PERFORMANCE ENHANCEMENT OF BOILER IN MFL ADVANCED HIGH-STRENGTH STEEL FAMILY CAR ENERGY CONSERVATION IN ELECTRICAL SYSTEM CASE STUDY

Submitted by

S. HARI KRISHNAN V. KOTHANDAN S. SATHEESH KUMAR R. VINODHRAJ

(11908114021) (11908114029) (11908114070) (11908114087)

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING
In

MECHANICAL ENGINEERING VEL TECH ENGINEERING COLLEGE, CHENNAI

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2012

ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

This is to certify that this case study is the bonafide work of

S. HARI KRISHNAN V. KOTHANDAN S. SATHEESH KUMAR R. VINODHRAJ

Carried out the case study under my supervision.

(11908114021) (11908114029) (11908114070) (11908114087)

Mr.S.JAYAVELU, M.E

Mr.SANDEEPKUMAR

BW,M.Tech

HEAD OF THE DEPARTMENT

SUPERVISOR

DEPT. OF MECHANICAL ENGG., VEL TECH, AVADI,CHENNAI 600 062. .

DEPT. OF MECHANICAL ENGG., VEL TECH, AVADI,CHENNAI 600 062.

Submitted for viva-voce held on .. At Vel Tech

INTERNAL EXAMINER

EXTERNAL EXAMINER

S.NO 1.

TOPICS
PERFORMANCE ENHANCEMENT OF MFL BOILER IN

PAGENO.

2.

ADVANCED HIGHSTRENGTH STEEL FAMILY CAR 13

3.

ENERGY CONSERVATION IN ELECTRICAL SYSTEM 19

CASE STUDY 1
PERFORMANCE ENHANCEMENT OF BOILER IN MFL
ABSTRACT:
The case study is about the modification of existing boiler in MFL to improve its performance and minimizing its emission. The modifications carried out by four steps:

Replacement of air registers(Burners) Introducing radial fan in an Induced duct Modifying Duct in accordance with radial fan Addition of soot blowers in super heater Introducing radial fan along with the existing axial fan increases the exhaust suction and creates a huge vacuum in the exhaust and lets the excess air to the chamber and thus the fuel is burnt completely. Due to excess air, fuel is minimized and pollution is controlled. Presence of white smoke indicates the complete combustion. Then by replacing air registers in order to increase the burning efficiency, according to the radial fan design, ducts are modified. New soot blowers are introduced in order to eliminate the deposits on the sides of the ducts & furnace tubes, thus Thermal efficiency is increased. Thus the above modifications improve boiler life and efficiency.

INTRODUCTION:
Boiler-Boiler is defined as a closed vessel in which steam is produced from water by combustion of fuel. Induced Draft-The purpose of the induced draft is to pull out the flue gas obtained from the boiler. Normally the induced draft have axial fan alone which creates vacuum in the furnace for better combustion. EXISTING B0ILER IN MFL

Fig1.1 Existing boiler in MF

The existing model of the boiler is shown in the figure. In MFL there are three plants namely Ammonia, Urea & NPK plants. In MFL oil fired water tube boilers are used. The work of the boiler is to generate heat and to produce steam for various mechanical operations. There are two boilers are in MFL utility plant namely B1, B2. The boilers B1 is running with in better performance, while the boiler B2 partially lost its efficiency due to improper combustion. After Demineralisation the water from the Deaerator is pumped out and sent into the economiser coil1 then transferred into economiser coil2 then it is sent to the steam drum then it is circulated between steam drum and mud drum
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till it attains saturated condition. After that, the saturated steam is passed through the super heater coils and converted to superheated state and that the line is connected to main header used for various mechanical purposes.

