13.

Audit of Electrical Systems

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ELECTRICAL DISTRIBUTION SYSTEM -EB POWER DG SET M

SINGLE LINE DIAGRAM

Metering

TRIVEATOR METER

Transformer Effi.95-98%

M Dist. loss 4 - 8%

Feeders, Capacitors

C C

Distribution Panels

FANS & BLOWERS

PUMPS

R & AC COMPRESSORS

LIGHTING, HEATING

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MECHANICAL

Motors Effi.85-96%

ELECTRICAL

11 KV/440V

Typical Range of Losses in Common Electrically Operated Equipment

Equipment Outdoor circuit breaker (15 to 230 KV) Medium voltage switchgears (5 to 15 KV) Transformers Load break switches Medium voltage starters Bus ways less than 430 V Low voltage switchgear Motor control centers Cables Motors (1-10 HP) 10 200 HP motors 200 1500 HP motors Capacitors (Watts / KVAR)
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% Energy Loss at Full Load 0.002 - 0.015 0.005 - 0.02 0.40 - 1.90 0.003 - 0.025 0.02 - 0.15 0.05 - 0.50 0.13 - 0.34 0.01 - 0.40 1.00 - 4.00 14.0 - 35.0 6.0 - 20.0 4.0 - 7.0 0.50 - 6.0
3

How to reduce Electricity Bill in an Industry ?

By reducing
kVA

Maximum Demand
Contracted demand 2250 kVA
2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0

MD (KVA)

Minimum billable demand 1683 kVA

M ay '0 1 Ju n' 01

Energy ( KWH)
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Ju l'0 1 Au g' 01 Se p' 01 O ct '0 1 No v' 01 De c'0 1 Ja n' 02 Fe b' 02 M ar '0 2 Ap r'0 2
Month

How to reduce MD charge?

Tariff Management

Electrical Load Management

Power Factor Improvement

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ELECTRICAL LOAD MANAGEMENT OPTIONS

Shift the load to non peak hours

Install MD controllers (Automatic load shedding)

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Maximum Demand
Contracted demand 2250 kVA
2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0

Minimum billable demand 1683 kVA

kVA

Ju l'0 1 A ug '0 1 Se p' 01 O ct '0 1 N ov '0 1 D ec '0 1 Ja n' 02 Fe b' 02 M ar '0 2 A pr '0 2
Month
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01 ay '

Ju n'

01

Demand, Kva

1000

1200

7:

200

400

600

800

00 30

8:

Maximum Demand curve

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Time (Hrs)

10 :0 0 11 :3 0 13 :0 0 14 :3 0 16 :0 0 17 :3 0 19 :0 0 20 :3 0 22 :0 0 23 :3 0 1: 00 2: 30 4: 00 5: 30
8

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Reducing MD by Power Factor Improvement

KW = KVA x P.F 100 = 142 x 0.7
KW or active power is what is required by the plant. Suppose if we increase the P.F. to 0.95, then

KVA= 100 / 0.95

KVA= 105
So increasing power factor reduces the Maximum Demand
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How to improve power factor ?

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What does the capacitor do to improve P.F. ?

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Other benefits of power factor correction

Increase Currentcarrying capacity Improve voltage to equipment
% Voltage rise = Capacitor kVAR x (Transforemr % Impedence) Transformer kVA

Reduce power losses

(Power Loss =I2R)

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Where to reduce Kwh in electrical systems ?

Transformers Distribution systems Motors

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Energy savings in Transformers

Optimise loading of transformers Switch off the primary side of transformer if it is not serving any loads Maintain balanced voltage with polyphase transformers by maintaining equal tap settings. Balance single-phase loads among phases to keep voltages within 1% of the average.
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Energy loss in Transformers

Transformer kVA 100 kVA 160 kVA 200 kVA 250 kVA 315 kVA 500 kVA 630 kVA 750 kVA 1000 kVA No load loss (Watts) 260 330 540 600 700 840 1000 1100 1300 Full load copper loss (Watts) 1760 2200 3300 3600 4200 5700 6400 7500 9800

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Typical Losses in Induction Motor

Loss component % of total loss Iron Losses 25 Stator I2r loss 45 Rotor I2r loss 25 Stray load loss 2 Friction & windage loss 3

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Load vs P.F. and Eff.

