Energy conservation

Why this topic is chosen ?
Energy conservation is the burning issue
nowadays due to the tremendous scarcity
of electricity across the country.
It is specifically quantifies as optimum
use of electricity available.
Normally it is extended to all the sectors
viz, Industrial, commercial, residential as
well as agriculture.
Energy conservation is a journey, not a destination

Energy efficiency is a technique which
needs to be adopted seriously and
religiously for effective energy
conservation.
Energy saved by efficient use of energy of
any electrically operated device not only
leads to monetary saving but is extra
energy generated for the use elsewhere.
Why this topic is chosen ?
It won't take much energy to conserve energy

MM MuraliMurali MohanMohan
DyDy. Manager, NTPC. Manager, NTPC

India - Power Sector
India installed capacity at the time
of independence is 1,362 MW.
End of Aug - 2014 - 253.389 GW.
World's fourth largest producer of
electricity.
The total annual generation for the
year 2013 - 1102.9 TWh.
Save Energy :For nature, For future

 All India per capita consumption of
Electricity (KWh) for 2012-13 is
917.81.
 Is among the lowest in the world.
 In comparison, China has 4,000 kWh.
 With the developed countries
averaging around 15,000 kWh.
India - Power Sector
Energy misused cannot be excused

Capacity Vs Supply
 While India has
installed power
generation capacity
of 253 GW,
 Daily generation is
only to the tune of
140 GW (55%).
It won't take much energy to conserve energy
Forced outages are approx – 50 GW

There are many reasons…….
 There is low demand from states because of the poor
financial health of DISCOM’s.
 Second, there is scarcity of fuel (coal, gas and oil) to
run the power plants.
 There is lots of unplanned shutdowns in the system
because of older generating assets, hydro power not
catering to peak due to less rainfall.
 An estimated 30 GW capacity is lying idle because of
inadequate supplies of coal.
Turn off the unwanted light keep the future bright

Energy efficiency is a journey, not a destination
52.40% 53.90%
63.00%
69.00%
74.30%
77.70%
75.10%
73.32% 72.31%
70.10%
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
1985-86 1990-91 1995-96 2000-01 2005-06 2009-10 2010-11 2011-12 2012-13 2013-14
All India PLF (%) of Coal based power stations
As pr CEA

Fuel supply………
A thing which burns never returns
Actual
462 mt

Fuel supply…….
Energy earns or simply burns, choice is yours
Kbpd – Tousand barrels per day, mmscmd – million metric standard cubic Meter per day

Energy Demand……..
Overall energy demand has been increasing at the
rate of 7% per annum in the last seven years.
Today's wastage is tomorrows shortage

Power supply position in Aug - 2014
Region Demand & Availability (MU) Peak Demand & Availability (MU)
Demand Availa
bility
Shortage
(%)
Peak
Demand
Peak
Availability
Shortage
(%)
Northern 33774 31137 - 7.8 50999 46681 - 8.5
Western 25354 24984 - 1.5 40750 38269 - 6.1
Southern 23586 22757 - 3.5 35492 34165 - 3.7
Eastern 11124 11013 - 1.0 16045 15768 - 1.7
N-E 1257 1156 - 8.0 2356 2053 - 12.9
India 94095 91047 - 4.3 145642 136936 - 6.0
Power saved is Power produced
As per CEA

Anticipated All India Power Supply
Position for the year 2014-15
Region Peak
Demand
Peak Met Surplus (+) / Deficit (-)
MW MW MW (%)
Northern 47570 46899 - 671 - 1.40
Western 45980 52652 + 6672 + 14.5
Southern 41677 32423 - 9254 - 22.2
Eastern 17608 17782 + 174 + 1.0
N-E 2543 2215 - 327 - 12.9
India 147815 144788 - 3027 - 2.0
Save one unit a day, keep power cut away
As per CEA

Forecasted installed capacities (LH) and
electricity consumption (RH)
Energy serves you the way you deserve

Estimation………..
 The IEA estimates India will add between
600 GW to 1,200 GW of additional new
power generation capacity before 2050.
Manage energy well, To avoid damage and hell!