FACTORS AFFECTING THE EXISTING BOILER: 1. IMPROPER COMBUSTION DUE TO LACK OF VACUUM INSIDE THE FURNACE: Due to single axial fan setup in induced draft, its couldnt able to pull out high amount of flue gas .So, less vacuum is created inside the furnace which reduces the internal air supply that lead to poor combustion. 2. POOR THERMAL CONDUCTIVITY DUE TO SOOT DEPOSITS: Soot deposited on the water wall tubes of a boiler acts as a heat insulator. This result less heat transfer to the water to raise steam and more heat is wasted. This leads to higher fuel consumption at the same time poor steam production. 3. HIGH OIL CONSUMPTION DUE TO DEFECTIVE AIR REGISTERS: Due to aging of air registers rust occurred between the nozzle tip and the fuel (oil) discharge get increased than the desirable discharge. EFFECIENCY MONITERING: It is the most important techniques in boiler maintenance. The performance of the boiler is determined by its efficiency. Increase in the efficiency denotes the good boiler performance. Efficiency of the boiler is calculated by its output and input ratio. Actual Load of the Boiler = 58 tons/hour

Boiler Name

Year

Month

Load (tons/hr)

Efficiency % 87.93 84.48 77.58 68.96 63.79 63.79

January 2009 July January B2 2010 July January 2011 July

51 49 45 40 37 37

MODIFICATION OF BOILER IN MFL: Boiler is an apparatus for converting a liquid to vapour. A boiler consists of a furnace in which fuel is burned, surfaces to transmit heat from the combustion products to the water (or other liquid), and a space where steam (or vapour) can form and collect. MODIFICATIONS: INTRODUCING RADIAL ID FAN IN ADDITION TO AXIAL ID FAN REPLACEMENT OF AIR REGISTERS ADDITION OF SOOTBLOWERS IN SUPER HEATER ZONE

INTRODUCING RADIAL ID FAN IN ADDITION TO AXIAL FAN: The existing boiler in MFL had axial fan alone in induced draft, which could not pull out high rate of flue gas. So, the efficiency of boiler is reduced. In order to increase the suction of flue gas we introduced radial fan along with the axial fan. Thus the suction rate is increased and a lot of vacuum is created and the inlet air in the burners gets increased. Due to excess air presence complete combustion takes place and boiler efficiency is increased. Radial fan are otherwise called as Centrifugal fan. In radial fan the airflow is in a radial direction relative to the shaft. It has a fan wheel composed of number of fan blades mounted around a hub. The hub turns on a driveshaft that passes through the fan housing. The gas enters from the side of the fan wheel, turns 90 degrees and accelerates due to centrifugal force as it flows over the fan blades and exit the fan housing REPLACEMENT OF AIR REGISTERS: Air registers are called as burners, which burns the fuel to obtain heat. In the existing boilers burners got rust and weak. We replaced it by new gas burners without replacing the whole set up. There are two burners, each having a capacity of 500NM3/hours capacity with a gas pressure of 12psig at the burner tip.

Fig1.2 Air register

ADDITION OF SOOTBLOWERS IN SUPER HEATER: Soot blowers, they are main element of boilers which pulls out the deposited impurities in furnace tubes, which are responsible for restricting heat transfer. So, we replaced the old one with the modern Soot blowers. By adding soot blowers in super heater zone, eliminates the soot deposited in the super heater coil. So the heat transfer in the coil increases and the super heated steam discharge is increased. SOOT BLOWER (RETRACT TYPE): A Soot blower is a system for removing the soot that is deposited on the furnace tubes of a boiler during combustion. Blowers and Air Heater Blowers are used for the cleaning. Steam is normally used as a medium for blowing away the soot. It consists of lance tube at tip of which a nozzle head with two specially designed nozzles are arranged. The lance tube moves in forward and backward direction blowing steam along its direction and eliminates the soot by passing

high pressure steam. Soot blower that modified in MFL is Long Retractable soot blower type soot blower.