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Energy savings in motors

Motor Load Survey
of all identified key equipments measurement of electrical parameters, V, A, PF, kW compare with the design load and calculate % loading Opportunities would include reshuffling of motors, replacing with energy efficient motors, Rewinding vs new motor

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Motor load survey

Typical worksheet for Motor load analysis Sl. No. 1 2 3 4 5 Dust collector fan 100 ton EPN Press Circulation Pump A/C Plant No.4 A/C Plant No.1 30 10 30 50 50 1470 38 397 1440 14.7 413 1460 41 408 1460 65 398 1460 65 408 29.3 7.34 17.3 37 22.3 15.9 2.11 2.64 17.2 10 0.82 0.4 0.21 0.09 0.63 11.1 4.77 12.0 18.7 12.5 20.1 5.21 12.2 26.1 19.9 48.0 48.1 48.1 48.1 48.2 Motor Location HP RPM Amp Volt Amps KW PF KVAr KVA HZ Load % 71 28 12 46 27

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Energy efficient motors

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Benefits of Energy Efficient Motors: Example

Case-1 Existing standard motor

Input kW 47.2

Motor Eff. 90%

Output - kW 42.5

Pump
Eff. 55%

Delivered kW 23.37

Case-2 Replaced with Energy Efficient motor

Input kW 44.7

Motor Eff. 95%

Output - kW 42.5

Pump Eff. 55%

Delivered kW 23.37

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Analysis of Electrical Power Systems

System Problem Common Causes Possible Effects Solutions
Improper transformer tap settings, one single-phase Voltage imbalances transformer on a polyphase Motor vibration, or differences system, single-phase loads premature motor failure, between relative Balance loads not balanced among energy waste. A 5% voltage levels among among phases. phases, poor connections, imbalance causes a 40% the three phases in all bad conductors, increase in motor losses. or part of a facility. transformer grounds or faults. Checkand Improper transformer Over-voltages in motors Voltage deviations correct settings, incorrect selection reduce efficiency, power refer to voltages ransformer of motors, e.g., a 230/208 factor, and equipment being too low or settings, motor motor (which is actually life, and increase high. ratingsand motor 230 rated) on a 208 circuit. temperature. input voltages Loose bus bar connections, Wastes energy, loose cable connections, produces heat, causes Use IR camera Poor connections corroded connections, poor failure at connection to locate hotmay be in distribution crimps, loose or worn site, leads to voltage spots and or at connected loads. contactors, corrosion or drops and voltage correct. dirt in disconnects. imbalances.

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Analysis of Electrical Power Systems (Contd.)

System Problem Common Causes
Undersized conductors.

Possible Effects

Solutions

Facilities expanding Reduce the load Voltage drop and energy beyond original designs, by conservation waste. poor power factors load scheduling. Degradation over time due May not cause breaker to extreme temperatures, to trip, and may leak to Replace abrasion, moisture, Insulation leakage ground or to another conductors, chemicals, conductor phase. Variable energy insulators insulation inappropriate for waste. conditions. Reduces currentInductive loads such as carrying capacity of motors, transformers, and Add capacitors wiring, voltage Low Power Factor lighting ballasts; non-linear to counteract regulation effectiveness, loads, such as most reactive loads. and equipment life. May electronic loads. increase utility costs. Office-electronics,PBXs, Over-heating of neutral Take care with Harmonics (non- UPSs, variable frequency conductors, motors, equipment sinusoidal voltage drives, high intensity transformers, switch selection and and/or current wave discharge lighting, and gear. Voltage drop, low isolate sensitive forms) electronic and core-coil power factors, reduced electronics from ballasts. capacity. noisy circuits.

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