Plan Vs Achievement
Five Year plan Target Achieved Shortage % Achieved
1st - 1951-56 1300 MW 1100 MW 200 MW 84.6%
2nd - 1956-61 3500 MW 2250 MW 1250 MW 64.2%
3rd – 1961-66 7040 MW 4520 MW 2520 MW 63.9%
4th – 1969-74 9264 MW 4519 MW 4745 MW 48.8%
5th – 1974-79 12499 MW 10202 MW 2297 MW 81.6%
6th – 1980-85 19666 MW 14226 MW 5440 MW 72.3%
7th – 1985-90 22245 MW 21401 MW 844 MW 96.2%
8th – 1992-97 30533 MW 16423 MW 14110 MW 53.7%
9th – 1997-2002 40245 MW 19015 MW 21230 MW 47.2%
10th – 2002-2007 41110 MW 21130 MW 19980 MW 51.3%
11th – 2007-2012 78000 MW 54964 MW 23036 MW 70.4%
Conserve & pay no price, spend & pay a great price
Average % achieved is 66.74 %

FRIDAY, 08 AUGUST 2014
Energy can’t be created but it can be destroyed. Save it!
“ Over 40 crore people living in eight
crore households have not got
electricity and the government is
making all efforts to give them power
connection as early as possible, Lok
Sabha was told”

Hurdles……..
Indian Power Sector is consistently facing
multiple challenges of
Shortage in Coal supply.
Fund availability,
Fuel linkages,
Land acquisition,
Environmental clearances,
Poor management practices of erstwhile State
Electricity Boards,
Delivery schedule for the equipments,
High ash content Coal. ETC.,,
Energy conservation… A little less now. A little more for the future

Challenges in Generation sector
 The share of Hydro is only about 19%
despite the fact that Hydro potential in
India is about 84,000 MW at 60% load
factor.
 The IEA Estimated that ideal mix of Hydro:
Thermal in India is concerned is 40:60.
 However, the share of Hydro is declining
and the current actual Hydro: Thermal mix
is 19:67.
Spare a Watt; Save a Lot

Final affect on Nation……..
 The power sector role in the overall
growth of the economy is
increasingly becoming important
and critical.
 Any slowdown in its performance
severely impacts GDP growth of the
country as a whole.
Energy Conservation-Nation’s Foundation.

Two ways…………
Go on
Increase
Installed
capacity
Minimize
Losses
&
Follow
Energy
Conservation

What is our role ?
 Growing populations and industrializing
sector create huge needs for electrical
energy.
 Unfortunately, electricity is not always
used in the same place that it is produced,
meaning long - distance transmission
lines and distribution systems are
necessary.
Switch-Off AC Units at least Half an Hour Before Leaving the Office.

 But transmitting electricity over
distance and via networks involves
ENERGY LOSS.
 So, with growing demand comes the
need to minimize this loss to achieve
two main goals: Reduce resource
consumption while delivering more
power to users.
What is our role ?
Energy conservation is the foundation of energy independence

Generation, Transmission, sub
transmission and Distribution system
Transmission lines
765 / 400 KV
Transmission
Customer-220/132
Sub Transmission
Customer
66/33KV
Primary
Customer
11KV/415V
Secondary
Customer
230 V

AT & C Losses – Figures…….
 India’s Aggregate Transmission and
Commercial (AT&C) losses, which are at
27% of generation compared to world
average of less than 15%.
 The concept of AT&C losses was
introduced in 2004. The advantage of the
parameter is that it provides a realistic
picture of energy & revenue loss situation.
Life should be built on the conservation of energy

AT&C Losses……..
 High levels of
AT&C loss poses a
major challenge as
a significant
portion of the
generated power
is lost or goes
unaccounted.
"Ecology and Energy are twin concerns of development"

Many reasons…………
Reasons
Over
loading
Poor
Maintenance
& repair
Lack of
Capital/
Investment
Low
efficiency
Obsolete
Technology
Lack of
R&M
E = mc2 = Energy = money control conservation

What standards are saying………
S.
No.
System Component Levels for peak
power losses
Target% Maximum
Tolerable %
1 Step up Transformer and EHV Transmission
system
0.50 1.0
2 Transformation to intermediate voltage
level, transmission system and step down
to sub transmission level
1.50 3.0
3 Sub transmission system and step down to
distribution voltage level
2.25 4.50
4 Distribution line and service connections 4.0 7.0
Total power losses 8.25 15.50
Today’s Electricity wastage is tomorrow’s Power shortage.