Fig 1.3 Soot blower BENEFITS AFTER MODIFICATRIONS Increase in performance Increase in thermal conductivity Pollution is minimized Less maintenance cost High life time Increase in productivity Less operating cost Maximum combustion in furnace
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 Low service cost INCREASE IN PERFORMANCE Due to rich combustion in furnace, performance of the boiler is increased. For the same operating cost the boiler gives 14 tons/hr more steam than the existing boiler after modification. INCREASE IN THERMAL CONDUCTIVITY After introducing soot blowers in super heater zone maximum soot deposits are blown out and thermal conductivity is increased. POLLUTION IS MINIMIZED Due to maximum combustion the toxic gas like so2 & co are minimized. LESS MAINTENANCE COST Due to minimizing of sulphur and carbon in the flue gas the corrosion in the ID blades are minimized and this results in less maintenance cost. HIGH LIFE TIME Due to above modifications the wear and tear in moving part is minimized. So, the life time of the boiler is increased. INCREASE IN PRODUCTIVITY Due to increase in steam production the productivity is increased. LESS OPERATING COST Due to maximum combustion the operating cost is minimized for the same production.

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MAXIMUM COMBUSTION IN FURNACE Due to introduction of radial fan more vacuum is created inside the furnace and excess air is let in and combustion is increased. LOW SERVICE COST Due to less corrosion, no frequent service is required, thus service cost is minimized.

CONCLUSION:
Percentage increase in efficiency due to modification By introducing radial fan in ID draft : 8% By adding soot blower Due to air register modification Total Efficiency in existing boiler Efficiency after modification : 3% : 3% : 14% : 37% : 51%

After modification, the boiler efficiency increased upto 14%. From the above modification we conclude that Introduction of radial fan and soot blower is really a reliable work. By introducing the radial fan, the fuel consumption is minimized and boiler performance would be increased. By addition of soot blowers in super heater zone the soot deposition in the water tube walls are minimized and heat transfer is increased between the tubes thus steam production is increased. By modifying air registers and creating high

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vacuum by introducing radial fan increases combustion in the furnace. So the pollution is minimized.

CASE STUDY 2
ADVANCED HIGH-STRENGTH STEEL FAMILY CAR
ABSTRACT:
This case study uses a life cycle assessment (LCA) approach to measure the potential greenhouse gas impacts from all stages of manufacture, product use and end-of-life. It has been developed to demonstrate the reduction of CO 2 emissions through the use of high-performance steels. The aim of this case study is to show how the use of AHSS provides a sustainable solution for reducing GHG emissions over the complete life cycle of the vehicle. If the body structures of all cars produced worldwide were made of AHSS instead of conventional steel, 156 million tonnes of CO2 equivalents would be avoided.

INTRODUCTION:
Steel is reinventing itself to provide significant automotive performance advantages at little or no additional cost to automotive manufacturers or consumers. New grades of Advanced High-Strength Steel (AHSS) provide lighter optimized body designs for improved vehicle crashworthiness, improved fuel economy and reduced total greenhouse gas emissions (GHGs). NEW STEEL GRADES AND OPTIMISED DESIGNS: Optimized AHSS designs take advantage of the strength and forming characteristics of these new steel grades to develop stronger body structures using lighter gauge steel, multiple welded blanks for part consolidation, and unique part geometries that could not previously be achieved.

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Table3.1 Comparision b/w former and optimized steel design

