ßf'k{kk ekuo dks cU/kuksa

ls eqDr djrh gS vkSj vkt ds

;qx esa rks ;g yksdra= dh
Hkkouk dk vk/kkj Hkh gSA
tUe rFkk vU; [Link] ls
mRiUu tkfr ,oa oxZxr
fo"kerkvksa dks nwj djrs
gq, euq"; dks bu lcls Åij
mBkrh gSAÞ
µ
bfUnjk xka/kh

ßEducation is a liberating force,

and in our age it is also a
democratising force, cutting
across the barriers of caste and
class, smoothing out inequalities
imposed by birth and other
circumstances.Þ
µ Indira Gandhi
 Indira Gandhi OEY-003
National Open University
School of Engineering and Technology ENERGY MANAGEMENT :
AUDIT AND CONSERVATION

Block

2
PRINCIPLES OF ENERGY CONSERVATION
UNIT 1
Development of Energy Balance 5

UNIT 2
Identification of Energy Conservation Measures 21

UNIT 3
Classification of Energy Conservation Measures 35
GUIDANCE

Prof. V.N. Rajasekharan Pillai, Vice Chancellor, IGNOU

COURSE CURRICULAM DESIGN COMMITTEE

Prof. Ajit Kumar Dr. Ashwani Kumar Dr. S. P. Singh

Director Scientist ‘F’ / Director, Head, School of Energy and
SOET, IGNOU Solar Thermal (ST) Environmental Studies,
Maidan Garhi Ministry of New and Devi Ahilya Vishwavidyalaya
New Delhi-110 068 Renewable Energy, Khandwa Road Campus,
Block. No. 14, CGO Complex, Indore-452001
Lodi Road, New Delhi-110003 Madhya Pradesh

Dr. Ram Chandra Dr. Jugal Kishor Prof. Santosh Kumar

Regional Director, Scientist ‘F’/ Director, Retired Professor and Head
IGNOU, Regional Centre, Ministry of New and NIT, Patna, Bihar
Delhi-I Renewable Energy,
Block. No. 14, CGO Complex,
Lodi Road, New Delhi-110003

Prof. S. Maji Prof. R. R. Gaur Dr. A. S. Guha

SOET, IGNOU, Dept. of Mechanical Engineering, Joint Director,
Maidan Garhi, IIT, Hauz Khas, RSD, IGNOU,
New Delhi-110 068 New Delhi-110 016 Maidan Garhi,
New Delhi-110 068

Dr. S. C. Sinha Mr. Sitaram Singh Mr. J. K. Sinha

Project Officer, Principal, Govt. Polytechnic Director,
Bihar Renewable Energy Patliputra Colony, Bihar Renewable Energy
Development Agency, Patna, Bihar Development Agency,
Sone Bhawan, 3rd Floor, Sone Bhawan, 3rd Floor,
Birchand Patel Marg, Birchand Patel Marg,
Patna, Bihar Patna, Bihar

BLOCK PREPARATION TEAM

Dr. Ram Chandra
Regional Director
IGNOU, Regional Centre, Delhi-1

BLOCK EDITED BY

Dr. V. P. Rupam
Assistant Regional Director (Selection Grade)
Regional Centre, Delhi-1

PRINT PRODUCTION

Mr. A. S. Chhatwal Mr. S. C. Pant

Asstt. Registrar (P), Sr, Scale CRC Preparation

September 2010
ISBN :
© Indira Gandhi National Open University, 2010
All rights reserved. No part of this work may be reproduced in any form, by mimeograph of any other means,
without permission in writing from the Indira Gandhi National Open University.
Further information on the Indira Gandhi National Open University courses may be obtained from the University’s
office at Maidan Garhi, New Delhi – 110 068.
Printed and published on behalf of Indira Gandhi National Open University, by Director, SOET, IGNOU.
Printed at : M/s Public Printing (Delhi) Service, C-80, Okhla, Phase –I, New Delhi-110 020
PRINCIPLES OF ENERGY CONSERVATION

An adequate and right kind of energy is necessary for the sustainable development of
human society. Today, we need energy for various activities like cooking, lighting,
heating, air-conditioning, transport, agriculture and industrial applications. Most of the
energy for these applications is derived from burning of fossil fuels (coal, oil and natural
gas). The excessive use of these finite sources is posing a serious challenge to human
society. On one hand, their use is deteriorating the environment and on the other hand
their stock is fast depleting. The only option left to human society is to adopt the policy
of interaction of 3E’s (Energy, Economy and Environment). In its simplest form, it refers
to adopting the policy of Energy Conservation and Energy Substitution. Energy
conservation means to use energy efficiently and hence cutting out waste to zero level.
Energy substitution means to make use of renewable energy so that dependence on fossil
fuels is reduced. In this course, you will learn about various energy conservation
measures and the ways to identify them. Govt. of India is giving lot of emphasis on
energy conservation. Various acts and policies have been framed. The National
Electricity Policy 2005 in one of them.
National Electricity Policy 2005
The National Electricity Policy aims at achieving the following objectives :
1. Access to Electricity – available for all households in the next five years.
2. Availability of Power – demand to be fully met by 2012. Energy and
peaking shortages to be overcome and spinning reserve to be available.
3. Supply of reliable and quality power of specified standards in an efficient
manner and at reasonable rates.
4. Per capita availability of electricity to be increased to over 1000 units
by 2012.
5. Minimum lifeline consumption of 1 unit/household/day as a merit good
by 2012.
6. Financial turnaround and commercial viability of electricity sector.
7. Protection of consumers’ interests.
The Electricity Act 2003
The Electricity Act contains the following provisions pertaining to non-conventional
energy sources.
Sections 3(1) and 3(2)
Under Sections 3(1) and 3(2), it has been stated that the Central Government shall, from
time to time, prepare and publish the National Electricity Policy and Tariff Policy, in
consultation with the state governments and authority for development of the power
system based on optimal utilization of resources such as coal, natural gas, nuclear
substances or material, hydro and renewable sources of energy.
Section 4
Section 4 states that the Central Government shall, after consultation with the state
governments, prepare and notify a national policy, permitting stand-alone systems
(including those based on renewable sources of energy and other non-conventional
sources of energy) for rural areas.
Section 61
Section 61, 61(h) and 61(i) state that the appropriate commission shall, subject to the
provision of this Act, specify the terms and conditions for the determination of tariff, and
in doing so, shall be guided by the following, namely, the promotion of cogeneration and
generation of electricity from renewable sources of energy; and the National Electricity
Policy and Tariff Policy.
Section 86(1)
Section 86(1) and 86(1)(e) state that the state commissions shall discharge the following
functions, namely, promote cogeneration and generation of electricity from renewable
sources of energy by providing, suitable measures for connectivity with the grid and sale
of electricity to any person, and also specify, for purchase of electricity from such
sources, a percentage of the total consumption of electricity in the area of a distribution
license.
 Development of Energy
UNIT 1 DEVELOPMENT OF ENERGY Balance

BALANCE

Structure
1.1 Introduction
Objectives
1.2 Energy Audit of an Oil Mill
1.2.1 Energy Consumption and Production Data at a Glance
1.2.2 Data Collection and Tabulation
1.3 Electrical Energy Balance
1.4 Energy Audit of a Printing Press
1.5 Major Areas of Energy Use
1.6 Analysis of Energy Consumption
1.7 Development of Energy and Material Balance
1.8 The Sankey Diagram and its Use
1.9 Energy Balance of the Boiler
1.10 Let Us Sum Up
1.11 Key Words
1.12 Answers to SAQs

1.1 INTRODUCTION

In the previous Block you have learnt about energy audit. You have also learnt
about how to conduct the energy audit of your house, identify the wastage and
take steps to reduce it. In this Unit we shall expand the idea further and discuss
the energy audit of industrial units. We shall also discuss Energy Balance – an
important tool used for energy audit.
You would be aware that the overall energy situation in our country is far from
satisfactory. We are consuming our reserved fossil fuels (coal, petroleum, etc.) at
an alarming rate and at a rather low efficiency. The demand for electricity is
growing every hour both due to industrialization and increase in population.
A very large number of our villages do not have access to electricity. The
required installed capacity in order to meet the total demand of the country will
need enormous financial investment, which is a difficult option, as different
sectors of economy compete for allocation of funds. The only alternative left is
either making use of renewable sources of energy or adopting energy
conservation. A suitable combination of these two alternatives is likely to address
the problem to an appreciable extent.
Majority of our industries use energy rather inefficiently. This means that their
production/output per unit energy consumed is low. By adopting energy
conservation measures, a significant amount of energy can be saved with or
without making financial investment. The increasing cost of energy has forced
the industries to examine means of reducing energy consumption in their
5
Principles of Energy
Conservation
operations. Energy balances are used to examine the various stages of a process,
starting from raw material input to finished product.
In order to help you understand the idea of energy and material balance, two case
studies have been presented in the following Sections :
(1) Energy Audit of an Oil Mill
(2) Energy Audit of a Printing Press
Through these case studies you will be able to understand the details of energy
used and their areas of use. For an Oil Mill, we will demonstrate the concept of
energy balance and for printing press, the concept of material and energy balance
shall be explained.
Objectives
After studying this unit, you will be able to
· Understand components of energy audit of an industrial unit,
· Identify major energy use areas, and
· Develop energy and mass balance.

1.2 ENERGY AUDIT OF AN OIL MILL

For any energy audit exercise, you must collect the energy consumption and
production data as described below:
1.2.1 Energy Consumption and Production Data at a Glance
Audit of the Oil Mill provided the following data :
A : Production Data
· Production per year = 1993 tonne
B : Cost of Energy Used
· Annual cost of electricity used = Rs. 7,53,797
· Annual cost of Furnace Oil used = Rs. 5,00,000
· Annual cost of Diesel Oil used = Rs.1,50,000
As a result of energy audit, energy conservation measures were suggested, which
resulted in the following savings :
C : Saving of Energy Costs
· Annual costs of electricity saved = Rs. 61,105
· Annual cost of oil saved = Rs. 20,439
· Total cost of energy saved = Rs. 81,454
The cost of recommended energy conservation measures and payback period is
given below :
D : Cost of Energy Conservation Measure
The cost of recommended energy conservation measures was found out to be
Rs. 1,57,355.

