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PROJECT REPORT
(Project Semester January – May 2012)
STUDY ENERGY MANAGEMENT SYSTEMS (EMS) IN POWER GRID
AND SCOPE OF REDUCTION IN POWER LOSSES/CONSUMPTION.
Submitted by
Vijit Dubey
09104072
Under the Guidance of
Dr. Darshan Singh Mr. Yogesh Gupta
Associate Professor Front Line Entrepreneur
Department of Electrical Engineering
Punjab Engineering College, Chandigarh
(Deemed University)
9th January to 8th May 2012
Page | 2
DECLARATION
I hereby declare that the project work entitled “Study Energy Management Systems (EMS) in
power grid and scope of reduction in power losses/consumption” is an authentic record of my
Own work carried out at Trident Ltd, Sanghera, Barnala, Punjab. As requirements of six months
project semester for the award of degree of B.E. in Electrical Engineering, Punjab Engineering
College (Deemed University), Chandigarh, under the guidance of Mr. Yogesh Gupta and
Dr. Darshan Singh, during 9th January to 8th May, 2012.
(Signature)
Vijit Dubey
09104072
Date: ___________________
Certified that the above statement made by the student is correct to the best of our knowledge
and belief.
Dr. Darshan Singh Mr. Yogesh Gupta
Associate Professor Front Line Entrepreneur
(Faculty Coordinator) (Industry Coordinator)
Page | 3
ACKNOWLEDGEMENT
I acknowledge Mr. Yogesh Gupta for his support and motivation throughout the project. His
knowledge and experience in the Power industry was of great support for me. His guidance as
my mentor helped me to analyze several problems analytically. My kind thanks to Mr.Gupta. I
would also like to express my gratitude to Mr. Ashish Gupta and Mr. Honey Arora for their
support and guidance. They helped me to perform several Experiments & helped me greatly with
their knowledge in the field of Electrical Engineering. I would like to thank Mr. Ranjodh for
sharing knowledge about several experimentation and sampling processes. I extend my gratitude
to Mr. Dilbar Singh, Mr. Mohd. Arshad, Mr. Nawab Khan and other shift in-charges of Power
Grid for their continuous support.
I would extend my acknowledgment to the HR Team headed by Mr. Dibyakant Singh and Miss
Aditi Singh for helping me in management related problems.
Lastly I would like to than Mr. Darshan Singh for constantly keeping updates of my project. I
appreciate the pains he took to come visit the industry personally.
Page | 4
Index
S. No. Topic Page
1 About Trident 5
2 PEC University of Technology 11
3 66/11 KV Sub-Station 12
4 Coupling of Dhaula and PSPCL 15
5 Transformer Details 17
6 Learning Energy Management Systems (EMS) 21
7 How Decoupling of PSPCL and Dhaula Power looks on EMS 30
8 Shifting Load of Unit 4A from Dhaula To PSPCL 31
9 How could power factor change after step Down 33
10 Project 1: Installing a servo-stabilizer in IOL Building 34
11 Project 2: Installing a servo-stabilizer in Woodland Guest House 45
12 Project 3 – Reduction in Downtime via Thermography 50
13 Project 4: Reduction in Downtime via Interlocking 61
14 Project 5: Reduction in Power consumption of H-plant in Unit 5 66
15 Project 6- Self-made load manager 72
16 Total Overall Savings 78
17 References 79
Page | 5
Trident Group
Trident Group commenced its operations in 1985 with Single Super Phosphate (capacity 66000
tons per annum) & Sulphuric Acid (capacity 33000 tons per annum). Since then, the business of
the group witnessed a wide range of diversification and expansions and today, Trident Group is a
Rs. 30 billion global conglomerate with an employee headcount of more than 10,000, and
providing indirect employment to 20,000 people. Therefore, Trident is a pioneer at implementing
sound Corporate Governance as the basic management principle.
Trident Group is a dynamic and continuously growing group of companies creating a buoyant
economic climate. The group is focused on generating economic prosperity for the stakeholders,
while growing harmoniously with the community and environment.
Leveraging business from an expanding product portfolio, Abhishek Industries Limited, the
flagship company of the group, is one among the top 5 global terry towel giants of the world.
What's more, the company is one of the world's largest agro-based paper manufacturers and one
of the largest yarn producers in India.
Strong business ethics, excellence in business, productive work environment, continuous
improvement through sound corporate governance and dynamic employee engagement have
been at the foundation of the continuous success of the group.
Making way in Punjab as an agro-based manufacturer in 1990, the group has diversified and
expanded manifold, giving way to businesses based on sustainable growth. Under the dynamic
leadership of Mr. Rajinder Gupta, the CEO and MD of the group, Trident continues to grow
embracing new challenges, expanding boundaries and creating new opportunities.
With businesses spanning across more than 60 countries, Trident Group today is a Rs. 30 billion
enterprise with an employee headcount of more than 10,000, and providing indirect employment
to 20,000 people. Therefore, Trident is a pioneer at implementing sound Corporate Governance
as the basic management principle. And at the core of this progress is our motto - Inspired by
challenge.
