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‘'Good practices in energy management
and efficient execution with Automation'.
Shibu George
Apollo Tyres Ltd
‘E’nergy - Fest 2012
•Energy Prices have Risen to an all time high...
•Result the companies are spending Millions of
dollars more Electricity cost for same Product
output.
•Important for improving profitability and reducing
pollution by minimising the emissions of greenhouse
gases and other polluting gases.
•The latest department of Energy study said that
electric motors consume nearly 63 % of electricity
used by industry .
Why Energy Management
Good Practices In Energy Management
1. Upgrade to premium efficient motors .
2. Plan and use VFD for all the pump & fan
application .
3. Do complete Motor Survey of the facility.
4. Use " Right " motor size for the application .
5. Turn off motors when they are not needed ----
Myth that this will reduce the life of motor is
incorrect unless it exceeds the design -starting
specification.
6. Turn off lights when not required.
Good Practices In Energy Management
7. Integrate Electrical Automation with process automation system.
8. Consistently monitor energy prices and energy consumption .
9. Building accountability into your organizational metrics and provide useful reporting and analysis tools for accurate budgeting and allocations.
10. Set Specific Power consumption targets for each process & plan control action.
• Automating as many of these activities as
possible to ensure energy management is
a repeatable, documented business
process.
Tyre Industry Power Requirement
Utility
• Usage of VFD for all the Pump & Fan Application.
Throttling or VFD Usage ?
Controlling the flow with a throttling valve is like modulating the
speed of a car using only the brake pedal.
• Power usage is directly proportional to the cube of
the pump/ Fan speed.
• For eg. reducing speed by 50% requires only 12.5%
of the power needed at full speed
VFD – Vacuum Pump System,
Feed water system , Blowers
Production Review
Nerve Centre
Plant Floor
Usage of Data Collection
Secure Remote Access Power
Consumption
chart
SCADA
• “Energy cannot be controlled if it is not monitored
• Automatic Data logging system in a PC (SCADA) has been designed and developed right from the project stage to have an effective control in the use of energy
• Energy Monitoring SCADA:
Energy Data from all the energy Meter is being recorded in this SCADA continuously ( BU wise )
• Instrumentation SCADA:
– Steam, Air, Water, and Oil consumption has been continuously recorded and monitored in the SCADA System.( BU wise )
–
Sample of Consumption report
13698 KW
Thank You
Electrical Power distribution& Lighting
• Distributed Substation.
• Cable sizing.
• Energy efficient light – T5 Tube Light w.r.t Energy & Lux Level.
• Tuned filter/ Harmonic Filter are used to avoid loss.
• Solar street light for external areas.
• Movement sensors in all the Control Rooms , CFT Offices for Switching ON AC/ Lighting .
• LDR sensor for External Street Light Switching ON / OFF.
• Effective usage of Day light by Polycarbonate Roof sheet
14
Green IT- Typical Energy Flow/Use
Server Load/
Computing
Operations
Cooling
Equipment
Power
Conversion &
Distribution
Delivered
Power
Electricity
Generation &
Transmission
Losses
Fu
el B
urn
ed
at
Po
we
r P
lan
t
15
Will reduce cooling needs
Typical Energy Flow/Use
Server Load/
Computing
Operations
Cooling
Equipment
Power
Conversion &
Distribution
Reducing server power requirements
Lowering power conversion losses
Electricity
Generation &
Transmission
Losses
Delivered
Electricity
…ultimately reducing fuel burned at the power plant Reducing power demand and losses
Fu
el B
urn
ed
at
Po
we
r P
lan
t
On-Site Generation further
reduces losses and emissions!
Traditional Architecture
UPS
Standard PC
Clients
DC Thin Client Architecture
Battery Back-Up
Charge Controller Grid-Tie Inverter
Charger
4 to 8 times
Less Power than
Standard PC’s
Challenges faced • Effect of interferences of Equipment Wifi with the
Office Data Wifi .
• Unstable Ethernet network causing disturbance
to Production Equipment and also vise versa.
Plans –
1. Equipment Wifi Channels will be on separate
channel frequency.
2. VLAN creation and Network Architecture will be
designed with equipment.
3. Equipment layer on different communication
layer i.e. Control net & Device net instead of
Ethernet.
Typical Plant Level Equipment
Networking
Thank You