6
 Development of Energy
E : Simple Payback Period Balance
Simple payback period
= Cost of energy conservation measures/Cost of energy saved
= (157355/81454) ´ 12 = 23 months
You can see that the cost of implementing energy conservation measures is
recovered in less than two years. Thereafter, every year, it results in a saving of
Rs. 81454. Thus, energy conservation not only saves our scarce energy recourses,
it also makes sound business sense.
1.2.2 Data Collection and Tabulation
The following data were collected from the log books and bills obtained from the
management :
(1) Transformer Rating : 300 KVA
(2) Capacitor ratings : 48 KVAr
(3) Annual electricity consumption : 396522 KWh
(i) % of electricity used in Lighting = 19
(ii) % of electricity used by Motors = 81
(4) Annual Costs of Electricity : Rs. 753797
(5) Capacity of DG set : 125 KVA
(6) Annual Production : 1993 tonne
(7) Furnace oil used : 10 tonne
Once you have collected such data, you need to convert energy consumption data
into a common unit for developing energy balance. The common energy unit
chosen is GJ (Giga Joule; 1 GJ = 103 MJ = 106 KJ = 109 J).
I KWh = 0.0036 GJ
Industrial Diesel Oil = 45.56 GJ
Furnace Oil = 43.73 GJ
Relative density of Industrial Diesel = 0.84
Relative density of light diesel oil = 0.93
The data are summarized below :
· Monthly average consumption of diesel oil = 110.85 GJ
· Monthly average consumption of Furnace oil = 497 GJ
· Monthly average consumption of electricity = 128.95 GJ
· Excess demand charges = Rs. 17820
· Average power factor = 0.88
The variation of monthly average energy consumption is shown in Figure 1.1.
The energy consumption and specific energy consumption is given in Table 1.1.
The monthly variation of energy consumption and production is shown in
Figure1.2. This figure gives a fairly good idea of energy consumption vis-a-vis
the monthly production. Another good way is to look at the monthly variation of
specific energy consumption as shown in Figure 1.3. This figure gives an
excellent idea about the energy consumption linked with production figures.
7
Principles of Energy
Conservation
It can be seen that in the month of July, the value of specific energy consumption
is abnormally high and therefore needs special attention.

15.04 Monthly average

17.50
consumption of
diesel oil (GJ), %

Monthly average
consumption of
Furnace oil (GJ), %

Monthly average
consumption of
67.45 electricity (GJ),%

Figure 1.1 : Monthly Energy Consumption

Table 1.1 : Energy Consumption and Specific Energy Consumption
Total Energy Specific Energy
Month
(GJ) Consumption (GJ/Tonne)
August 736.18 4.37
September 721.59 4.18
October 748.9 3.72
November 740.04 4.45
December 755.96 4.55
January 739.11 4.36
February 710.25 5.33
March 642.71 5.03
April 719.64 2.93
May 758.26 4.57
June 741.28 4.46
July 707.79 6.45

800
748.9 755.96 758.26
736.18 740.04 739.11 741.28
721.59 719.64
710.25 707.79
700
642.71

600

500
Total Energy (GJ)

M onhly Production
400 (Tone)

300
245.61
201.32
200 168.46 172.63 166.30 166.15 169.52 165.92 166.21
133.26 127.78
109.73
100

0
Aug-91 Sep-91 Oct-91 Nov-91 Dec-91 Ja n-92 Feb-92 Mar-92 Apr-92 May-92 Jun-92 Jul-92

Figure 1.2 : Monthly Variation of Energy Consumption and Production

8
 Development of Energy
Specific Energy Consumption(GJ/Tonne) Balance

6.45
6

5.33
5 5.03

4.45 4.55 4.57 4.46

4.37 4.36
4.18
4
3.72

3 2.93

0
Aug- Sep- Oct-91 Nov- Dec- Jan- Feb- Mar- Apr- May- Jun- Jul-92
91 91 91 91 92 92 92 92 92 92

Figure 1.3 : Monthly Variation of Specific Energy Consumption

1.3 ELECTRICAL ENERGY BALANCE

We will consider the electrical energy balance which is relatively easy to develop
and understand. The electricity is consumed for artificial lighting and by motors.
The electrical connected load in various activities is as follows :
· Electricity connected load for lighting : 11.86 KW
· Electricity connected load for fan : 1.44 KW
· Electricity connected load for motors, etc. : 18.66 KW
· Total connected load : 31.96 KW
The energy consumption is a month is worked out as follows :
(i) Unit consumption in a day by FL (20W) = 2560 Wh
(ii) Unit consumption in a day by FL (40W) = 44680 Wh
(iii) Unit consumption in a day by fan = 6896 Wh
(iv) Unit consumption in a day by computers = 6000 Wh
(v) Unit consumption in a day by AC = 8400 Wh
(vi) Unit consumption in a day by coolers = 8832 Wh
(vii) Unit consumption in a day by miscellaneous load = 126057 Wh
Total units consumed in above mentioned load in a day = 233425 Wh/day
Total units of electricity consumed in the month of April = 5616 KWh
Total units consumed by motors = 22422 KWh
Total units accounted by energy audit = 5616 + 22422 = 28038 KWh
Electricity consumption in April as collected from Utility = 31596 KWh
Units generated by DG set = 1280 KWh
9
Principles of Energy
Conservation
The number of units consumed from the utility = 31596 – 1280 = 30316 KWh
Thus the energy balance looks as follows :
Units as consumed from the utility = Units accounted by energy audit
+ Units remaining unaccounted
30316 = 28038 + Unaccounted Units
or Unaccounted units = 30316 – 28038 = 2278 KWh which is almost 7% of
electrical consumption.
You must try to find out the possible reasons for the unaccounted consumption.
For the present case, the possible reasons for this unaccounted consumption could
be the following :
(i) The operating time and loading pattern of motors is not known
precisely.
(ii) Losses and consumption in welding units etc are not known.
The electrical energy balance is represented in Figure 1.4.
Unaccounted Units (2278 units), 7 %

30316 Units of
Electricity 28038 Units
Consumed in
93 %
(100 %) Lighting and Motors

Figure 1.4 : Electricity Consumption Balance

If the exact causes for the unaccounted units are ascertained, the expenditure on
electricity can be reduced.

1.4 ENERGY AUDIT OF A PRINTING PRESS

In this section, we shall move a step farther and develop ‘material and energy
balance’ for the unit named above.
The idea of material and energy balance is simple. If an operating unit, whatever
its nature is visualized as a whole, then the material and energy entering the
system must equal the material and energy stored in the system plus the material
and energy leaving the system.
The preliminary energy audit of Printing Press was carried out with the following
objectives in mind :
1. Field study at system and equipment level, auditing of energy
consumption after examination of work places, production,
transmission and distribution for each sector.
2. Analysis of present energy consumption pattern.
3. Identification of equipment and service where saving of energy is
possible.
4. Recommending energy efficiency measures and analysis of energy
usage.
10
 Development of Energy
5. Recommending alteration, modification, replacement of plant Balance
equipments for reducing consumption of energy; its cost and payback
period along with cost of energy saved and produced.
6. Estimation of annual energy saving.
7. Possible identification of co-generation of energies in case of
recycling, etc. wherever possible.
8. Energy management procedure and methodology giving analysis of
economic aspects and viability.

1.5 MAJOR AREAS OF ENERGY USE

The printing process under consideration demands very stringent environmental

specifications in terms of prevailing humidity and temperatures in the surrounding
atmosphere, attained thorough circulation of air characterized by well defined
temperature and humidity in addition to illumination level.
Fully saturated air is appropriately dehumidified by letting it pass across coils in
which hot water is circulated, being pumped from a mixing water tank.
For dehumidification of air, hot water at 50 to 70ºC (varying according to season)
is required. The hot water carrying pipes must be insulated to avoid excessive loss
of heat to the atmosphere due to both convective and radiation heat transfer.
In the present case this seems to have been ensured by burying all hot water pipes
underground.
The water at the desired temperature is pumped by two pumps of 25 HP and
7.5 HP rating, at the rate of 1638 liters per minute from the mixing tank.
The water temperature in the tank is maintained by a thermostatically operated
valve, set at a preset temperature. During the survey it was found to be 55ºC.
The temperature in the mixing tank is maintained through mixing of hot water
streams from two sources, hot water boilers and solar heated water panels.
Solar water heating systems with 300 solar collectors supply water through an
insulated storage tank of an estimated capacity of 30,000 liters. The mixing tank
is connected to outlet/inlet pipes of both the boiler and the solar water storage
tank. Two pumps of 20 HP each circulate 304 liters per minute of water through
the boiler and the economizer. When all the 300 solar water heating panels are
working, an amount of about 30,000 liters of water is available per day at about
80ºC. This hot water gets stored in the storage tank from where it is pumped to
the mixing tank according to requirements.

1.30%
16.50%
Electrical Energy

Oil

Solar Energy

82.20%

Figure 1.5 : Energy Consumption in the Printing Press

11
Principles of Energy
Conservation
The main AC plant consists of four chilling units each of 525 TR capacity and
having 600 HP compressors. Out of these a maximum of three operate
simultaneously, depending on requirements.
The bulk of energy used is electrical and constitutes 82.2% of the total energy
consumption. The remaining form of energy used are 16.5% as thermal in the
form of fuel oil and 1.3% as solar energy utilized for heating water. The monthly
average electrical consumption is about 19,35,712 KWh (excluding colony
lighting) and monthly average consumption of oil is 36041 liters. The total energy
consumption is as shown in Pie Chart (Figure 1.5).