Trident has 3 plants located at Dhaula (Punjab), Sanghera
(Punjab) and Budhni (Madhya Pradesh).
Page | 6
Textile
Abhishek Industries started its Home Textile operations in 1999 with the commissioning of its first
Terry Towel Operation with 68 looms. Two major expansions were done in the year 2004 and 2009 and
today the installed capacity stands at 100 MT / Day . The total no. of looms under operations are 374
and further expansions are planned.
Many more technological up-gradations have been done in different areas of operations - Weaving,
Dyeing, Finishing, IT Infrastructure etc. The latest addition is a bathrobe manufacturing facility that is
expected to start operations from mid-2010. These have ensured that Trident today has a very modern
& state of the art operation to deliver excellent value to its customer.
The product & customer portfolio has also enlarged with time & today Trident supplies to almost all
major terry towel markets in the world. The products go to all segments of the market - retailers,
importers, institutions etc.
Facilities & Technology
The plant is spread across about 300 acres of land with state-of-the-art technology sourced from Japan,
Switzerland, Germany, Belgium & Italy. The Plant facility comprises mainly of:
Yarn Processing
Weaving Preparatory
Weaving
Process House
Finishing House
Final Inspection Office and
Fully equipped Research Laboratory
Today, Trident is amongst the top 5 terry towel manufacturing facilities in the world in terms of its
capacity & technology.
The complete process - from yarn manufacturing, to weaving, to dyeing & final packing - is done in
house. We have a vertically integrated set-up with stringent quality controls at all levels.
Page | 7
Yarn
Trident Yarn manufactures both Ring Spun and Open End Yarn out of cotton, synthetic and special
fibers from its 2,24,448 spindles and 1920 rotors spread in Punjab and Madhya Pradesh. All our plants
are equipped with the latest machinery and technical knowhow. The prime focus remains on producing
value added yarn to meet all the innovative yarn requirement of the customers.
The company can today boast of being one of the leading players in the industry. With a customer
centric approach, Trident Yarn has achieved an enviable reputation not only in the domestic market but
also in the international markets. It has accomplished a significant presence in America, Europe, Africa,
and the Far & Middle East within a decade of commencement of yarn operations.
Facilities & Technology
The plant is spread across 100 acres of land and divided into six units, out of which 4 units are located
at Punjab & two units at Budhni (M.P) with a combined capacity of 2,24,448 spindles and 1920 rotors
utilizing almost 100% capacity.
Page | 8
Chemical
Trident Chemicals is the leading Sulphur based Sulphuric acid manufacturer in entire Northern India
with market share of more than 70% in Punjab. The Sulphuric acid plant was set up in 1985 with initial
production capacity of 33000 TPA, which was increased to 100,000 TPA in 1997. We are the biggest
producer of Sulphuric acid in the region and our services & supplies are the major instruments in
customer holding. We have been associated with corporate/direct customers, HLL inter-mediators,
OEM Batteries, fertilizers & leading pharmaceuticals.
Facilitites & Technology
Production process involves the principle of Double Conversion Double Absorption (DCDA
Process) for the most efficient use of energy and minimum emissions.
At Trident, special emphasis is laid on maintenance of quality standards of all the products.
Sulphuric Acid produced here finds applications in various segments of industry:
More Applications:
Catalyst and dehydrating agent in many organic chemical manufacturing and petrochemical
processes.
Manufacturing of detergents.
Manufacturing of titanium dioxide (a widely used white pigment), and other dyes and
pigments.
Manufacturing of fertilizers mainly phosphates but also zinc, ammonium and potassium
Sulphate.
Manufacturing process for a range of plastics.
Metal processing such as picking and de-scaling of steel, and non-ferrous metal plating and
purification.
Drug production via Sulphonation, manufacturing of food acids (citric and lactic acid) and
edible oils, Adhesives, Explosives, Synthetic rubber, Water and effluent treatment, Chlorine
drying, Wood pulping, Leather tanning, Car batteries.
Page | 9
Paper
At Trident, paper is produced for catering to both the domestic and international markets. The
focus is on producing different grades of premium & eco-friendly paper to meet the increasing
demands of the printing industry. Trident Paper is manufactured using the wheat straw and Hard
Wood as prime raw material. The first machine got commissioned in 1992, followed by
commissioning of second machine in 2009-10 & today we have a total paper capacity of 175,000
TPA. We produce both writing and printing grades of paper for various market segments.
Trident Paper as a brand has the following sub brands:
Spectra Copier
My Choice Copier
Trident Natural
Facilitites & Technology
We have the existing production capacity of paper manufacturing of 1, 75,000 TPA and pulping facility of
1,25,000 tpa.
Biggest Mill in the world based on Wheat Straw with "METSO Continuous Digester".
METSO Fiber line with ECF Bleaching sequence of O-D-E (OP)-D to get pulp brightness of
88% ISO.
Ultra-modern Paper Machine by Allimand, France( Asizer, coated paper).