Fig 3.1 Body-in-white of a five-passenger family car

The studies also show that for every 10% reduction in vehicle weight, fuel economy (litres of fuel per 100 km driving distance) is improved by between 1.9% and 8.2%. This range is based on driving cycle, vehicle size and
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powertrain selection. Values of 6% to 8% are possible with powertrain resizing for equivalent acceleration for conventional gasoline powertrains. AUTOMOTIVE GREENHOUSE GAS EMISSIONS: The use of road vehicles is estimated to account for 10% of man-made global GHG emissions5. This figure is set to grow, as the automotive sector is one of the fastest growing sectors. Steel and automotive engineers have replaced conventional steels with AHSS for the car body, or the body in white (BIW), resulting in 17% to 25% mass savings. With todays AHSS grades, savings of 25% are typically achieved and this corresponds to a total vehicle weight reduction of 9%.1,2. With increasing recognition of climate change issues and the contribution from the transport industry, improving vehicle fuel economy and emissions are the top challenges facing the industry. As a result, there is now a significant focus on vehicle mass reduction and alternative power train technologies to improve fuel efficiency. For both of these cases, the technological solutions for reducing emissions should be analyzed by taking a life cycle perspective, to avoid an unintended increase of CO2 emissions in material production and end-of-life. GHG REDUCTIONS: The total weight of a typical five-passenger family car is 1,260. When applied to a typical five-passenger family car, the overall weight of the vehicle is reduced by 117 kg, which corresponds 3kg, with the BIW structure accounting for 360 kg. By replacing the BIW with an optimized structure made of AHSS products 6 to a lifetime saving of 2.2 tonnes of CO2 equivalents vehicle, based on LCA. 4 per (at little additional cost relative to conventional steel) the overall weight saving is 117 kg or 9%. Due to this weight reduction, the power train can be down-sized to achieve vehicle.

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This saving in emissions is more than the total amount of CO2 emitted during the production of all the steel in the vehicle performance comparable to that of the heavier, conventional steel structure vehicle. The resultant fuel saving is 5.1%. This weight reduction means that less steel is required for each vehicle, which reduces emissions from steel production. The fuel savings also reduce emissions from driving the vehicle. Materials that compete with AHSS for lightweighting can be costly to the environment. Many of the most potent greenhouse gases, such as perfluorocarbons (commonly-known as PFCs) and sulphur hexafluoride, have a much stronger. For every 1 kg of AHSS used in a vehicle, total life cycle global warming impact (kg for kg) than CO2 and are emitted savings of 8 kg GHG (reported as CO2 equivalents) are achieved. This is a

5.7% reduction in GHG emissions over the full life cycle of the vehicle.

Table3.2 Advantages of AHSS compared to conventional steel

Thus, there is a lifetime saving of 2.2 tonnes CO equivalents 7 per vehicle. These savings more than offset the total CO2 emitted during steel manufacturing for all the steel used in the vehicle. If the body structures of all cars produced worldwide (predicted to be 71 million in 20088) were made of AHSS instead of conventional steel, this would result in total lifetime emission saving of 156 million tonnes CO2 equivalents.

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LEAN AND GREEN STRUCTURES: As we seek global reductions in GHGs, the automotive industry is moving towards more advanced power trains and fuel sources, and GHGs from material production will account for a much larger percentage of total GHGs. The material choice therefore becomes increasingly significant. Steel is successfully re-inventing itself. For a typical five- passenger vehicle with an internal combustion engine, GHGs from material production account for up to 9% of the total GHGs emitted during the entire life of the vehicle. Steel production results in much less GHG emissions than competing automotive materials and new steels are continuously being developed to meet changing needs in the production of competing automotive materials such as aluminium and magnesium. This is why life cycle assessment, which includes the analysis of a vehicles material production, use and end-of-life phases, is necessary to fully evaluate where the true GHG impact on the environment occurs and where any potential system improvements can be made. LCA captures environmental impacts across the life cycle, and thus is the responsible approach for measuring environmental costs and implementing effective, global solutions. It can also help to ensure that the material choice decision is combined with other relevant environmental initiatives in order to have an impact.

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CONCLUSION:
When one considers the extreme cost pressures in todays automotive market, AHSS is the only material choice that meets todays combined requirements in terms of cost, environment and performance. Steel is fully recyclable, and its production uses much less energy compared to competing automotive materials. Steel is safe. The use of AHSS in todays automot ive structures results in improved crash protection, keeping you and your family safe.