1.6 ANALYSIS OF ENERGY CONSUMPTION

Oil and electricity are the only energy sources used in the press. The former feeds
two hot water boilers which in turn supply hot water to the dehumidification
plant. The electrical connected load and consumption is as follows.
Electrical Energy Consumption
The total connected load in the plant is as follows :
(1) Press Section : 3900 KW
(2) Special Lighting : 500 KW
(3) Colony Lighting : 320 KW
The monthly consumption of electricity is given in Table 1.2. The total monthly
average electricity consumption on the basis for available data during audit for
10 months is 19,35,712 KWh (excluding residential lighting).
Scrutiny of electricity bills indicated that there were no problems connected with
either low power factor or penalty associated with exceeding maximum demand.
Air conditioning Plant
The major part of electrical energy is consumed in maintaining air conditioning
requirements.
Table 1.2 : Monthly Electricity Consumption in Printing Press
Months Consumption (KWh)
(1992-93) Press section Sp. Lighting Residential
April 14,58,240 1,76,248 1,13,170
May 17,18,400 1,86,034 71,889
June 19,27,320 1,90,970 83,291
July 20,73,720 2,04,538 1,08,459
August 19,08,720 1,78,928 58,236
September 21,33,360 2,13,916 60,765
October 14,43,620 1,60,905 58,236
November 16,20,840 2,06,284 75,643
December 15,26,280 2,05,504 95,666
January 15,89,880 2,33,420 82,163
Monthly Average 17,40,038 1,95,674 80,851
Consumption
12
 Development of Energy
1.6.2 Lighting Balance
The lighting load is very high. It seems that for printing purposes especially high
illumination lighting is required. This has been achieved through the installation
of around 12,000 fluorescent tube lights in the printing area positioned at a height
of six meters which appears to be a wasteful practice. The detailed implications of
this are discussed later.
For street lighting, high pressure mercury lamps of 125 W (125 Poles) and
fluorescent tube lights of 40 W (56 poles), 3 numbers on each pole were found.
1.6.3 Thermal Energy
The monthly thermal energy consumed in the form of fuel oil (LDO) in the boiler
is given in Table 1.3 at the time of audit.
Table 1.3 : Monthly Oil consumption of Boiler

Months Consumption in Liters

April 26,947
May 30,050
June 31,710
July 52,026
August 48,900
September 47,050
October 38,380
November 28,300
December 33,353
January 35,407
February 24,330
Monthly average consumption 36,041

The above table clearly distinguishes three months, namely July, August, and
September when the oil consumption is more. The average monthly consumption
for these three months and the remaining months are 49326 and 31060 liters
respectively. Assuming density of oil to be 0.9 this leads to consumption of
80 and 51 Kg per hour respectively. Assuming that there was no sunlight during
the three months characterised by higher consumption, the difference of 29 Kg
per hour implies the saving resulting from the use of solar heated water.

1.7 DEVELOPMENT OF ENERGY MATERIAL

BALANCE

Introduction to Material and Energy Balance

The Material and Energy (M&E) balances are very important tools for the Energy
Audit. The basic purpose of M&E balance is to :
· quantify all the material,
· quantify energy,
· quantify waste streams in a process or a system,
13
Principles of Energy
Conservation · find out the difference between calculated/designed values and
measured/actual values, and
· making it possible to identify previously unknown losses and
emissions.
The objective of M&E balance is to assess the input, conversion efficiency, output and
losses. A M&E balance is a powerful tool for establishing the basis for improvements and
potential savings.

The various components of inputs, outputs and waste streams are illustrated in
Material and Energy Balance (Figures 1.6 and 1.7).

Electricity Energy in vapours

Radiation Loss
Steam Process
or Energy in hot products
Cooling Water
Unit Energy in hot residue
Compressed Air Operation
Energy in Condensate

Energy in Raw Energy in Cooling

Material Water

Figure 1.6 : Components of Energy Balance

Products
Raw Material
Byproducts
Chemical Process
Waste Water
Water/Air or
Liquid Waste
Energy/Power Unit
Operation Solid Waste
Reusable Waste
Gaseous
Emissions

Figure 1.7 : Components of Material Balance

1.8 THE SANKEY DIAGRAM AND ITS USE

The energy input and output flow from any energy device, such as boiler, heater,
and furnaces can be best described by Sankey diagram. It is a powerful tool to
visually represent various outputs and losses.
Let us consider energy balance of a furnace as shown in Figure 1.8. The figure
shows that flue gas losses constitute a major area of energy loss and hence is a
priority area of energy conservation. Since the furnaces operate at high
temperatures, the exhaust gases leave at high temperatures resulting in poor
efficiency. Hence a heat recovery device such as air pre-heater has to be
necessarily a part of the system for energy conservation. The lower the exhaust
temperature, higher is the furnace efficiency.
14
 Development of Energy
Useful Output Balance
(50-60%)

Flue Gas Losses

(30-50%)

Energy Input Cooling Losses (6-12%)

(100 %)

Operating Losses (2-3%)

Other Losses (5-10%)

Figure 1.8 : Energy Balance of a Typical Furnace

The entire unit may be considered as a composite unit of two major processes as
shown in Figure 1.9.
Energy Energy Process Waste
Inputs

Material Waste
Material Process
Inputs

Figure 1.9 : Typical Process Flow

The energy use in a plant may consist of the following :
· Electrical energy,
· Conventional fuels such as furnace oil , gas and coal,
· Boiler for heating requirement, and
· Ventilating and air conditioning system.
Following three formulas may be used for energy balance.

SAQ 1
What is the main factor for low furnace efficiency, and how can the furnace efficiency
be improved?
………………………………………………………………………………………………
………………………………………………………………………………………………
………………………………………………………………………………………………

1.9 ENERGY BALANCE OF THE BOILER

The boiler and the furnace are essential components of many industrial units.
We will now discuss the energy balance of the boiler.
The principle components of energy balance for the boiler are :
· heat losses associated with dry flue gases,
· heat losses arising due to the presence of water vapour in the flue
gases,
15
Principles of Energy
Conservation · energy taken up by the boiler to generate hot water at the working
temperature; this is a measure of the working efficiency of the boiler,
· losses springing from the boiler not always working at its rated value
or what has been called the load factor, and
· losses due to incomplete combustion resulting from bad tuning, etc.
A heat balance is an attempt to balance the total energy entering a system against
that leaving the system in different forms. Figure 1.10 illustrates the heat balance
and different losses occurring while generating steam.
Heat in Steam (75%)

12.2% Dry Floe Gas Loss

Fuel 7.1% Heat Loss due to hydrogen in fuel

(100%) Steam
1.7% Heat Loss due to moisture in Fuel

Boiler
0.3% Heat Loss due to moisture in air

2.7 % Heat Loss due to unburnt residue

1 % Heat Gas due to radiation

Figure 1.10 : Heat Balance in Boiler

Figure 1.11 below gives a graphical representation of the combustion in the boiler
furnace. CHONSAW are the percentages of Carbon, Hydrogen, Oxygen,
Nitrogen, Sulfur, Ash, and Water present in the fuel. This information is supposed
to be obtained from the ultimate analysis of oil. CO, H2S, NO, O2, SO2, NOx, are
the combustion products formed by the burning of oil. In addition to these
components water vapour is also produced during combustion due to the presence
of hydrogen in oil.

External Air for

Combustion
CO2
Dry Flue Gases

CO
C O2
Nitrogen H N2
Actual Air

Oxygen O Moisture
Moisture N
+
Ash S
Water A
Vapour Solid Refuse
W
Ash +
Combustion

Figure 1.11 : Schematic Diagram of Combustion in Boiler

16
 Development of Energy
Heat losses in the flue gases can be estimated from the actual measurements of Balance
the constituents of flue gases. These measurements were taken several times with
the help of Fuel Efficiency Monitor (FEM). The results for a typical test run are
given in the Table 1.4.
Table 1.4 : Measured Data of Flue Gas by FEM
Boiler Load Temperature % Oxygen Efficiency
of Flue in Flue Gases %
Gases (ºC)
Below Economiser
Half load 222 14.8 64.6
218 15.2 63.3

Full load 325 11.5 65.2

333 11.2 65.4
Above Economiser
Half load 164 14.2 73.2
164 14.4 72.7
Full load 234 10.7 73.8
238 10.5 73.9

The primary air is being supplied for combustion to the burner through a 3 HP
blower. Let us work out heat released per hour and heat used per hour.
A : Heat released per hour
Calorific value of oil = 10000 KCal/litre
Density of oil = 0.9 Kg/litre
Burning rate of oil on the basis of total operating hours of boiler/day
= 51.0 Kg/hr
Heat released per hour = 51.0 ´ 10000 ´ 0.9
= 4.59 ´ 105 KCal/hr
This heat so released is used/carried by various processes as discussed below :
B : Heat taken by flue gases
Specific heat of flue gases = 0.28 KCal/Kg ºC
Theoretical amount of air required for oil = 14.3 Kg/Kg
Actual air being used in view of excess air factor
= 14.3 ´ 1.25 = 17.9 Kg/Kg
Mass flux in the flue gases = 51.0 ´ 17.9 + 51.0
= 963.9 Kg/hr
Temperature of flue gases = 330ºC
Hence, Heat flux in the flue gases = 963.9 ´ 0.28 ´ (330 – 30)
= 8.1 ´ 104 KCal/Kg
Hence, percentage of heat lost in the flue gases
= 8.1 ´ 104/4.59 ´ 105 = 17.6 %.
17
Principles of Energy
Conservation
C : Heat loss associated with water vapor in the flue gases
The water vapour in the flue gases from burning fuel oil enters, essentially from
two sources. The first is the water formed during combustion of oil due to the
presence of hydrogen in oil. The second component is in the form of water vapour
that is a constituent of the external air supplied for combustion.
(1) Assuming hydrogen in oil to be 12%, the amount of water formed per
Kg of oil during combustion is 9 ´ 0.12 = 1.08 Kg
Latent heat of water vapour = 546 KCal/Kg
Hence, heat lost due to latent heat of vapourisation in the flue
Gases = 1.08 ´ 546 = 589.68 Kcal.
(2) Specific heat of water vapour = 0.48 KCal/Kg/ºC
Heat lost due to sensible heat of water vapour
= 1.08 ´ 0.48 ´ (330 – 30) = 155.52 KCal/Kg.
(3) Assuming 40% relative humidity of the external air, the amount of
water vapour present per Kg of air is 0.008 Kg.