World at a glance……………
China 6.6 Austria 4.9
Hong-Kong 11.3 Belgium 4.7
India 27.0 Bulgaria 13.6
Indonesia 10.4 Cyprus 4.3
Japan 4.5 Czech Rep 7.0
Mongolia 12.5 Denmark 6.8
Nepal 28.5 Estonia 11.7
Pakistan 16.5 Finland 3.0
Philippines 12.4 France 7.0
South Korea 3.8 Germany 6.4
Sri-lanka 14.0 Greece 4.4
Taiwan 4.3 Hungary 9.5
Thailand 6.8 Ireland 7.7
Paraguay – 31.2 %
Luxemburg – 1.8 %
Energy is life - use it wisely

The AT&C Losses comprise of two elements:-
 Technical Losses &
 Commercial Losses.
Formula for AT&C Losses =
{1-(Billing efficiency X Collection efficiency) } X 100
Total units sold (MU)
Where Billing efficiency = -----------------------------
Total Input (MU)
Revenue collected (Rs)
Collection efficiency = -----------------------------
Amount billed (Rs)
AT & C Losses…….
Save electricity today for a bright tomorrow.

AT&C Losses – Region wise
Region 2010-11 (%) 2011-12 (%)
Eastern 38.72 42.61
North Eastern 37.03 34.85
Northern 29.22 31.49
Southern 19.21 18.62
Western 24.47 24.86
National 26.04 27.00
Courtesy:- PFC
Turn off light and equipments when not in use.
As per CEA

T & D Losses – All India- Year wise
Courtesy:- CEA
Practice energy conservation for future generation
As per CEA

AT&C Losses – Technical losses
Main Reasons for Technical Losses
 Desired investment ratio between generation and
T&D should be 1 : 1, during the period 1956 - 97 it
decreased to 1 : 0.45.
 Low investment has resulted in overloading of the
distribution system.
 Haphazard growths of sub-transmission and
distribution system with the short-term objective of
extension of power supply to new areas.
 Large scale rural electrification through long 11kV
and LT lines.
Save energy, save money and save planet

AT&C Losses – Technical losses
Installation of Dist. Txfmrs away from load centers.
Inadequate Size of Conductors of Distribution lines.
Too many stage of transformations.
Improper load management.
Bad Workmanship.
Feeder Phase Current and Load Balancing.
Transformer Sizing and Selection.
Inadequate reactive compensation.
When it is bright, switch off the light

Non-technical (commercial losses)
1. Power theft.
2. Metering inaccuracies.
3. Unmetered losses for very small load.
4. Error in Meter Reading.
5. Making unauthorized extensions of loads,
especially those having “H.P.” tariff.
6. Billing problems.
AT&C Losses – Non Technical losses

AT&C Losses – Non Technical losses
7. Tampering the meter readings by mechanical
jerks, placement of powerful magnets or
disturbing the disc rotation with foreign matters.
8. Stopping the meters by remote control.
9. Willful burning of meters.
10.Bypassing the meter.
11.Changing C.T ratio and reducing the recording.
12.Errors in meter reading and recording.
13.Improper testing and calibration of meters.
The less you burn, the more you earn

How to reduce Technical Losses ?
1. Converting LV Line to HV Line.
2. Large Commercial / Industrial Consumer get direct Line
from Feeder.
3. Adopting HVDS for agricultural customer.
4. Adopting Arial Bundle Conductor (ABC).
5. Utilize feeder on its average capacity.
6. Replacements of old conductor / cables.
7. Feeder renovation / Improvement program.
8. Industrial / Urban Focus Program.
9. Strictly Follow Preventive Maintenance Program.
A thing which burns never returns

10.Private sector participation in Distribution.
11.SCADA & IT application.
12.Use of Remote Meters.
13.Distribution Transformer & Feeder-wise Metering.
14.Reactive Power compensation by Capacitors.
15.Separation of Agriculture & Distribution Feeders.
16.Avoid sub-standard CRGO steel for Transformers
affecting its reliability.
17.TOD (Time of Day) Metering.
18.Promoting Energy efficient BEE rated equipments.
How to reduce Technical Losses ?
Conserve & pay no price spend & pay a great price