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CASE STUDY 3 ENERGY CONSERVATION IN ELECTRICAL SYSTEM ABSTRACT: Electrical energy is universally accepted as an essential commodity for human beings. Energy is the prime mover of economic growth and is vital to the sustenance of a modern economy. Future economic growth crucially depends on the long-term availability of energy from sources. Areas of application of Energy Conservation are Power Generating Station, Transmission & Distribution system, Consumers premises. Steps are to be taken to enhance the performance efficiency of generating stations. Energy Conservation technology adopted in Transmission & Distribution system may reduce energy losses, which were in tune of 35% of total losses in Power system. Acceptance of Energy conservation technology will enhances the performance efficiency of electrical apparatus used by end users. Implementation of Energy conservation technology will lead to energy saving which means increasing generation of energy with available source. Scope of the study is about Implementations of Energy conservation technologies, case studies, related industries, Municipal to Electrical systems Hospitals, adopted by

Corporation,

residential consumers,

Utilities. This paper also covers Roll of Government, State nodal agencies, Energy Act, and Energy Policies.

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INTRODUCTION: Energy is the primary and the most universal measures of all kinds of work by human being and nature. Electrical energy is proved to be an ideal energy in all sorts of energy available in nature. Energy is the prime mover of economic growth and is vital to the sustenance of a modern economy. Future economic growth crucially depends on the long-term availability of energy from sources that are affordable, accessible and environmentally friendly.

ENERGY SCENARIO: Energy is prime factor for national economic development. India ranks sixth in the world in total energy consumption and needs to accelerate the development of the sector to meet its growth aspirations. Per capita energy is use in India is much below compared to many countries. Installed capacity of India: Installed capacity of Maharastra: Available power: Peak demand: Power shortage: 110,000MW 20,289.5MW 13,375MW 18,049MW 4,774MW

Fossil fuel stocks are limited up to 50 to 100 years only. Fossil fuels like coal, oil that has taken years to form is on the verge of depleting soon. In last 200 years we have consumed 60% of all resources. For sustainable development we need to adopt energy efficiency measures. Today 85% of

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primary energy sources come from non-renewable and fossil sources. These reserves increasing consumption and will exist for future generations. Energy survey conducted by Ministry of Power in 1992 reveled that there is requirement of improvement in energy generation efficiency, improvement in energy transportation (transmission & distribution systems) and enhancing the performance efficiency of use end apparatus. Study of Energy strategies for Future evolved two things - efficient use of energy, energy conservation and use of Renewable Energy. Energy conservation emerges out to be the first and least cost option.

ENERGY CONSERVATION: Energy conservation means reduction in growth of energy consumption and is measured in physical terms. Energy conservation is the practice of decreasing the quantity of energy used while achieving a similar outcome of end use. (This practice may result in increase of financial capital, environmental value, national security, personal security and human comfort.) Energy conservation also means reduction or elimination of unnecessary energy used and wasted.

AREA OF APPLICATION OF ENERGY CONSERVATION: Electrical system is a net work in which power is generated using non-renewable sources by conventional method and then transmitted over longer distances at high voltage levels to load centers where it is used for various energy conversion process. End user sector are identified as three major areas -Power Generating station, Transmission & Distribution systems, and Energy consumers. Consumers are further classified as Domestic, commercial and Industrial consumers.

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EC IN POWER GENERATING STATION: To generate 1MW power generation cost is Rs 4.5 to 5.25 crores and T& D cost is Rs.2 crores. But cost of saved power is Rs.1Crores/Mw. The important note is time period to set a power plant is 5 years; to set up transmission line 1 year and to plan energy conservation is only 1 month. We have less opportunity for EC in generating area but we can improve the performance efficiency of generators by optimization of load, optimal distribution of load among different units, periodical maintenance and also increasing the capacity by adopting advanced technology using renewable energy sources.

EC IN TRANSMISSION & DISTRIBUTION: In India the power transmission and distribution (T&D) system is a three tire structure comprising of state grids, regional grids and distribution network.