Upgraded Finishing House with latest equipment (Lino metic cutter , Allimand Winder, Wills A4
cutter, Pasaban
Sheeter, Automatic Packing machine & many more).
First Mill in the world to use ECF bleaching and Oxygen Delignification on Wheat Straw.
First Mill in India to Adopt Fuzzy logic for Burner Management in Limekiln.
Recovery Boiler and Power Boiler designed for Low emission level less than 75 mg/Nm3.
Evaporators designed for high solids with higher steam economy.
Flexibility of operations and Raw material mix.
Latest DCS and Energy efficient equipments ordered.
Production of Eco friendly and Value added papers for better Eco System.
Page | 10
Energy
Keeping in view the increasing requirements of our continuously expanding operations, we at
Trident generate captive power to meet the demands of the industry. The power generated
internally aids in uninterrupted supply of power for the production processes, ensuring enhanced
efficiency, round-the-clock production and cost saving.
With theme of Energy conservation and green environment, Abhishek Energy is producing
steam and power using eco-friendly process. The total Black Liquor effluent of pulp process
along with Biomass and Coal is used to generate High pressure steam in cogeneration process.
The First unit of 9.4 MW got commissioned in 1999; the production capacity of which has been
increased to 49.4 MW by addition of 2 nos. 20 MW units. The commissioning dates of the units
are as below--
Cogen 1 (9.4 MW) 30/4/1999
Cogen 2 (20 MW) 28/2/2007
Cogen 3 (20 MW) 28/3/2008
Facilitites & Technology
Multifuel AFBC boilers with complete automated DCS operation and intelligent Load
management system
Having infrastructure to receive 63 Kg / cm2 steam generated from recovery boilers
running totally on black liquor effluent of Pulp process
Infrastructure for export of power to PSEB and other states under open access.
Synchronisation facility for the total network
Coal Linkage
Page | 11
PEC University of Technology
PEC University of Technology, Chandigarh is the leading engineering college of the country and
also ranked 15th in the list of top engineering colleges in India. Known for its excellent world
class facilities and academic system, PEC is the hub of research activities in the country. Every
year around 450 students get their undergraduate degree from the institute. PEC offers 9 different
undergraduate engineering courses & is best known for its undergraduate program that includes
the Bachelor of Engineering program
The entrance to undergraduate programs in PEC is through AIEEE, All India Engineering
Entrance Examination. It is considered as one of the most difficult exams in the world with 1%
of the students appearing is selected. PEC attracts the top brains of the country for research and
engineering study.
Page | 12
66/11 KV Sub-Station
The 66/11 KV substation was allotted as the site for project. It is located in the Sanghera,
Barnala, Punjab. The plant manufactures yarn, there are 5 such units. This substation provides
energy to these units. There is a total demand of 17MW for the entire plant. We partly rely on
Dhaula Co-gen and partly on PSPCL. The commercial rate of electricity in Punjab is Rs. 6/unit.
So there are two switchyards here. One amongst them being Dhaula, other being of PSPCL. Bois
th of them are transmitted by 66 KV.
Here are the details of load sanctioned by the PSPCL:
Connected load 36987 KW
Contract Demand 35000 KVA
Peak Load Allowed 11400 KW
PSPCL has kept a strict rule to keep the power factor above 0.9 lagging. A penalty has been kept
if it exceeds. However, power is subsidized if the power factor is above 0.95 lagging. This rule
of keeping the power factor above 0.9 is also applied for Dhaula co-gen. PSPCL gives enegy to a
load of 8.5 MW in coupled mode and 5 MW in decoupled mode.
PSPCL transmits 220KV to Handyaya Grid and then steps it down to 66KV and transmits it to
Sandghera.
There are two transformers of PSPCL. One has a capacity of 12.5/16 MVA, made by Emco. The
other has a capacity of 16/20 MVA, made by Areva. Emco transformer was used before the load
up gradation. It is still kept charged, but not used. It is kept for emergency purposes.
Dhaula co-gen has a total capacity of 49.4 MW. Dhaula is fed 8.5 MW on coupled mode and
12 MW in decoupled mode.
There are separate switch yards for both of these T&D. PSPCL have their own metering CTs,
PTs and Energy Meters. They are sealed and checked once a month when reading for billing
amount is noted.