How to reduce Non-Technical losses ?
1) Making mapping / Data of Distribution Line.
2) Implementation of energy audits schemes.
3) Mitigating power theft by Power theft
checking Drives.
4) Replacement of Faulty/Sluggish Energy
Meter.
5) Bill Collection facility.
6) Reduce Debit areas of Sub Division.
7) Watchdog effect on users.
"Energy Saved Today is Asset for Future"

APDRP Programme
 The scheme hardly met with any success.
 According to the Government claims, the scheme
led to reduction in the overall AT&C loss from
38.86% in 2001-02 to 34.54% in 2005-06. Later,
the government restructured the APDRP
programme.
 The Restructured APDRP (R-APDRP) was
launched in 2008 as a central sector scheme for
XI plan.
Accelerated Power Development & Reforms Programme
As per CEA

R-APDRP Aims for……..
Reduction of AT&C losses.
Bring about Commercial viability.
Reduce outages & interruptions.
Increase consumer satisfaction.
The programme has two components:
INVESTMENT COMPONENT covers strengthening
and up gradation of sub-transmission & distribution.
INCENTIVE COMPONENT is a grant for states /
Utilities towards reduction of cash losses with 2000-01
as the base year.
"To be energy wise, cut your use to size"

Target of AT&C Losses………
 The GOI has set a target of reducing them to
17.1% by 2017 (12th plan) & to 14.1% by 2022
(13th plan).
“Our earlier generations spent dark nights but we see bright lights.
Let us conserve energy to keep away future dark frights”

Reduction in 5% of AT&C Losses...
 Peak demand supply is 140 GW.
 Total losses towards AT&C is – 0.27 X 140 GW =
37800 MW.
 If 5% reduction achieved from AT&C losses, 140
X 0.05 = 7000 MW.
 Average generation cost per unit is Rs. 3.78, then
total loss per year is = 7000X1000X8760X3.78 =
~ 230000000000.
Be a part of solution, not the problem

Auxiliary Power consumption
All India Average APC of Generating stations, As per CEA
8.53%
9.05%
8.57%
8.44%
8.29%
8.17%
8.32% 8.34%
8.49% 8.44%
7.60%
7.80%
8.00%
8.20%
8.40%
8.60%
8.80%
9.00%
9.20%
2002-
03
2003-
04
2004-
05
2005-
06
2006-
07
2007-
08
2008-
09
2009-
10
2010-
11
2011-
12
ALL INDIA APC (%)
As per CEA

NTPC – Auxiliary Power consumption
 Total installed capacity of NTPC is 43,128 MW as
on 18.09.2014.
 Auxiliary power consumption of NTPC is
It is considerably low as compared to All India APC
7.83%
8.83%
7.45%
7.02% 6.87% 6.67% 6.57% 6.62% 6.60%
6.03%
0.00%
1.00%
2.00%
3.00%
4.00%
5.00%
6.00%
7.00%
8.00%
9.00%
2002-
03
2003-
04
2004-
05
2005-
06
2006-
07
2007-
08
2008-
09
2009-
10
2010-
11
2011-
12
NTPC - APC
As per CEA

Scope of reduction in APC….
 Auxiliary power consumption in a
thermal power plant is a major
source of energy consumption.
 During 2011-12, total generation by
Thermal plants 606684 MUs and
average auxiliary power
consumption as 8.44 %.

It is possible…………
 If steps could be taken to reduce this APC
to 8.0 %, it will help in avoiding fresh
capacity addition of a unit of 400 MW size.
 Thus APC reduction initiatives not only
reduce energy consumption but also
ensure more revenue because of increase
in energy export.
Energy Conservation-Nation’s Foundation.