The Relative humidity is defined as follows :

Relative humidity =

The actual amount of water vapour in the air ´ 100%

The amount of water vapour required to saturate the air at
that temperature

OR

The actual vapour pressure ´ 100%

The saturated vapour pressure at that temperature

The amount of air being supplied for one Kg of oil is 17.9 Kg.
The amount of water vapour present in the air required for the combustion of one
Kg of oil = 17.9 ´ 0.008 = 0.14 Kg
The amount of heat spent to bring it to the state of the flue gases
= 0.14 ´ 0.48 ´ (330 – 30) = 20.16 KCal
Hence total heat loss associated with the water vapour in the flue gases
= (589.68 + 155.52 + 20.16) = 765.36 KCal/Kg of oil burnt.
51 (Kg./hr) ´ 765.36 (KCal/Kg.) ´ 100
Percentage loss due =
to water vapour 4.59 ´ 105 (Kg./hr)
= 8.5%
D : Boiler Efficiency (Process Heat)
The efficiency of the boiler at full load as measured with the help of F.E.M is
73.0% which is the energy used in the process heat.
18
 Development of Energy
Thus to summarize the energy balance terms, we have Balance
Process heat = 73.0 %
Heat loss in dry flue gases = 17.6 %
Heat loss due to water vapour
In the flue gases = 8.5 %
Total of clearly definable heat losses = 99.1 %
Unexplained losses are less than 0.9 % which may be associated with unburned
carbon.

1.10 LET US SUM UP

The energy audit of two units : (1) an Oil Mill and (2) a Printing Press has been
discussed. The details of energy used and their areas of use have also been
discussed. The energy balance has been developed.
Material and Energy balances are important, since they make it possible to
identify and quantify previously unknown losses and emissions. These balances
are also useful for monitoring the improvements made in an ongoing project,
while evaluating cost benefits. Raw materials and energy in any manufacturing
activity are not only major cost components but also major sources of
environmental pollution. Inefficient use of raw materials and energy in production
processes are reflected as wastes.
The Energy and Mass balance is a calculation procedure that basically checks if
directly or indirectly measured energy and mass flows are in agreement with the
energy and mass conservation principles.

1.11 KEY WORDS

Heat Balance
An attempt to balance the total energy entering a system against that leaving
the system in different forms.
Relative humidity
The ratio of the actual amount of water vapour in the air to the amount of
water vapour required to saturate the air at that temperature. It is expressed
in percentage.
Renewable Energy
Energy resources that constantly renew themselves or that are regarded as
practically inexhaustible; include solar, wind, geothermal, hydro and wood.

1.12 ANSWERS TO SAQS

SAQ 1
The key to higher efficiency of the furnace is that the exhaust temperature should
be as low as possible.

19
 Identification of Energy
UNIT 2 IDENTIFICATION OF ENERGY Conservation Measures

CONSERVATION MEASURES

Structure
2.1 Introduction
Objectives
2.2 Need for Energy Conservation
2.2.1 Reasons for Increased Emphasis on Energy Consumption
2.3 Identification of Energy Conservation Measures
2.3.1 Energy Conservation Measures in Buildings
2.3.2 Energy Conservation Measures in Motors
2.3.3 Energy Conservation Measures in Transport
2.3.4 Energy Conservation Measures in Industrial Sectors
2.3.5 Energy Conservation Measures in Different Industrial Equipments/Processes
2.3.6 Energy Conservation Measures in Lighting
2.4 Let Us Sum Up
2.5 Key Words
2.6 Answers to SAQs

2.1 INTRODUCTION

In Unit 1, you have learnt about the energy audit of a printing press. In this Unit
you will learn about the identification of equipment and services where energy
conservation is possible. The connected measures and related techno-economic
analysis appears later. Let us look at some of the findings of the preliminary
energy audit of printing press.
· The air conditioning of working rooms needed careful attention
because it appeared somewhat wasteful.
· The installation of air curtains was likely to reduce infiltration losses.
· The use of a heat pipe for cooling incoming fresh air could lead to
energy saving.
· The efficiency of the cooling tower could be improved by replacing
the existing fan with a FRP fan and lower HP motor.
· For certain blowers of air washer units the driving motors were kept
inside the cooled air path adding unnecessary heating load.
The motors should be kept outside these rooms.
· The lighting arrangement in the main printing halls needed review;
there was lot of scope for energy saving in view of developments in
the area of efficient luminaries.
· A lot of electrical energy could be saved by making use of Energy
Saver with fluorescent lamps.
· The existing use of boiler could be considerably reduced by suitably
augmenting the number of solar water heating panels.
21
Principles of Energy
Conservation · There was no provision of periodic flue gas analysis or control or fine
tuning of primary air for combustion. It needed proper measuring
systems.
· A better use of the flue gases going out of the chimney was possible
by way of heat recovery. Measurements indicated that flue gases had
temperature of about 330ºC.
· A proper control of Total Dissolved Solids (TDS) in boiler water
could lead to better heat transfer efficiency and hence higher overall
boiler efficiency.
· The wastage recovered from the printing ink had an energy potential
that could be exploited.
Keeping these points in mind, we will identify energy conservation measures.
Objectives
After studying this unit, you will be able to
· understand how to identify energy loss areas in a unit, and
· understand how to identify energy conservation measures.

2.2 NEED FOR ENERGY CONSERVATION

You are aware that energy can be converted from one from to another. You have
also learnt that the rate of doing work (i.e. energy consumption) is called power.
The total energy consumed in any activity may be written as :
Total Energy Consumption for an activity
= Energy required for the activity
x Frequency of activity
The energy required for an activity, may be called the intensity of the activity, and
is the energy required to do the task once.
Let us take an example. Suppose you need 2 units of electricity to make 5 cups of
tea (the activity) and you need tea 10 times a day (the frequency). The energy
consumption for this activity will be 20 units per day. Now see Figure 2.1 where
we have shown the variation of frequency of the activity with the intensity of the
activity. There are two rectangles’; each of same area and hence same energy
consumption. We observe the following :
Case (a) : A high frequency with low intensity.
Case (b) : A low frequency with high intensity.

Frequency
Case
(a)

Case
(b)

Intensity
Figure 2.1 : Energy Use as a Function of Intensity of Energy Use and Frequency of Activity
22
 Identification of Energy
All efforts of energy conservation are directed towards these factors. You can Conservation Measures
immediately see that if we are able to reduce the size of the rectangles
representing the total energy used, it is nothing but equivalent to energy
conservation.
Broadly speaking, we can think of two approaches for achieving this :
· Use energy efficiently by using energy efficient devices like CFL as
compared to incandescent bulbs, efficient motors as compared to
traditional motors.
· Adopt housekeeping measures i.e. using energy as and when needed -
there is no use of leaving light and fan switched on in a room where
no one is present.
2.2.1 Reasons for Increased Emphasis on Energy Conservation
The need for energy conservation can hardly be over-emphasized. Some of the
reasons why we must emphasize on energy conservation are:
1. Energy saved is like energy generated, Either we conserve energy or
add more capacity to meet the demand. Obviously, the first choice is
more cost-effective. It will definitely cost less to save 100 units of
electricity than to generate 100 units in a power plant.
2. Energy conservation is environment friendly. Using less energy
(i.e. using it efficiently) means the following:
Less energy use less pollution (air and water).
less thermal pollution.
less global warming.

About 5 billon tonnes of carbon is added to our atmosphere every year by fossil-fuel
combustion.

3. Conservation measures could be applied quickly as compared to

adding addition capacity.
It usually takes 5 to 7 years to build a thermal power plant. Good
housekeeping measures could begin immediately whereas short term
and medium term measures may take about a year to payback the
entire investment.
4. Conservation of fossil fuels is very important because of their use as
raw material in many industries in addition to their use as fuels in
power generation.
5. Most importantly, every human being can be an instrument of energy
conservation because conservation measures can be adopted by each
and every individual.

SAQ 1
Give the advantages of energy conservation in relation to environment.
………………………………………………………………………………………………

………………………………………………………………………………………………

………………………………………………………………………………………………
23
Principles of Energy
Conservation 2.3 IDENTIFICATION OF ENERGY
CONSERVATION MEASURES
Energy Conservation Measures
In its simplest form, “Energy Conservation Measures” means any modification in
any energy using installation for reducing energy consumption and operating
costs without affecting the basic purpose of the installation.

We must remember that one watt of electricity saved at the users end is more than
1.5 watts generated at the generating end. If, however, transmission and distribution
losses are considered than saving would be about 2.2 watts.