Page | 13
The order how PSPSCL transmission line is controlled:
Ratings of PSPCL equipment:
CT-1 ratio 400/1
PT-1 ratio 66/0.11
SF6 breaker 2500 A
Isolator 1250 A
Earth Switch 1250 A
CT-2 ratio 400/1
PT-2 ratio 66/0.11
LIGHTING ARRESTER-1
CT-1 (PSPCL )
PT-1 (PSPCL )
ISOLATOR-1EARTHING SWITCH-1
PT-2 (METERING)
SF-6 BREAKER
CT-2 (METERING)
ISOLATOR-2
EARTHING SWITCH-2
LIGHTING ARRESTER-2
T/F 66/11KVSTAND ALONE
PANEL
Page | 14
The order how Dhaula transmission line is controlled:
Ratings of Dhaula Switchyard equipment:
CT-1 ratio 400/1
PT-1 ratio 66/0.11
SF6 breaker 2500 A
Isolator 1250 A
Earth Switch 1250 A
CT-2 ratio 400/1
PT-2 ratio 66/0.11
LIGHTING ARRESTER
PT-1 (PSPCL )
CT-1 (PSPCL )
ISOLATOR-1EARTHING SWITCH-1
PT-2 (METERING)
SF-6 BREAKER
CT-2 (METERING)
ISOLATOR-2
EARTHING SWITCH-2
LIGHTING ARRESTER-2
T/F 66/11KVSTAND ALONE
PANEL
Page | 15
Coupling of Dhaula and PSPCL
Here at Trident, Sanghera there is a demand of a load of 17MW. This is filled up by PSPCL and
Dhaula co-gen. Both of these powers are coupled together. The bus coupler operates in normal
conditions, but when there is any fault or any of the parameters exceeds the range of normal set
values the bus coupler trips. Then the system runs in de-couple mode. On decouple mode the
load is equally distributed and falls unto 8.5MW onto both of them.
The panels for which feeder are there are:
Unit 1
Unit 2
Unit 3
Unit 4
Unit 5
Gyaanpeeth
The power factor of Unit 1, 2 and 5 remains above 0.95 lagging. This is because they have
capacitor banks installed in them. Since PSPCL bills on power factor also we have kept these
units on PSPCL on de-couple mode. According to the PSPCL rule one has to keep power factor
above 0.9 lagging or else it would be charged a penalty. However incentives would be given if
power factor is above 0.95 lagging.
Unit 3 and 4 do not have capacitor banks. This is because they have too many electrical drives.
Due to this the Total harmonic distortion increases. These harmonics determine the strength of
the capacitor banks. Since, we do not want to jeopardize our capacitor banks these units no
capacitor banks. Dhaula can be run in a low power factor of 0.9 lagging hence we keep them
loaded onto them.
Both of the transformers are fed with a input of 66KV. The transformer gives out a output of
11KV. This then goes to the stand-alone panel and is then fed to charge the bus. Now there are
two busses. One is the Dhaula bus the other is the PSPCL bus. There is a bus tie to trip off a bus
for protection measures. But since the voltage running them is very high i.e. 11KV we cannot
break the circuit directly. This would result in a flash. So first the circuit in broken in the VCB
Page | 16
then the bus coupler is tripped. VCB stands for vacuum circuit breaker. Since there is no air at
the time of breaking the circuit the spark produced while breaking would not be transmitted
further. There are actually two bus couplers. We use bus coupler 2 while bus coupler 1 is kept for
emergency purposes.
So in coupled mode the power is distributed proportionately depending what comes from Dhaula
co-gen rest of it is covered by PSPCL.
This SLD below shows the arrangement discussed in coupled mode.This is how it is split.
Currently there is no difference in which feeder serves which feeder, since it is running coupled
condition. But as soon as it would be in decoupled mode the distinction would occur and there
would be two separate circuits then.
PSPCL Bus
Dhaula Bus
To unit 1 VCB-630A
To unit 2 VCB-630A
To unit 3 VCB-630A
To unit 4 VCB-630A
To unit 5 VCB-630A
To 5 B VCB-
To Gyaanpeeth VCB-630A
Bus coupler VCB 1600A
SLD of power supply in coupled mode
Page | 17
Transformer Details
There are three transformers here at power grid. One, is for Dhaula co-gen. The other two are for
PSPCL.
The names of make are following:
Emco transformer (12500/16000 KVA)
Areva Transformer (16000/20000 KVA)
Crompton Greaves (16000/20000 KVA)
The capacity of Emco transformer is less than the others. It was previously used. But after the
load increased on PSPCL we had to buy a new transformer, Areva in order to meet the new
power demands. Emco is still kept charged but it is not used. It is just kept for emergency
purposes now.
Crompton Greaves transformer transforms Dhaula power from 66 KV to 11 KV. The incoming
isover-head while the outgoing is underground. It has a automatic tap changer to control the
voltage and vary the ratio of windings accordingly. It also has Neutral Ground resistor to detect
and ground line to line faults.
Areva is kept on the old switchyard. It was bought recently when the contract demand with
PSPCL exceeded. It is newer machinery than its counterpart Emco. The capacity is also more
than Emco. While Emco has a capacity of 12.5/16MVA, Areva transformer has a capacity of
16/20 MVA. It also has a tap changer to control the voltage. Also it has a NGR to ground its line
to line faults. Here also the incomer is overhead transmission and the outgoing is underground
transmission.
The power after transforming is sent to a standlone panel. This were the main control is there
since it is the spot where the bus is charged. The protection is a VCB since the voltage is very
high and breaking the circuit would result in a flash.