Norms notified by GOI for APC
Year 200/210/250 MW 500 MW with TDBFP’s
1992 9.50 % 7.50 %
2009-14 9.0 % 6.50 %
2014-19 9.0 % 5.75 %
Today's wastage is tomorrows shortage
As per CEA
Year 2009-14 2014-19
Average St - I & II 7.21 % 6.68 %
Station 7.08 % 6.50 %

APC Elements in Power Plant….
Condenser
Cooling
water
Draft
System
(ID/FD/
PA/SA)
Condensate
& FW
System
Compressed
Air
system
Ash
handling
system
Coal
Handling
system
AC, AHU
& AWU
Lighting
Auxiliary
Power
Consumption
Water
Treatment
system
Fuel
Handling
system
Take advantage of every opportunity

Typical APC (%) in TPS
35% - Condensate & Feed water system
30% - Air & Flue gas system
15% - Circulating water
10% - Milling system
4% - Coal Handling
2% - Ash handling
2% - Compressed Air
2% - Lighting & Misc.
Opportunities don’t just happen. You created them
Typical APC (%) in TPS
35%
30%
15%
10%
4% 2%2% 2%

Auxiliary Power Consumption
Operating the
equipment
At max.
efficiency
Reduction
Of Aux.
Power
consumption
Energy
Conservation
Factors
Affecting APC
Plant Load Factor
Operational
Efficiency of equipment
Start up & Shutdown
Age of the plant
Coal quality
Small opportunities are often the beginning of great achievements

Plans to reduce station APC
I. Short term plans.
II. Medium term plans.
III. Long term plans.
If opportunity does not knock, build a door

Short term plans to reduce APC
 The short term plans are those
which can be implemented
immediately OR at a low cost.
 Poor house keeping increases
maintenance of auxiliaries.
Don’t wait for Extraordinary opportunities

 Avoiding low / partial load running of HT
Motors. We can expect higher efficiency from
the Induction Motors if we loaded to maximum
capacity.
 Identifying of air / flue gas path, compressed
air, steam, oil and water leakages in units.
 Air ingress points in the boiler & ESP to be
identified.
 BFP/CEP R/C valves passing: - BFP/CEP Power
consumption increases due to passing of R/C
valve.
It is not about how much energy you make its how you save

 Maintaining the Air-fuel mixture as per available
coal.
 Better pulverized coal fineness and quality to
ensure optimum combustion. Breakeven point for
replacement must be identified.
 Better ESP and ash collection system.
 Poor insulation leaking ducts and expansion
joints lead to high radiation losses and heat
losses.
Unless commitment is made, there are only promises and hopes, but no plans

 Some of the applications in our plant, motors
are oversized. Hence efficiency can be
improved by replacing correct size of motors.
 Poor water chemistry lead to high boiler tube
failures.
 Avoiding of Boiler Blow down frequently.
 Charging of PRDS from CRH Steam system.
Commitment is what transforms a promise into reality

 Optimum position of burner tilt and
secondary air dampers, fuel air control.
 Insulation to piping to avoid radiation and
loss of heat energy.
 Poor condition of critical valves, Drain valves
& vent valves lead to high DM consumption.
 Energy efficient lighting system to utilize the
latest LED’s to reduce the life cycle cost.
Productivity is never an accident. It is always result of commitment

 Use of Dry ash Evacuation instead of WET
deashing System - Dry Deashing system
consumes less power.
 Optimization of level set point in LP & HP heater -
Heater drip level affects TTD & DCA of heater
which finally affect feed water O/L temp. Hence
it requires setting of drip level set point correctly.
 BFP scoop operation in three element mode with
variable speed instead of constant speed and DP
mode.
Commitment – It’s the little choices everyday that lead to the final results we’re striving for

 Avoiding idle running of conveyors & crusher
in CHP.
 Optimizing Voltage level of distribution
transformer.
 Optimizing discharge air pressure by tuning
loading/unloading cycle: - It helpful to
reduce specific Power consumption of
compressors.
Commitment is pushing yourself when no one else is around

 Isolating cooling water supply of standby
auxiliaries.
 For steam temperature control, the careful
control of combustion, possibly with the aid of
tilting burners, will reduce the need for steam
attemperation flows.
 Study on Thermostat location in ESP, FOPH and
in other locations where heaters supposed to
be cut in / cutout as per the temp set point.
Commitment leads to action, action brings your dream closer

Medium term plans to reduce APC
 The medium term plans pertain to
those works which can be taken up
during major shut down or during
overhauling.
Commitment is the glue that bonds you to your goals