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To meet the energy demand power system networks are interconnected through INTRA-REGIONAL LINK. The inter-regional power transmission capacity of India at end of 2007 was 14000 MW. T&D system in India is characterized by heavy losses of about 34.54% according to statistics of 2005-06, as compared to 10-15% in developed countries Power losses in T&D system can be classified as Technical losses and Commercial losses. Power losses in T&D system Technical losses Transformer losses Transmission line losses Inter-link losses Distribution losses Commercial losses Metering Inefficient management Improper maintenance

TECHNICAL LOSSES IN T&D SYSTEM: Power losses occurring in T&D sector due to imperfection in technical aspect which indirectly cause loss of investment in this sector, are technical losses. These technical losses are due to inadequate system planning, improper voltage and also due to poor power factor etc.

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COMMERCIAL LOSSES: Commercial losses are those, which are directly responsible for wastage of money invested i n transmission and distribution system. These l o s s e s improper maintenance etc.

a r e e f f e c t s of inefficient management,

Corruption is also the main reason contributing to the Commercial losses. Metering losses includes loss due to inadequate billings, faulty metering, overuse, because of meters not working properly and outright theft. Many of the domestic energy meters fail because of poor quality of the equipment.

ENERGY CONSERVATION TECHNIQUES: EC TECHNIQUES IN TRANSFORMERS: i) Optimization of loading of transformer: By proper Location of Transformer preferably close to the load center, considering other features like centralized control, operational flexibility etc. This will bring down the distribution loss in cables. Maintaining maximum efficiency to occur at 38% loading (as recommended by REC), the overall efficiency of transformer can be increased and its losses can be reduced Under fluctuating load condition more than one transformer is used in Parallel Operation of Transformers to share the load & can be operated close to the maximum efficiency range ii) By Improvisation in Design and Material of Transformer: To reduce load losses in Transformer, use thicker conductors so that resistance of conductor reduces and load loss also reduces.

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To reduce Core losses use superior quality or improved grades of Cold Rolled Grain Oriented (CRGO) laminations. iii) Replacing By Energy Efficient Transformers: By using energy efficient transformers efficiency improves to 95 % to 97%. By using Amorphous transformers efficiency improves to 97 % to 98.5%. By using Epoxy Resin cast/ Encapsulated Dry type transformer- efficiency improves to 93 % to 97%.

ENERGY CONSERVATION IN TRANSMISSION LINE: To reduce line resistance-R solid conductors are replaced by stranded conductors (ACSR or AAC) and by bundled conductors in HT line. High Voltage Direct Current (HVDC) is used to transmit large amount of power over long distances or for interconnections between asynchronous grids By transmitting energy at high voltage level reduces the fraction of energy lost due to Joule heating (V 1/I so I 2 R losses reduces). As load on system increases terminal voltage decreases. Voltage level can be controlled by using voltage controllers and by

using voltage stabilizer If required reactive power transmitted through transmission lines, it

causes more voltage drop in the line.

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To

control

receiving

end

voltage,

reactive

power

controllers or reactive power compensating equipments such as Static VAR controllers are used.

ENERGY CONSERVATION IN DISTRIBUTION LINE: a) Optimization of distribution system: The optimum distribution system is the economical combination of primary line (HT), distribution transformer and secondary line (LT), To reduce this loss and improve voltage HT/LT line length ratio should be optimized. b) Balancing of phase load- As a result of unequal loads on individual phase sequence, components causes over heating of transformers, cables,

conductors, motors. Thus, increasing losses and resulting in the motor malfunctioning under unbalanced voltage conditions. c) Harmonics: With increase in use of non-linear devices, distortion of the

voltage and current waveforms occurs, known as Harmonics. Due to presence of harmonic currents excessive voltage and current in transformers

terminals, malfunctioning of control equipments and Energy meter, over effect of power factor correction apparatus, interference with telephone circuits and broad casting occurs. Distribution Static Compensator and Harmonic filters can reduce this harmonics. d) Energy Conservation by using power factor controller: Low power factor will lead to increased current and hence increase losses and will affect the voltage. We can use Power Factor Controller or Automatic Power Factor Controller that can be located near receiving substations, load centers or near loads. e) Energy Conservation By Demand side management control
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(DASTACOM)