If as a nation we save 1 MW for future generation capacity, then this amounts to :

Saving of about 5-6 crores of rupees, some of which may be foreign exchange.
Saving of about 17 metric tones of coal/day/MW.
Protecting the environment by avoiding coal dust and sulpher dioxide, etc.
Saving of energy required in mixing, transporting and storing coal.
The possible energy conservation measures may be in the following areas :
Energy Substitution : Identification of an appropriate energy source for efficient
energy conversion. Examples could be solar water heaters to heat feed water to
the boiler.
Energy Generation : Identifying opportunities of energy efficiency in energy
conversion equipment/utility. Some of the areas where this possibility exists are :
· steam generation in boilers,
· optimal loading of DG sets,
· minimum excess air combustion with boilers,
· optimising existing efficiencies, efficient energy conversion
equipment, and
· biomass gasifiers.
Energy Distribution : Identifying opportunities of energy efficiency in the
energy distribution network such as transformers, power factor improvement in
electrical systems and chilled water, cooling water, hot water, compressed air, etc.
Energy Usage by Processes : This is the area where major opportunities for
improvement exist. The key is to identify energy losses in the system.
The easiest way to identify energy loss areas is to conduct energy and mass
balance and then to develop Sankey diagram which shows all the associated
losses. The areas having relatively large losses should be attempted first.

SAQ 2
Give the advantages of avoiding 1 MW of generation.
………………………………………………………………………………………………

………………………………………………………………………………………………

………………………………………………………………………………………………
24
 Identification of Energy
The manufacturing sector in India is one of the largest energy consuming sectors Conservation Measures
where about 40% of the available commercial energy is being used. The energy
saving potential of about 15-20% exists in manufacturing sector as shown in
Table 2.1.
Table 2.1 : Energy Saving Potential in Major Industries
Sl. No. Industry Estimated Saving Potential
(%)
1 Aluminium 8-10
2 Cement 10-15
3 Fertiliser 10-15
4 Glass 15-20
5 Iron & Steel 8-10
6 Petrochemicals 10-15
7 Pulp & Paper 20-25
8 Sugar 25-30
9 Texttiles 20-25

2.3.1 Energy Conservation Measures in Buildings

Let us consider energy conservation measures in a building. Imagine that you
have conducted an energy audit of a government building which is consuming
high energy in heating and air conditioning. The possible energy conservation
could be the following :
· Improving insulation level for stopping leakages of hot and cold air,
· Improving windows and doors,
· Improving or installation of automatic energy control systems,
· Improving heating and air-conditioning system, and
· Improving or replacing lighting fixtures by energy efficient fixtures.
2.3.2 Energy Conservation Measures in Motors
It is found that in industries, motors are often under loaded. You need to measure
the details of the motors like KW (HP) rating, voltage, current, power factor at
full load as well as the name plate data and then work out motor loading. Let us
take an example.
Example 2.1
A three phase motor (15KW) has the name plate data as 415 V, 30 amp and
0.85 PF. Actual energy audit measures these values as 415 V, 14 amp, 0.75 PF
when motor was in use. Determine the motor loading.
Solution
Rated output at full load = 15 KW
Rated input at full load = 3 V ´ I ´ P.F.
= 1.732 ´ 0.415 ´ 30 ´ 0.85
=18.32 KW
Rated efficiency of the motor at full load = 15 ´ 100/18.32 = 81.87%
Actual (Measured) input power = 1.732 ´ 0.415 ´ 14 ´ 0.75 = 7.54 KW.
25
Principles of Energy
Measured kW 7.54
Conservation Motor Loading% = ´ 100 = ´ 100 = 41.15%
Rated kW 18.32

Motors with such level of loading are a source of energy wastage and hence
should be replaced with correct size of efficient motors.
2.3.3 Energy Conservation Measures in Transport
We cannot imagine life today without means of transport – be it a bullock cart or
boat, bicycle or car. It is also not possible to move goods and other essential items
without means of transport.
Over the years, more and more people have moved from the traditional systems of
transport to the mechanized ones, i.e. car, scooter, bus, truck, etc. These modes of
transport have till recently been running on fossil fuels. These are not only
burning out a non-renewable source of energy, but also causing a great deal of
pollution. Therefore, the need of the hour is conservation of energy in the
transport sector. Individual owners of vehicles as well as the transporters have to
be sensitized to the need to conserve energy to protect the environment and to
make their systems more cost-effective.
There are a number of rules to be followed for the conservation of energy, i.e.
fuel, in the transport sector. Some of them are listed below :
· Avoid Wasteful Driving : The first rule of fuel conservation would
be to plan travel in such a manner that will curtail wasteful driving.
· Use Public Transport : Wherever possible and convenient, use
public transport instead of using personal transport.
· Chose the Right Means of Transport : Use the scooter when only
two persons have to travel and the car if more persons have to travel
or heavy luggage needs to be transported. Car-pooling to go to work
places is a very effective means of conserving fuel.
· Follow Traffic Signals : Following traffic signals will help avoid
traffic jams that lead to a great deal of wastage of fuel.
· Avoid Idling the Vehicle : As far as possible, avoid idling the
vehicle, be it a car, scooter, or any other mechanized transport.
· Maintenance : Regular servicing and tuning of the vehicle makes it
more efficient and thereby helps in fuel conservation and emission
control.
· Check for Emission Control : The vehicles should be checked for
emission control regularly because it leads to fuel conservation and
pollution control.
· Use Alternative Fuels : Alternative fuels such as CNG (compressed
natural gas), etc. should be used.
2.3.4 Energy Conservation Measures in Industrial Sectors
The industrial sector uses about 50% of the total commercial energy available in
India. Of the commercial sources of energy, coal, lignite, and oil and natural gas
are mainly used. The Indian industrial sector is highly energy intensive but its
energy efficiency is far below that of other industrialized countries. Efforts are
made on a regular basis to promote energy conservation in these countries as this
will help reduce the cost of production. The estimated conservation potential of
this sector is around 20% of the total energy used.
26
 Identification of Energy
There is considerable scope for improving energy efficiency in all kinds of Conservation Measures
industries, mainly dealing with iron and steel, chemicals, cement, pulp and paper,
fertilizers, textiles, etc. If such industries can promote energy conservation, it
could lead to substantial reduction in their costs of production.
Energy management is very important as all well-planned actions can help reduce
an organization’s energy bills and minimize the damage it does to the
environment. The two main energy management strategies are conservation and
efficiency. This requires the establishment of a system of collection, analysis, and
reporting on the organization’s energy consumption and costs.
Conservation Initiatives : Some Options
The four important energy conservation measures are :
(1) Waste heat recovery systems,
(2) Cogeneration,
(3) Utilization of alternative sources of energy, and
(4) Technology up-gradation, modernization, and the introduction of
control instrumentation.
To motivate the industrial sector to take up energy conservation seriously, the
government has from time to time introduced fiscal incentives such as cut on
import duty for specific items, cogeneration systems, power factor correcting
devices, and specialized boilers and furnaces.
The coal industry is both a source of energy and a consumer of energy. Energy
can be conserved in both these areas. Coal reserves can be conserved through
proper methods of exploration, improved recovery, and introduction of new
mining technologies.

Hydrocarbons continue to be the major source of energy. The conservation of this form
of energy is essential as it will reduce environmental pollution.

2.3.5 Energy Conservation Measures in Different Industrial

Equipments/Processes
We will discuss energy conservation measures in different equipments/processes
in industries like boilers, compressed air, etc.
Boilers
(1) Boilers are used in various industrial units to provide heat for
different process applications.
(2) The motive of the industry should be to generate the required quantity
and quality of steam at minimum cost.
(3) An optimum excess air level should be maintained.
(4) The method of return steam condensate to the boiler helps reduce fuel
consumption; along with this method various other methods could be
applied to minimize the loss of energy.
A schematic diagram of Boiler use is shown in Figure 2.2.
27
Principles of Energy
Conservation Heat to generate steam: recover condensate

Heat losses through flue gases:

Water Boiler recover heat
in
(1) to heat air required for
combustion and/or
(2) to heat water for boiler
Coal in + Excess air in feed

Figure 2.2 : Schematic Diagram of Boiler Use

Steam
(1) Steam plays an important part in the chemical plants for process
heating and turbine drives. The rising cost of fuel has made it
necessary to adopt measures to reduce energy losses in the steam
distribution network. The insulation on the distribution pipes should
be kept in good condition, all valves and other parts of the system
should be constantly checked.
(2) Condensation recovery in the steam system is very important. When
steam condenses, it transfers about 75% of the heat content to the
process and the remaining is withheld in the condensed water. A good
condensate recovery system should be installed to collect the
condensate from the process.
Compressed Air
(1) Compressed air is used in almost all types of industries and accounts
for a major share of the electricity used in some of the plants.
(2) It is utilized for a variety of end-uses such as pneumatic tools and
equipment, instrumentation, conveying, etc. and is preferred in
industries because it is more convenient and safe.
(3) The compressor is the main component of this system and its
selection must be done carefully.
(4) Leakage points have to be identified and sealed, and proper pressure
has to be maintained.
Refrigeration
(1) Refrigeration is done by various methods such as the vapour
compression system and absorption system.
(2) An air conditioning and a refrigeration plant are efficient when all the
system components, i.e. the compressor, the condenser, the
evaporator, the cooling tower, etc. are working in matching condition.
Motors and Pumps
(1) Motors and pumps are used to facilitate the transportation of fluids
(water/air, etc.).
(2) These can be operated either through a diesel engine or an electric
motor, or a gas or steam turbine.
28
 Identification of Energy
(3) All these consume energy either in the form of electric power or Conservation Measures
petroleum products like diesel, oil, or gas.
(4) Of the total electricity consumed in the industrial sector, electric
motors account for approximately 70%. These motors are classified
under DC (direct current) and AC (alternating current).
(5) Electricity consumption in these motors can be reduced if the cooling
is improved along with the controls, if they are operated at the rated
voltage, and are regularly maintained.
(6) The new energy-efficient motors have better performance as they
have incorporated design improvements to reduce energy loss.