 Use of wind turbo ventilators instead of
conventional motor driven exhauster.
 Application of special coating on CW pump, RW
Pump, ARCW, CFW and Ash slurry Pump impeller:
- It improves pump impeller profile condition,
increasing pump performance (4-5%).
 Energy efficient cartridges for BFP.
Possibilities are always endless

 Major maintenance of CW system and cooling
towers to achieve quality and quantity of water,
a clean condenser tubes to achieve better heat
transfer and possible vacuum to gain maximum
output.
 Belts have the lowest efficiency of all the
common coupling methods, V-belts are the least
efficient belt type due to inherent slip, followed
by cogged V-belts, flat belts, and synchronous
belts. Synchronous belts are the most efficient
belt type (up to 97%).
Educate yourself learn to conserve

 Detailed study of entire system from intake
to make-up water has potential in
optimization of complete system
(intermittent operation of additional pump,
avoiding recirculation).
 Study on installation of VFD’s for Raw water
make-up, Clarified water make-up, ash water
make-up, service water make-up, drinking
water make-up.
If you are the last one out, Turn off all the lights

 The long term plans cover R&M aspects of
the plant.
Long term plans to reduce APC

 Vacuum pumps in place of steam ejectors.
 Energy efficient variable pitch axial fans.
 Numerical control relays, New switch gears and
Advanced DVRs.
 VAM system for AC system by utilizing the waste
heat after APH.
 The amount of slip is generally lower if high-
efficiency motors are used. While designing for
new applications, consider high efficiency motors.
Set your target and keep trying until you reach it

 Changing the auxiliary steam header from MS
to CRH.
 Use of heat of compression air dryer instead
of electrically heated air dryer.
 Round ducts have less surface area per unit
of cross - section, and smoother flow
compared to ducts with square cross -
sections.
Save energy, save resources, reserve life on earth

 Installation of variable frequency drives in
CEP’s, BFP’s, PA Fans, ID Fans, Seal Air
fan’s etc., The benefits of VFD’s are larger
on low static head and high friction
systems.
 Tubular and heat-pipe (recuperative) air
heaters have no mechanical seals and
therefore have low leakage rates, typically
under 3%.

Power demand for methods of flow
control for radial fans

 Up gradation of C&I system to replace the
obsolete technology and installation of more
close loop controls to avoid manual
interference.
 Smart wall blowing system for optimizing
wall blowing and improving heat rate.
 Use of screw compressor instead
reciprocating compressor: - Sp. Power
consumption of screw compressor is less.
Do the earth a favour be a power saver

 Improvement of power factor to plant distribution
system by power factor correction capacitors.
 Wherever possible, work out for Energy-efficient
motors (EEM) in which, design improvements are
incorporated specifically to increase operating
efficiency.
 Soft starter provides a reliable and economical solution
to delivering a controlled release of power to the
motor, thereby providing smooth, steeples acceleration
& deceleration. Motor life will be extended as damage
to windings and bearings is reduced.
Saving energy is easy at home and at work

 Torque is reduced by about 1%
per deg of misalignment up to 5
deg, after which failure is likely.
Flexible couplings compensate
for minor alignment errors and
reduce the risk of bearing failure,
but at the cost of reduced
efficiency.
 Rigid couplings with laser-aided
alignment are recommended.
Life should be built on the conservation of energy

While designing………
 Use 3-phase transformers instead multiple single phase.
 Upgrade old transformers to achieve higher efficiency.
 Use PF correction, near the inductive sources where
possible, to approach 0.95 PF.
 Use a generous cable laying method; avoid methods which
lead to cable derating.
 Consider a plant arrangement which reduces length of
cable runs & voltage drops.
 Ensure that harmonics are well within tolerance.
 Understand motor duty and size accordingly.
 Ensure phase loads and voltages are balanced.
Conserve Energy, achieve synergy

ConclusionConclusion
 Yesterday, we operated plant processes, systems
and equipments with more power.
 Today, we are operating these with localized
monitoring and partial integrated controls.
 Tomorrow, we will have to operate with full
efficiently with innovative solutions, where we do
more than we can imagine today, with less than
we used yesterday!
Save energy, save money, serve nation

“Earth provides
enough
to satisfy
every
man's needs,
but not
every man's
greed.”

Energy conservation

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