Demand-side management is used to

describe the actions of a utility,

beyond the customer's meter, with the objective of altering the end-use of electricity - whether it be to increase demand, decrease it, shift it between high and low peak periods, or manage it when there are intermittent load demands in the overall interests of reducing utility costs. Nearly energy of 15,000 MW can be saved through end-use energy efficiency. By using DSM saving potential in Industry and Agriculture - 30-35% Commercial/Government establishments and residential houses -25-30%

ENERGY CONSERVATION IN LIGHTING SYSTEM: Good lighting is required to improve the quality of work, to reduce workers 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. a) Optimum use of natural light: Whenever the orientation of a building permits, day lighting has to be used in combination with electric lighting. The maximum use of sunlight can be get by means of transparent roof sheets, north light roof, etc b) Replacing incandescent lamps by Compact Fluorescent Lamps (CFL's): CFL's are highly suitable for places such as Living rooms, Hotel lounges, Bars, Restaurants, Pathways, Building entrances, Corridors, etc.

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Area

Existing lamp Proposed lamp Power CFL 9w Blended CFL 160w 25w savings 4 w 31% 40w 20% 35w 58%

Industry GLS 13w GLS 200w Domestic GLS 60w

c) Replacing conventional fluorescent lamp by energy efficient fluorescent lamp: Energy efficient lamps are based on the highly sophisticated technology. They offer excellent color rendering properties in addition to the very high luminous efficacy. Area Lamp Type Existing Proposed Industry TL 40w TLD 36w Street lighting TL 2*40 w TL 2*36 w Domestic TL 40w T-8 28w Power Saving Watts Efficiency 4w 10% 08w 06 12w 30

d) Replacement of Mercury/Sodium Vapour Lamp by Halides Lamp: MHL provides high colour rendering index and offer efficient white light. Hence for critical applications where higher illumination levels are required, these lamps are used. They are highly suitable for applications such as assembly line, inspection area, painting shops etc. e) Replacing HPMV Lamps by High pressure sodium Vapour Lamp (HPSV): Where color rendering is not critical for such applications e g street lighting, yard lighting because CRI of HPSV is low but offer more efficiency.

f) Replacing filament lamps on panels by LED: LED lamps consumes less power (1 W lamp), withstand high voltage fluctuation in the power supply, longer operating life (>100,000 hrs). Hence nowadays they are also used in
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street lighting, signalling, advertising boards, even as replacement for tube light or CFL. g) Replacement of conventional ballast by Electronic ballast:

Installation of high frequency (28 32 MHz) electronic ballast in place of conventional ballasts helps to reduce power consumption up to 35%.

Area Street lighting

Existing lamp HPMV - 125w HPMV250w 250w

Proposed lamp HPSV70w HPSV150w HPSV150w

Power savings 25 w 100 w 100 w 44% 40% 40 %

Yard lighting HPMV-

h) Installation of separate transformer for lighting: In most of the industries, the net lighting load varies between 2 to 10%. If power load and lighting load fed by same transformer, switching operation and load variation causes voltage fluctuations. This also affects the performance of neighboring power load apparatus, lighting load equipments and also reduces lamps. Hence, the lighting equipment has to be isolated from the power feeders. This will reduce the voltage related problems, which in turn provides a better voltage regulation for the lighting. This also increases the efficiency of the lighting system. i) Installation of servo stabilizer for lighting feeder: Wherever, installation of separate transformer for lighting is not economically attractive and then servo stabilizer can be installed for the lighting feeders. j) Control over energy consumption pattern: Occupancy Sensors, Daylight Linked Control are commonly used in commercial buildings, malls, offices, where more no. Of lights are to be controlled as per operational hours
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microprocessor based Light control circuits are used. As a single control unit it can be programmed to switch on /off as per the month wise, year wise and even season wise working schedule. k) Periodic survey and adequate maintenance program: Illumination level reduces due to accumulation of dirt on lamps and luminaries. By carrying periodic maintenance i.e. cleaning, dusting of lamps and luminaries will improve the light output / luminance. As part of maintenance programme, periodic surveys of installation, lightning system with respect lamp positioning and illumination levels, proper operation of control gears should be

conducted to take advantage of energy conservation opportunities as user requirements changes.