The temperature of the windings and the oil temperature is monitored. It should not exceed a
limit. Moreover water should not get mixed up with the transformer oil. If it does the dielectric
of the oil decreases and is prone to breaking down easily. So to prevent moisture from getting in
Page | 18
silica gel is kept. It has a property to soak in moisture. Moreover oil is changed frequently to
avoid it.
The remote tap changer is kept with the transformer. Its function is to keep changing the
windings ratio so that we get the correct voltage. It is automated and easily changes its tap and
voltage variation is avoided.
DHAULA TRANSFORMER DETAILS
MAKE OF: CROMPTON GREAVES
KVA :16000/20000
VOLTS AT NO LOAD : HV 66000
: LV 11000
CURRENT RATING : HV 140/175 A
: LV 839.8/1049.7
MAKER SERIAL NO. : MT 5888/1
TYPE OF COOLING : ONAN/ONAF
IMPEDANCE VOLTAGE : 11.16%
VECTOR SYMBOL : YNynO
CORE AND WINDING KG : 18800
WEIGHT OF OIL : 8485 KG
TOTAL WEIGHT : 37000 KG
OIL : 9700 KG
YEAR OF MANUFACTURE : 7/2006
DAIGRAM DRG. No. :RDM 5888/1
Page | 19
PUNJAB STATE POWER CORPORATION LIMITED(PSPCL) -(OLD)
MAKE OF: ( EMCO TRANSFORMER )
KVA :12500/16000
VOLTS AT NO LOAD : HV 66000
: LV 11000
CURRENT RATING : HV 109.34 139.96 A
: LV 656.07 839.78
MAKER SERIAL NO. : 2/11/0117/R
TYPE OF COOLING : ONAN/ONAF
IMPEDANCE VOLTAGE : 11.16%
VECTOR SYMBOL : YNynO
CORE AND WINDING KG : 13400 KG
WEIGHT OF OIL : 8550 KG
TOTAL WEIGHT : 33650 KG
YEAR OF MANUFACTURE : 1998
Page | 20
PUNJAB STATE POWER CORPORATION LIMITED(PSPCL) T/F DETAILS (NEW)
MAKE OF : AREVA
KVA :16000/20000
VOLTS AT NO LOAD : HV 66000
: LV 11000
CURRENT RATING : HV 140 175 A
: LV 839.8 1049.7
MAKER SERIAL NO. : D-10267
TYPE OF COOLING : ONAN/ONAF
IMPEDANCE VOLTAGE : 11.16%
VECTOR SYMBOL : YNynO
CORE AND WINDING KG : 17600 KG
TANK AND FITTING MASS :11700 KG
WEIGHT OF OIL : 9400 KG
TOTAL WEIGHT : 38700
YEAR OF MANUFACTURE : 1998
DAIGRAM DRG. No. :D2-86244
No. OF PHASES : 3
TYPE : DOUBLE WOUND
Page | 21
Learning Energy Management Systems (EMS)
Introduction:
EMS is a very flexible tool for power services. This is basically used to note down the values of
the variables required for substation monitoring. For e.g. Voltage, Current, Power factor etc.
Load management is the process of balancing the supply of electricity on the network with the
electrical load by adjusting or controlling the load rather than the power station output. This can
be achieved by direct intervention of the utility in real time, by the use of frequency sensitive
relays triggering circuit breakers (ripple control), by time clocks, or by using special tariffs to
influence consumer behavior. Load management allows utilities to reduce demand for electricity
during peak usage times, which can, in turn, reduce costs by eliminating the need for peaking
power plants. In addition, peaking power plants also often require hours to bring on-line,
presenting challenges should a plant go off-line unexpectedly. Load management can also help
reduce harmful emission, since peaking plants or backup generators are often dirtier and less
efficient than base load power plants. New load-management technologies are constantly under
development, both by private industry and public entities.
Here at Sanghera’s 66KV sub-station EMS from ‘Conzerv’ has been installed.
It collects or calculates point data that it distributes to:
1. CimView screens
2. Alarm Viewer screens
3. Alarm printers
4. Logging tables
Page | 22
Method of Operation:
This software is scalable from a Human Machine Interface to a fully networked Supervisory
Control and Data Acquisition (SCADA) system. The networking capabilities inherent at all
levels within the product line lets to achieve the levels of integration that virtually eliminate
redundant configuration within a network.
Firstly, data is sent by the panel via a communication cable. This is received by ‘Conzerv’
RS485 data converter. It analyses and converts the signal in binary form. This data is further
decoded by the Conzerv software installed in the computer.
This saves a lot of time, manpower and reduces the chances of instrumentation and recording
errors.
Why Should we use EMS?
The reason we are moving on from our traditional way of noting down the readings from energy
meter are as follows.
Suppose we have 32 energy meters to take reading from.
Now we normally measure all the values, current, voltage running load, power factor,
total harmonic distortion and consumption.
It normally takes 2 minutes to cover readings from one energy meter.
Since we have 32 energy meters it would take us 64 minutes to cover all of them.
This means we are taking more than an hour to cover it.
Now suppose we need to write down readings at 6 am and we start on time. We would
cover the last feeder at atleast 7am.
