of
above

1524

40.057

100.285

24,068

Table. VII Savings with Sensors, efficient lighting Control

The Combination of Occupancy Sensors & New Fittings

(energy efficient lamps) resulted in a saving of 38274.9kWh
per year with a payback period of 4 years.
No.
Lamps

of

Wattage
(kW)

kWhr
(1day)

Annual
kWhr

Original
system

482

21.584

213.93

69,173.8

After
implement
ation
of
above

446

21.486

200.285

30,898.9

Table. VIII Savings with sensors, energy efficient lamps

IV.

CONCLUSION

India targets 9 10% economic growth rate in a sustainable

manner over next 10-15 years. Over last 10-15 years, private
investments are being encouraged, particularly in petroleum,
natural gas and power. While India is fully committed to
develop and expand its energy markets, it is equally committed
to ensure environmental safeguards. Using latest cost effective
technologies in all the energy segments forms an important part
of policy and strategy.

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