SAQ 3
State the energy conservation measures in motors.
………………………………………………………………………………………………

………………………………………………………………………………………………

………………………………………………………………………………………………

2.3.6 Energy Conservation Measures in Lighting

If the right lamp is selected for the right type of function, it is possible to save
energy. The basic types of lighting systems are: incandescent, fluorescent, high
intensity discharge, low pressure sodium and LED.
Incandescent lamps are the least expensive to buy but are the most expensive to
operate. They have the shortest lives and are inefficient compared with other
lighting types.
Fluorescent lighting is used mainly indoors and is about three to four times as
efficient as incandescent lighting. They last about ten times longer than the
incandescent types.
Compact fluorescent lamps or CFL are the efficient lighting devices developed
in recent years. They combine the efficiency of fluorescent lighting with the
convenience and popularity of the incandescent fixtures. They can replace
incandescent lamps, saving up to 70% of the initial lighting energy. Although
these bulbs cost ten to twenty times more than the ordinary bulbs, they last ten to
fifteen times as much. In fact all this makes it the most energy efficient option for
the purpose of lighting.
High intensity discharge lamps or the HID provide the longest service life and
the highest quality of lighting. They are commonly used for outdoor lighting and
in large indoor areas. These lamps and fixtures can save 70%-90% of lighting
energy when they replace incandescent ones. The three most common types of
HID lamps are the mercury vapour, metal halide, and high-pressure sodium
lamps.
Low pressure sodium lamps are the most efficient artificial lighting systems,
having the longest service life, and maintain their light output better than any
other lamp type. They work similar to fluorescent lights and are used where
colour is not so important. Its typical applications include highways and security
lighting.

29
Principles of Energy
Conservation
LED Lights
About 1.5 billion people in the world live without access to electricity. Many
households rely on kerosene lanterns and candles to meet their lighting needs.
These light sources are expensive, hazardous, polluting and produce low-quality
light.
The lighting technology based on the light emitting diode (LED) may become an
important alternative. Replacing a kerosene lamp with a LED light will provide
increased safety by eliminating the possibility of accidental fires. This will also
help in reduction of indoor air pollution.
LEDs are very efficient and produce more light per watt than incandescent bulbs.
LEDs are capable of emitting light of an intended color without the use of color
filters. LEDs have a relatively long useful life, ranging between 35,000 to
50,000 hours. The life of fluorescent tubes is typically about 10,000 to
15,000 hours, depending on the conditions of use, and that of incandescent light
bulbs is about 1,000-2,000 hours.
A 13 watt LED lamp produces 450 to 650 lumens, which is equivalent to a
standard 40 watt incandescent bulb. A standard 40 W incandescent bulb has an
expected lifespan of 1,000 hours while an LED can continue to operate with
reduced efficiency for more than 50,000 hours, 50 times longer than the
incandescent bulb.
A single kilowatt-hour of electricity will generate about 0.610 Kg of CO2.
Assuming the average light bulb is on for 10 hours a day, a single 40-watt
incandescent bulb will generate about 89 Kg of CO2 every year. The 13-watt LED
equivalent will only be responsible for about 29 Kg of CO2 over the same time
span. A building’s carbon data from lighting can be reduced by 68% by reducing
all incandescent bulbs with LEDs.
LED light bulbs could be a cost effective option for lighting a home or office
space because of their very long life, though they have a much higher purchase
price.

2.4 LET US SUM UP

In this Unit, energy conservation measures in various sectors have been

discussed. A preliminary energy audit of a plant helps in identification of various
energy conservation measures. Following points emerged from a preliminary
audit printing press.
The installation of air curtains to reduce infiltration losses, use of a heat pipe for
cooling incoming fresh air, replacing the existing fan with a FRP fan and lower
HP motor in cooling towers were some of measures to reduce energy losses and
increase efficiency. Similarly, the use of boiler can be considerably reduced by
suitably augmenting the number of solar water heating panels.
The provision of periodic flue gas analysis or control or fine tuning of primary air
for combustion is a useful energy conservation measure.
· Energy saved is like energy generated. It usually takes 5 to 7 years to
build a thermal power plant. Good housekeeping measures could
begin immediately whereas shore term and medium term measures
may take about a year to payback the entire investment.

30
 Identification of Energy
· It is possible to reduce the consumption of energy up to 20% energy Conservation Measures
in the industry sector, which accounts for nearly half of the total
energy consumption of the country.
· Energy conservation also helps reduce environmental pollution.
· Possibilities of energy conservation exist in all sectors and processes,
e.g. manufacturing, transport, buildings, motors, boilers, lighting etc.
· Waste heat recovery systems, cogeneration, utilization of alternative
sources of energy, technology, up-gradation, modernization, and the
introduction of control instrumentation are some ways for effecting
energy conservation.

2.5 KEY WORDS

Boilers
Boilers are used for generating steam and heat for different process
applications.
Compact Fluorescent Lamps (CFL)
These are energy efficient lighting devices. They can replace incandescent
lamps saving up to 70% of the initial lighting energy.
Fluorescent lighting
The energy efficient lighting fixtures which are three to four times as
efficient as incandescent lighting. They last about ten times longer than the
incandescent types.
High Intensity Discharge (HID) Lamps
HID lamps and fixtures can save 70%-90% of lighting energy when they
replace incandescent bulbs. The three most common types of HID lamps are
the mercury vapour, metal halide, and high-pressure sodium lamps.
Incandescent Lamps
Widely used filament bulbs for producing light.
LED
Light Emitting Diodes. LEDs are capable of emitting light of an intended
color without the use of color filters.
Low Pressure Sodium Lamps
These are the most efficient artificial lighting, having the longest service
life. They work similar to fluorescent lights and are used where colour is not
so important.

2.6 ANSWERS TO SAQS

SAQ 1
The energy conservation is environment friendly because less use of energy
means less pollution (air and water), less thermal pollution and hence less
global warming.

31
Principles of Energy
Conservation
SAQ 2
The saving of 1 MW for future generation capacity amounts to the
following :
(a) Saving of about 5-6 crores of rupees, which may contain foreign
exchange.
(b) Saving of about 17 metric tones of coal/day/MW.
(c) Protecting the environment by avoiding coal dust and sulphur
dioxide, etc.
(d) Saving of energy required in mixing, transporting and storing
coal.
SAQ 3
The energy conservation measures in motors including the following :
(a) Improving the cooling along with the controls.
(b) Operating them at the rated voltage.
(c) Using energy efficient motors.
(d) Adopting regular maintenance.

32
 Identification of Energy
REFERENCES Conservation Measures
Cassedy, E. and Grossman, P. 1990, An introduction to Energy : Resources,
Technology and Society, Cambridge University, Press.
· [Link]
· [Link]/timeis/technology/[Link]
· [Link]/[Link]

33
 Classification of Energy
UNIT 3 CLASSIFICATION OF ENERGY Conservation Measures

CONSERVATION MEASURES

Structure
3.1 Introduction
Objectives
3.2 Classification of Energy Conservation Measures
3.2.1 Short Term : Low Investment
3.2.2 Medium Term : Less Investment
3.2.3 Long Term : High Investment
3.3 Short Term : Low Cost Measures
3.3.1 Tuning of a Boiler
3.3.2 Use of Energy Saver
3.3.3 Replacement of 40 W Tubes with 36 W Tubes
3.3.4 Replacement of Conventional Chokes with Electronic Chokes
3.4 Medium Term : Medium Cost Measures
3.4.1 Recovery of Waste Heat from Flue Gases
3.4.2 Installation of Solar Water Heating Systems
3.4.3 Energy from Ink and Paper Wastage
3.5 Long Term : High Cost Measures
3.5.1 Solar PV Panels for Street Lighting
3.5.2 Replacement of Existing Motors by Energy Efficient Motors
3.6 Let Us Sum Up
3.7 Key Words
3.8 Answers to SAQs

3.1 INTRODUCTION
Based on the energy audit of a unit, different kinds of energy conservation
measures emerge. These may be classified under three categories, namely short-
term measures, medium-term measures and long-term measures. The technical
feasibility of energy conservation measures should address the following issues:
· Availability of technology,
· The impact of energy conservation measure on production, and
· The maintenance requirements and availability of spares.
The economic analysis of energy conservation measures can be conducted by
using a variety of methods (see Block 5, Unit 3 of this course for details). The
techniques used are : Simple payback method, Internal Rate of Return method,
Net Present Value method, etc.
Objectives
After studying this unit, you will be able to
· understand different types of energy conservation measures,

35
Principles of Energy
Conservation · classify energy conservation measures of any unit into short-term
measures, medium-term measures and long-term measures, and
· develop the techno-economics for each category.

3.2 CLASSIFICATION OF ENERGY

CONSERVATION MEASURES

As stated above, the energy conservation measures could be classified into three
broad categories discussed below.
3.2.1 Short Term : Low Investment
The short term measures include the following :
· Operational Improvement like tuning of a boiler,
· Use of energy saving devices,
· Good Housekeeping, and
· Payback Period: few days or few months.
For carrying out the economic analysis of low investment short duration
measures, the simple payback method is usually sufficient. The following
procedure may be adopted :
Step 1 : Name the energy conservation measure.
Step 2 : Determine the likely investment in equipments, civil works,
instrumentation and auxiliaries.
Step 3 : Determine annual operating costs. This includes cost of capital,
maintenance, manpower, energy, depreciation, etc.
Step 4 : Determine annual savings in thermal energy, electrical energy, raw
material, waste disposal, etc.
Step 5 : Determine net savings :
Net Annual Savings/Year (Rs. /year) = (Annual savings-annual
operating costs).
Step 6 : Determine the simple payback period :
Simple payback period in months = (Investment/net savings/year) ´ 12
The above steps may be repeated for all the energy conservation measures and
summarized as shown in the Table 3.1.
Table 3.1 : Summary of Recommended Energy Conservation Measures
Sl. No. Recommended Annual Energy Annual Capital Simple
Energy Saving (Fuel and Savings Investment Payback
Electricity) Savings (Rs.) (Rs.) Period
(KWh/Kl/MT)
1
2
3
4
Total
36
 Classification of Energy
3.2.2 Medium Term : Less Investment Conservation Measures

The medium term measures include the following :

· Use of Controls,
· Equipment Modification,
· Process Change,
· Energy Efficient Technologies, and
· Payback Period: few months to about a year or so.