ENERGY CONSERVATION IN MOTORS: Considering all industrial applications 70% of total electrical energy consumed by only electric motors driven equipments. a. Improving power supply quality: Maintaining the voltage level within the BIS standards i.e. with tolerance of +/-6%and frequency with tolerance of +/-3% motor performance improves and also life. b. Optimum loading: Proper selection of the rating of the motor will reduce the power consumption. If the motor is operating at less than 50% of loading (<50%) significant power saving can be obtained by replacing with properly sized high efficiency motors. If the motor is operating at loads below 40% of its capacity, an expensive and effective measure might be to operate in star mode. c. Improving transmission efficiency: Proper selection of power transmission means (belts, gears) will reduces transmission losses. d. Stopping idle or redundant running of motors or lights will save 100% power.
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e. By use of Soft Starter: Soft starters are essentially stator voltage controllers; helps to over come above problem. It helps to restrict starting current and also provide smooth start and stop operation.

f. By improving power factor: For improving p.f., connect the capacitor bank, which will improve the p.f. of the system from installation to generating station. Maximum improvement in overall system efficiency is achieved, which also reduces maximum demand of the system and that will reflect in energy bill. g. Use of high efficiency or Energy efficient motors: The motors have reduced losses energy efficient
0

through improved design, better materials and

improved manufacturing techniques. Generally motor life doubles for each 10 C reduction operating te mp e r a t u r e . While s e l e c t i n g EEM , s e l e c t i n with 1.15service factor, design for operation at 85% of rated load.

CASE STUDY: THANE MUNICIPAL CORPORATION Thane Municipal Corporation initiated the project of energy conservation in year 2001 by identifying the area- municipal building, municipal hospital, street lights, pumping station sewage pumping station. The initial energy status was Municipal Buildings: Municipal Hospital: 2970 kW 1276 kW
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Streetlight: Water supply: Sewerage pumping stations:

7364 kW 6634 kW 1299 kW

Municipal Buildings

Preventing wastage & leakages in AC system Revision of contract maximum demand with MSCDL Improving the power factor to unity Use of electronic ballast & T8 tube lights Creating awareness of energy saving among the

Streetlight Using employees microprocessor based cyclic timers

Rs 1523.4 lacs

Energy efficient components (SV Lamps) for street light (331 units) Adaptation of solar based LED lights Municipal Hospital Use of electronic ballast & T8 tube lights Adopting solar water heating system Creating awareness of energy saving among the employers Optimization of air conditioned load & light load Improving the power factor to unity Use of Time Of Day (TOD) Tariff Replacement by efficient pumps By undertaking water audit project /annum Rs 24.96 lacs Up to year 2006 Rs 15.46 lacs/annum

Water supply

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Sewerage Pumping stations Total:

Improving the power factor to unity Optimization of load on transformer Voltage stabilizers 19573 kW (19.5 MW)

Rs 12.3 lacs /annum

Table: List of energy conservation techniques adopted

Total saving Through energy conservation cell awareness program, periodical maintenance program utilization of alternative energy sources, energy generation (methane gas), quality control & use of in-house man power TMC obtained the success in all its energy conservation programs For its efforts TMC received first prize in, State Level Award For Excellence In Energy Conservation & Management for year 2004 & 2006 first prize in National Energy Conservation Award2005

CONCLUSION: Everything what happens in the world is the expression of flow of energy (Electrical) in one of its forms. In development process to cope with increasing energy demands, conservation and energy efficiency measures are two parallel paths. It takes an hour one hour to promote energy conservation, but only one second to save energy.

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