This is a waste of skill of manpower. Worker’s time and skill are wasted.
Page | 23
Moreover an error is introduced in the accuracy since the readings were meant to be
taken at 6am but the last feeder is covered 1 hour later.
- A Rough Flow chart
C- Substation Controllers S- Server V- Viewer
Advantages:
1. Saves time: Every possible required value is available on the screen at the same time.
Where other meters have a switch to skim through the values, this saves time.
2. Reduced error: All the human errors that could take place while instrumentation or noting
down the values is ruled out. This makes it very reliable
3. Consistency: Sometimes we need values on special time intervals and at specific time for
surveying. This builds up a platform for the same.
4. Record & History: EMS also keeps a record of the past values and stores them for future
reference. A graphical representation for the values is also done.
Page | 24
Brief
The term Energy Management System can also refer to a computer system which is designed
specifically for the automated control and monitoring of those electromechanical facilities in a
building which yield significant energy consumption such as heating, ventilation and lighting
installations. The scope may span from of a single building to a group of buildings such as
university campuses, office buildings, retail stores networks or factories. Most of these energy
management systems also provide facilities for the reading of electricity, gas and water meters.
The data obtained from these can then be used to perform self-diagnostic and optimization
routines on a frequent basis and to produce trend analysis and annual consumption.
There are many such tools to monitor the trends variation and comparison. All of them are
discussed in further pages.
Page | 25
Tools
The tools/functions which ‘Conzerv’
1. Mimics:
As the name suggests this mimic the meters on the panels. A value corresponding to the same
time is displayed on the screen. Since TRIDENT has a big campus/units. It would be difficult to
go to the units again and again to notice/note the values (current, voltage). Moreover fault
detection would be easy and prompt actions can be taken. Sometimes when values of specific
timing are needed, without an EMS it would be difficult. It also keeps a track record in form of a
graph to study the changes in the parameters at anytime.
E.g.
This is a demonstration of mimic of 66 KV main panel – Dhaula.
-Here we can see than we can monitor all the parameters all together on one screen.
Page | 26
2. Matrix:
This tool enlists all the values of the parameters all together and displays them I the form of a
matrix. Values like current; voltage, frequency etc. are represented from all the feeders.
E.g.
This is a demonstration of matrix.
We can clearly see that we can see the comparison of all the parameters all together. If the value of the
parameter is black it means that the communication cable of the the energy meter is loose and is not
reaching the RS 485 converter.
Page | 27
3. Trends
This tool is used to display the variable values of the parameters in the form of graphs. The
feeder is selected and and the graphs such as current, voltage etc. are displayed on the screen.
The representation is dynamic. It means that the values keep on updating and the graph runs live.
The scale selection can also be done. Scale can be varied according to the need.
E.g.
This is a demonstration of trends.
Page | 28
Any of the feeders can be selected and the trends can be observed in a graphical format. The live analysis
can be seen of all the parameters all together. One of the trend is shown in next page.
Trend of Unit 4A DBB:
We can clearly observe the trend of Unit 4A. we have trends of KW, Ampere, line to line voltage
and power factor. It is represented in a graphical format.
Page | 29
4. History:
As we discussed above trends is a function to make graphs of the past records plus the live feed
is also considered. In history function we compare those trends with each other on the same axis.
We can insert any number of parameters and examine the comparison done in graphical form.
For differentiation a clear cut demarcation of separate colors is done so that we can differentiate.
Moreover, a key is made below the graph to demonstrate the color representation
correspondingly.
E.g.
This is a demonstration of history.
Page | 30
5. Reports:
Everyday a report is prepared which contains the variation and measurements of former day
(6am to 6am). An MS excel sheet is formed everyday containing all the information to be
recorded and is saved for future records. It’s a C program coded interface. One just needs to
select the date and click on execute.
E.g. This is a demonstration of history.
How to fill the report?
First the date is set for which we want to make the power report.
Manual entry is done and all the enteries are entered in the next excel sheet.
Execute is clicked and daily report I generated.
The report is the data from last day’s 6am to the filled date’s 6am. The parameters are shown in
graphical format also.
Page | 31
How Decoupling of PSPCL and Dhaula Power looks on EMS
Findings and reports:
The bus coupler tripped earlier this day due to over-current from Dhaula. As seen from the
history. The load was increased onto the PSPCL. The power was then controlled and coupled via
a synchronizer. The even took hardly 16 mins, as seen in the graph after coupling them together
there was a sharp change in the power. This was primarily due to back emf or flow into each
other (i.e. from PSPCL to dhaula and vice versa).
Before decouple Dhaula provided 12MW and PSPCL provided 5MW.
After decouple both Dhaula and PSPCL provided 8.5MW each.
After coupling again the situation was resumed.
Page | 32
Shifting Load of Unit 4A from Dhaula To PSPCL (14-2-12)
How load shift looks on EMS?
Today the engineers from Dhaula called and asked to decrease the load as less power will be
generated. The reasons explained for the same were cited to be some faults in the turbine.