3.2.3 Long Term : High Investment

The long term measures include the following :
· Energy Efficient Devices,
· Product Modification,
· Technology Change, and
· Payback Period : few years.
We have given several energy conservation measures with payback periods in
subsequent Blocks. We will now demonstrate one energy conservation measure
with payback period. Table 3.2 below shows the format of reporting energy
conservation measures.
Table 3.2 : Energy Management and Audit Reporting Format
for Energy Conservation Recommendations

A : Energy Audit of Existing System

There are 3 motors in the unit Source of Data

Motor 1
· Motor Rated HP = 40 Name plate data
· Rated Full Load (Ampere) = 53 Name plate data
· Actual load (Ampere) = 28 Measured data
· Loading (%) = 28 ´ 100/53 = 52.8 Calculated data

Motor 2
· Motor Rated HP = 40 Name plate data
· Rated Full Load (Ampere) = 53 Name plate data
· Actual load (Ampere) = 29 Measured data
· Loading (% ) = 29 ´ 100/29 = 54.7 Calculated data

Motor 2
· Motor Rated HP = 40 Name plate data
· Rated Full Load (Ampere) = 53 Name plate data
· Actual load (Ampere) = 32 Measured data
· Loading (%) = 32 ´ 100/53 = 60.3 Calculated data

37
Principles of Energy
Conservation B : Recommended Energy Conservation Measures

Replacement of existing motors by energy efficient motors

The motors are designed to be efficient at full rated load.

The motor efficiency reduces drastically when the load factor on the motor is less
than 50-60% of rated load.
The proper selection of a motor for a particular condition depends primarily on the
following factors :
Ø Running Characteristics
Ø Losses
Ø Power Factor
Ø Starting Characteristics and Operation under variable loads

C : Techno economics of Recommended Energy Conservation Measures

There are two costs involved :
(1) Capital cost
(2) Operational (Running) cost
In the present scenario of energy crisis (higher price and limited availability) the running cost
assumes greater significance. The running cost of a motor depends upon its efficiency which
is defined as following :
Power Loss Mechanical Energy Out
Efficiency = =
Power Input Electrical Energy In
The cost of annual energy conserved with the recommended energy efficient motors may be
calculated as follows :
Annual Savings =
é1 1ù
Power Output in KW * ê - ú *100 * No of Working Hr in a Year * Tariff
ëho h n û
where, ηo = efficiency of old motor and ηn = efficiency of new motor

While considering the tariff in the above example, following observations should
be kept in mind.
Electricity price in India not only varies from State to State, but also from city to
city and consumer to consumer though it does the same work everywhere. For
example, the rates for domestic use of electricity are lower than the rates for
industrial use. Many factors are involved in deciding final cost of electricity
purchased, such as :
· Maximum demand charges, KVA : How fast is the electricity used?
· Energy charges, KWh : How much electricity is consumed?
· Peak/Non-peak period: When is electricity utilized?
· Power Factor Charge, P.F : Real power use versus.
· Apparent power use factor.
· Other incentives and penalties applied from time to time.
38
 Classification of Energy
3.3 SHORT TERM : LOW COST MEASURES Conservation Measures

We will discuss energy conservation measures emerged in the audit of printing

press discussed in the earlier units.
3.3.1 Tuning of a Boiler
The boilers used in any industry need careful attention during its operation. The
tuning of boilers simply means improving the performance of boilers by changing
the air and fuel flow rate.
In the boiler used in printing press, the following observations were made :
· In the operation of the boiler no attention was paid to the control of
combustion air. There seemed to be no organized practice of
controlling excess air through analysis of the flue gases.
· Some of the flue-gas parameters changed over a wide range as the
amount for air supplied to the furnace was varied from a dangerously
low to a wastefully high level. These were unburned hydrocarbons,
O2, CO, CO2, NOx, SO2. Several of these parameters can be used to
determine the optimum level of air for safe and efficient boiler
operation.
· The major cause of boiler losses, both avoidable and unavoidable is
the boiler draft : 79 % of the air that is blown into the furnace is
nitrogen, and this must be heated along with the products of
combustion and sent up the stack. If the level of excess air is higher
than necessary, excess oxygen, in addition to even more nitrogen,
carries still more heat up the stack.
· All boilers need some excess air to ensure proper combustion of the
fuel. With appropriate control of air for combustion, based on daily
testing as stated above, it may be safely said that the working
efficiency of the boiler may be increased by at least 10%. The
payback period of such measures is few months.

SAQ 1
What is meant by tuning of a boiler?
………………………………………………………………………………………………

………………………………………………………………………………………………

………………………………………………………………………………………………

3.3.2 Use of Energy Saver

As discussed earlier in the context of lighting in the printing press, the electricity
consumption in lighting constitutes a significant portion. An energy conserving
device like a P-20 BEBLEC device can cut down lighting load by about 20%
without affecting lighting level. P-20 introduces an inductive impedance across
the lighting circuit and thus reduces the current drawn by the load. P-20 is largely
available in 1.5, 3.0, 4.5, 6.0 and 7.5 KVA rating. This device is more useful in
installations where lights are on for 24 hours, as is in the case of printing press.
Let us see how much electricity can be saved using such a device.
39
Principles of Energy
Conservation
The 12,000 fluorescent tube lights of 40 W each consume effectively 54 W due to
loss of 14 W in conventional ballasts.
Hence, total consumption due to these tube lights will be
= 12,000 ´ 54/1000 = 648 KW
For an average Power Factor of 0.9, the connected load = 648/0.9 = 720 KVA
Present energy consumption = 648 KW ´ 300 Days/year ´ 24 Hrs/Day
= 4665600 KWh/year
Energy saving by Beblec unit (20%) = 0.2 ´ 4665600
= 933120 KWh/year
Cost of saving @ 2.0 Rs./KWh = Rs. 1866240/- per year.
Recommended model of P-20 (18 KVA, 40 nos.)
Total cost per unit = Rs. 30000/-
Total cost of 40 units = Rs. 30000 ´ 40 = Rs. 1200000/-
Simple payback period = (1200000/933120) ´ 12 = 8 Months
If the costs of the electricity get increased, the payback period will get reduced.
3.3.3 Replacement of 40 W Tubes with 36 W Tubes
There are about 12000 fluorescent tubes of 40 W each operating 24 hrs per day.
The tubes are fitted with conventional chokes which consume about 14 W of
power. Thus for 300 operational days in a year, the annual consumption is given
by :
1200 * 54 * 300 * 24
Annual Consumption E1 = KWh / year
1000
= 46,65,600 KWh/year
These tubes can be replaced by fluorescent lamps of 36 W in periodical
replacement. The 36 W tubes will consume 50 W (36 W + 14 W in conventional
choke). The annual consumption after replacing all the tubes will be:
1200 * 50 * 300 * 24
Annual Consumption E 2 = KWh / year
1000
= 43,20,000 KWh/year
The saving in electricity consumption = E1− E2
= 3,45,600 KWh/year
Cost of electricity saved @ Rs. 2.0/KWh
= Rs. 6,91,200/-
The cost of 36 W tube is Rs.30, the total investment for replacing 12,000 tubes
will be Rs. 3,60,000.
The payback period will be as follows :
Payback period = (360000/69200) ´ 12 = 6 months.
40
 Classification of Energy
3.3.4 Replacement of Conventional Chokes with Electronic Conservation Measures
Chokes
In fluorescent lighting ballast (choke) and a starter are essential for starting and
running the fluorescent lamp. Approximately one fourth of power is lost in
ballast. Electronic ballast overcomes this problem with better quality of
fluorescent lighting.
If the conventional chokes are replaced by electronic chokes (they need to be
replaced every year anyway) there would be no additional investment as
described in the Table 3.3. Suppose 500 fixtures are replaced with electronic
choke per year, the cost details are given below.
Cost of each choke = Rs. 125
Cost of starter = Rs. 10
Cost of electronic choke = Rs. 250
Table 3.3 : Cost Analysis of Replacing Conventional Chokes
by Electronic Chokes

Conventional Choke Electronic Choke

Parameter
(Rs.) (Rs.)
Investment/year (Rs.) 125 ´ 500 = 62500 500 ´ 250 = 125000

Cost of starters (Rs.) 10 ´ 500 = 5000 -

Net Investment Rs.) 125000 – (62500 + 5000) = 57500

Power Rating (W) (40 + 14) ´ 500 (40 + 3) ´ 500
= 27000 = 21500

Annual Energy 27000 ´ 24 ´ 21500 ´ 24 ´ 300/1000

consumption (KWh) 300/1000 =194400 = 154800

Cost of energy 388800 309600

@ Rs. 2.0/KWh; (Rs.)

Net amount of annual 79200

savings (Rs.)
Simple Payback Period 57500 * 12/79200 = 8.7 months

3.4 MEDIUM TERM MEDIUM COST MEASURES

3.4.1 Recovery of Waste Heat from Flue Gases

Use of heat recovery devices based on exploitation of the heat contained in the
flue gases is an attractive option. The waste heat in flue gases could be recovered
by any one of the following measures :
(1) By pre-heating the oil.
(2) By pre-heating boiler feed water; the device is known as economizer.
(3) By pre-heating the excess air needed for the combustion; the device is
known as air pre-heater.