We had to decrease the load by 4MW. Hence it was decided to shift 4a and 4b onto PSEB. Hince
in the picture below we can clearly see that how it has been shifted. Earlier it was on the ABB
feeder from dhaula now it was loaded on ALSTOM feeder onto PSPCL.
The red one denotes the ABB feeder – Dhaula
The green one denotes the ALSTOM feeder – PSPCL
Page | 33
Effect seen on the power changes
As we see the power from Dhaula was initially high as normally we put most of our load at
Dhaula supply. Next we can observe the Dhaula slowly goes down and PSPCL comes up,
keeping the overall power constant.
The red one denotes the PSPCL KW stats
The green one denotes the Dhaula KW stats.
Page | 34
Observation- How could power factor change after step down?
The snapshot of the EMS shows that power factor increases after stepping down the voltage from
66KV to 11KV.
But it was observed that it was not true.
In the 11KV power factor measurement the effect occurring due to the windings of the
transformer were not considered. Since the windings of the transformer would be inductive the
power factor would be low.
Power factor due to transformer winding is included in the 66KV line but not in the 11KV line.
This is why the power factor of 66KV line is coming to be lesser than that of 11KV.
Page | 35
Project 1: Installing a servo-stabilizer in IOL Building
A servo-stabilizer installed in IOL building’s lighting load
Date: 31 Jan 2012
Capacity: 100KVA
Company: Neel
Page | 36
What is a Servo Stabilizer?
The Servo Stabilizers uses an advanced electronic servo-motor concept to control a motorized
variable transformer.Because of the motorization, there is a small delay in voltage correction.
However, output voltage accuracy is usually ± 1% with input voltage changes up to ± 50%.
These machines are not affected unduly by power factor or frequency variation. This type of
technology tends to be extremely effective when considering large three phase applications, as it
is able to maintain its accuracy of all three phases, both line to line and line to neutral,
irrespective of input voltage balance and load balance at any power factor. They are also able to
withstand large inrush currents, normally experienced with inductive loads. However due to the
mechanics of this type of stabilizer, periodic maintenance is required.
Various Design Topologies:-
Single Phase Input & Single Phase Output:
This type of servo stabilizer consists of an AC synchronous motor coupled with an Auto
Transformer using gears. Now depending upon the input fluctuation, the servo motors
adjusts the output of the Auto-transformer to provide a stabilized output. Its application is
where input supply & load output are single phase operated.
Three Phase Input & Three Phase Output- Balanced Load
This type of servo stabilizer consists of an AC synchronous motor coupled with three
Auto Transformer using a shaft & compatible gears. Now depending upon the input
fluctuation, the servo motors adjusts the output of the Auto-transformer to provide a
stabilized output. Its application is where input supply is three phase & output required at
load is balanced in all 3 phases.
Three Phase Input & Three Phase Output- Unbalanced Load
This type of servo stabilizer consists of three independent
AC synchronous motors coupled with three Auto Transformer using a shaft & compatible
gears. Now depending on the fluctuation, the servo motors adhust the output of the auto-
transformer to provide a stabilized output.
Page | 37
Working
Servo voltage stabilizers save the life of costlier appliances, CNC machines, electrical equipment, medical
equipment, motors lab equipment etc. through connecting AC voltage which is not stabilized, and dips
at one point of time and at other point of time rises to very high value. The principle of operating Servo
Stabilizer involves comparing the output voltage with built in stable reference voltage source. The solid
state control circuit operates the motor whenever the output voltage falls or rises beyond the preset
voltage.
Precisely engineered to perfection, our servo voltage stabilizer features a solid state circuit to control
the servo motor. The motor is mechanically attached to the arm of a continuously variable auto
transformer which feeds to the primary of a series control buck boost transformer. The stabilizer output
voltage is compared with the reference voltage & resultant error signal controls the Servo Motor
providing true proportional control systems rather than on/ off circuit.
General Technical Specifications*
Input voltage - 270,480 V, 300V-480V or as per requirement.
Output voltage - 415V +/- 2.5% Adjustable
Rate of correction - more than 8V / Sec
4Cooling - Air/ Oil
Capacity - KVA (1 KVA to 1000 KVA)
General Protections* :
High & Low voltage cut off
Short circuit protection
Over load protection
Single phase protection
Bypass arrangement
* varies with models
Page | 38
Overview
IOL building was fed by unit 4 directly. Since it would be directly fed by the industrial supply,
after all the voltage drops, a voltage of around 420 is received (line to line). This comes out to be
around 242V (=420/1.732). All the lighting equipments are rated to perform their best in 220 V.
An exceeded value of 22V would not only increase the consumption but also put a burden on the
system.
To avoid thus a servo-stabilizer was installed in the building. It was tried and experimented at
which voltage the results were ought to come most efficient. At high voltage of 230 V, high
consumption was observed. Even at low voltage of 210V high current was drawn, thus high
consumption was observed.
Setting it at 220 V gave the most economical results. A stand-by feeding from unit three is also
done, to bye-pass in case some accident happens at the stabilizer end. The SLD of the same has
been mentioned below.