41
Principles of Energy
Conservation
You need the input and output data as follows :

Quantity of flue gases

Feed water
inlet
Quantity of heat available in flue
temperature
gases

Rise in feed water temperature

Oil Heat required pre-heating feed
Fired water
Fuel oil supply Boiler or
rate
Rise in air temperature
Heat required to pre-heat air
or
Rise in oil temperature
Heat required to pre-heat oil

Oil Pre-heating
The proposed heat recovery system recommended for the printing press was in
the form of oil pre-heater and air pre-heater as shown in Figure 3.1. The costs
may be worked as follows :
The flue gas temperature was 330ºC. It was proposed to preheat oil first so that
the temperature of flue gases reduced to 324ºC.
Energy content, Q, in flue gases at 330ºC.
Q = Mass flux of flue gases ´ specific heat of flue gases ´ temperature difference
Mass flux of the gas = 963.9 Kg./hr
Specific heat of the flue gas = 0.28 KCal/Kg.ºC
Temperature difference = 330 – 324 = 6ºC

Available Waste Heat used for

Heat: Waste preheating the oil. Flue gas
Heat in Flue temperature reduces to 324
Gases: ºC
Temperature
330 ºC

Figure 3.1 : Schematic Diagram of Waste Heat Recovery from Flue Gases
Q = 963.9 ´ 0.28 ´ 6 = 1619.4 KCal/hr
Specific heat of oil = 0.510 KCal/Kg ºC
Mass flow rate of oil = 51 Kg/ hour
Let T be the Temperature up to which oil can be heated.
Initial temperature of oil = 30ºC.
Thus, 51 ´ 0.510 ´ (T − 30) = 1619.4
Giving T = 92.3ºC
Calorific value of oil = 10000 Kcal/Kg.
42
 Classification of Energy
Savings in terms of fuel oil = 1619.4 Kcal/Kg/10000 Kcal/Kg Conservation Measures
= 0.16194 Kg/hr
Running operating hours = 300 days ´ 24 hrs/day = 7200 hrs
Annual savings of fuel oil = 0.16194 Kg/hr ´ 7200 hr = 1166 Kg.
Annual cost of oil saved = 1166 Kg. ´ Rs. 20/Kg = Rs. 23320
We can work out the cost of heat exchanger required. The detailed calculations
are not given here. The cost of pre-heater comes out to Rs. 6000 and the simple
payback period is just about 3 months.

It has been shown that the existing electric oil heater can be replaced by a small heat
exchanger heating the oil to the desired temperature by flue gases. It emerges as a highly
cost effective device giving payback period of just a week.
Since this does not require much heat the flue gases continue to be a potential heat source
for another heat recovery in the form of air pre-heater. This is also very cost effective,
leading to payback period of less than a year.

3.4.2 Installation of Solar Water Heating Systems

We have observed that the boiler consumes oil at the rate of 80 Kg per hour
during the period of the year when there is no sunshine. Water is circulated
through the boiler at the rate of 304 liters per minute. For this consumption the
rise in the water temperature in the boiler works out to be = 27ºC. A detailed
analysis is given below.
It has been observed that the oil consumption during the sunny months of the year
is 51 Kg/hour. If we want to do away with this consumption by the installation of
more solar water heaters, we need to know the cost of solar water heater and other
associated costs.
The total heat released by the boiler
= 51 Kg./hr ´ 9000 KCal/Kg. ´ 0.73 (efficiency of boiler)
= 335070 KCal
A standard 2 m2 solar water heater is needed for heating water from ambient 30ºC
to 80ºC at the rate of 100 litres per day. Assuming 6 hours of sunshine in a day,
the number N of collectors required to provide heat at the above rate may be
calculated by using the following relation :
N ´ 100 ´ (80 – 30)/6 = 335070
Giving N = 402
The cost analysis based on approximate market prices is as follows :
1. Cost of Solar collector system including cost of civil work, Piping,
insulation, etc. = Rs. 13,000/-
2. Subsidy on each collector = Rs. 2,000/-
3. Subsidy by state Government @ 20% = Rs. 2,200/-
4. Total investment by Printing Press = 402 ´ (13000 − 2000 − 2200)
= Rs. 3.53 ´ 106
5. Annual saving of oil, assuming 275 sunny days in a year
= 275 ´ 6 ´ 51 = 84150 Kg = 93500 Litres

43
Principles of Energy
Conservation 6. Saving per year @ 6.0 Rs. /litre = 93500 ´ 6.0 = Rs 0.56 ´ 106
7. Payback period = 6.3 years.
The payback period based on the current prices will be about 5 years.
3.4.3 Energy from Ink and Paper Wastage
The ink waste available in the Printing Press could be mixed up with waste paper
and could be used in gasifier for power generation. The process involves the
making of small brickets of ink waste and paper and then burning them in
gasifier. The ink waste available was found out to be 30000 1/day and waste
paper 5.5 Ton/day. When these two are mixed to make brickets, the annual
availability may be 5000 tons.
Cost of Gasifier system = Rs. 65,000/-
Calorific value of the waste ink = 190.9 KCal/Kg
Burning rate of biomass = 3 Kg/KWh
Operating hours = 6000 hr/year
Total electricity produced = 5 ´ 6000 = 30000 KWh/year
Total biomass required = 3 ´ 30,000 = 90000 Kg = 90 Tonnes
Cost of electricity produced @ Rs. 2.0 per KWh
= 30000 ´ 2
= 60000 Rs./ year
Total system cost = Rs. 65000/-
Simple payback period = (65000/60000) ´ 12 = 13 months
When a single unit is tested fully, multiple units can be installed.

3.5 LONG TERM : HIGH COST MEASURES

3.5.1 Solar PV Panels for Street Lighting

Continuing with the example of the printing press, it was noted that there were
400 numbers of poles and there were two 40-watt tubes on each pole. These tubes
operated for 12 hours/day. The existing street lights could be replaced by solar PV
system.
Annual electricity consumption = 400 ´ 2 ´ 40 ´ 12 ´ 365
1000
= 140160 KWh
One pole of solar PV system consists of two numbers 11 W fixture. By replacing
all poles by solar PV system, the saving of electricity would be :
Saving in electricity by PV system = 140160 KWh
Cost of one pole with fixture = Rs. 25000/-
Government Subsidy on one pole = Rs. 18000/-
Investment required = 7000 ´ 400 = Rs. 2800000
The cost of electricity saved @ Rs. 3/KWh
= 140160 KWh ´ Rs. 3/KWh = Rs. 420480
The payback period = (2800000/420480) = 6.7 years
44
 Classification of Energy
3.5.2 Replacement of Existing Motors by Energy Efficient Conservation Measures
Motors
A large number of electric motors of different horse power ranges are employed
in the press to carry out a variety of functions involving varying loads and duty
cycles. With so many applications of the motors it is difficult to lay down a
comprehensive set of guidelines for all applications.
During the energy audit, measurements of actual currents being drawn by some
large sized motors were made and are given in Table 3.4. It was found that some
of them were running up to 65% below the rated current. An induction motor
should always be loaded to its maximum efficiency (Figure 3.2). These motors
are designed to be efficient at full rated load. The motor efficiency get reduced
drastically when the load factor on the motor is less than 50-60% of rated load.
Hence, the practice of periodic measurement of currents of motors when these are
running should be followed regularly. This data should be well documented over
a period of time so as to cover all likely loads.
The proper selection of a motor for a particular condition depends primarily on
the following factors :
1. Running Characteristics
(a) Losses, (b) Power Factor
2. Starting characteristics and operation under variable loads
3. Speed Control
4. Braking
Table 3.4 : Loading Pattern of Selected A.C. Motors
Sl. Selection Motor Rated Full Actual Load Loading
No. H.P. Load (Ampere) (Ampere) %
Air conditioning Room
1. Condenser 50 96 56 58.3
Pump 50 96 66 68.8

2. Chilled water
Pump

i) Primary 40 53 28 52.8
40 53 29 54.7
40 53 32 60.3
40 53 - -

ii) Secondary 50 96 52 54.1

50 96 68 70.8
100 128 98 76.5
100 128 68 53.5
15 20 17.5 87.5
15 20 - -
7.5 10.5 7.0 66.6
7.5 10.5 7.5 71.4
7.5 10.5 - -
7.5 10.5 9.0 85.7

3. Boiler Room 20 - 28 -
20 - - -

45
Principles of Energy
Conservation

100

90

Efficiency 80
(%)

70

60

0 25 50 75 100

Load (%)

Figure 3.2 : Variation of Motor Efficiency with Load

3.6 LET US SUM UP

In this Unit, we have discussed short term, medium term and long term energy
conservation measures.
Short-term energy conservation measures like tuning of boilers, use of energy
savers, and replacement of conventional chokes with electronic chokes require
very small investment which can be covered in a very short period.
Medium-term measures like heat recovery from flue gases, installation of solar
water heating systems, using ink and paper wastage in gasifiers to generate
energy, etc. require relatively small investment which can be recovered in a year
or so.
Long-term measures like using solar PV panels for street lighting require large
investment. However, the cost can be recovered a few years’ time.
Energy conservation measures, whether short-term or long-term, are a desirable
option, as they not only help us save energy, but are also beneficial from
monetary point of view.

3.7 KEY WORDS

Ballast
A device that gives starting voltage and limits the current during normal
operation in electrical discharge lamps (such as fluorescent lamps)
Efficiency
Efficiency is the ratio of power loss to the power input
Energy Saver
A device to save electricity
46
 Classification of Energy
Long Term High Investment Conservation Measures
The energy conservation measures with high expenditure such that payback
period is more than a year or so.
Medium Term: Low Investment
The energy conservation measures with expenditure such that payback
period is about a year or so.
Short Term: Small Investment
The energy conservation measures requiring small investment and having
very small payback period ranging from a few weeks to a few months.
Payback Period
The time taken by an energy saving device to recover the cost of the device
through cost of energy saved.

3.8 ANSWERS TO SAQS

SAQ 1
Tuning of a boiler means improving the efficiency of the boiler by
optimizing the air and fuel flow rate.

47