Page | 39
Certain facts discussed:
Input supply of 410-415 V (3 phase AC-line to line) which falls around 240V line to
neutral.
Lighting loads are rated to work efficiently at 220 V.
Power consumption is directly proportional to the voltage
More the voltage, more will be the power consumption
Decreasing the voltage beyond 220V reduces the intensity of the light.
Research says that Intensity of 450 lumens is fit for office.
Decreasing the voltage will decrease the intensity.
Hence we come across an idea to reduce the power consumption.
Self-noted readings on the IOL energy meter (on working days)
Stabliser voltage Stabliser current
Date Voltage (LL) Current P.F.
Running
load (KW)
capacity
(KVAR)
Metering
(MWH)
Metering
(MVAH) R Y B R Y B
24-Jan-12 400.80 111.40 0.95 74.32 21.30 815.86 895.79
NA
25-Jan-12 399.40 114.50 0.95 74.75 21.62 816.84 896.82
29-Jan-12 404.10 100.30 0.95 66.23 20.37 821.18 861.33
31-Jan-12 399.40 113.40 0.95 74.64 28.51 823.30 903.56
1-Feb-12 400.80 106.10 0.95 68.13 21.95 824.57 904.91 200 200 200 35 40 20
2-Feb-12 408.90 108.10 0.95 72.81 21.00 825.93 906.30 200 200 200 27 46 33
3-Feb-12 397.90 109.60 0.95 72.76 20.76 827.06 907.48 200 200 200 35 44 23
7-Feb-12 401.40 99.92 0.95 65.19 18.74 831.22 911.82 200 200 200 25 35 20
8-Feb-12 405.20 31.61 -0.99 21.43 1.05 832.37 913.02 220 220 220 40 42 25
9-Feb-12 399.70 113.10 0.95 74.31 21.14 833.41 914.10 220 220 220 35 42 25
10-Feb-12 402.20 35.94 -0.99 24.86 -0.16 834.44 915.17 220 220 220 44 43 28
11-Feb-12 404.30 117.30 0.95 78.34 21.36 835.23 915.97 220 220 220 35 45 28
13-Feb-12 406.90 31.91 -0.99 21.12 -2.57 836.19 916.94 220 220 220 25 38 20
14-Feb-12 406.90 41.78 -0.99 29.06 0.03 836.77 917.50 210 210 210 50 50 25
15-Feb-12 369.20 117.60 0.95 77.32 21.65 837.89 918.70 210 210 210 50 46 28
16-Feb-12 399.90 114.10 0.95 75.20 20.96 839.15 920.01 205 205 205 40 48 20
17-Feb-12 400.00 108.90 0.95 71.26 21.37 840.07 920.97 210 210 210 35 45 25
18-Feb-12 399.40 114.60 0.95 79.91 21.54 841.23 922.18 210 210 210 40 45 25
20-Feb-12 405.70 38.95 -0.99 29.06 -0.11 844.47 925.50 210 210 210 45 40 25
21-Feb-12 405.00 38.95 -0.99 27.19 -0.14 845.07 926.17 210 210 210 55 50 30
23-Feb-12 404.60 41.90 0.99 26.67 0.17 846.14 927.24 210 210 210 50 40 25
25-Feb-12 402.80 36.45 -0.99 26.75 -0.24 846.65 927.77 210 210 210 30 45 28
27-Feb-12 403.90 39.45 0.99 26.69 1.00 847.50 928.69 210 210 210 50 45 25
Page | 40
Readings as per SAP
Date Units Date Units
Read
ings
Before After
09-01-12 1,063.00 02-02-12 1,127.00
1063.00 1171.00
10-01-12 1,032.00 03-02-12 1171.00
1032.00 1026.00
11-01-12 1050.00 04-02-12 1026.00
1050.00 880.00
12-01-12 1058.00 05-02-12 880.00
1058.00 1012.00
13-01-12 1059.00 06-02-12 1012.00
1059.00 1039.00
14-01-12 1082.00 07-02-12 1039.00
1082.00 1033.00
15-01-12 970.00 08-02-12 1033.00
970.00 1072.00
16-01-12 1049.00 09-02-12 1072.00
1049.00 1042.00
17-01-12 972.00 10-02-12 1042.00
972.00 659.00
18-01-12 1072.00 11-02-12 659.00
1072.00 672.00
19-01-12 1058.00 13-02-12 766.00
1058.00 766.00
20-01-12 1059.00 14-02-12 1032.00
1022.00 1032.00
21-01-12 1011.00 15-02-12 1095.00
1011.00 1095.00
22-01-12 1013.00 16-02-12 1047.00
1013.00 1047.00
23-01-12 1025.00 17-02-12 1052.00
1025.00 1052.00
24-01-12 1125.00 18-02-12 1296.00
1125.00 1296.00
25-01-12 1125.00 19-02-12 1243.00
1125.00 1243.00
26-01-12 1075.00 20-02-12 1064.00
1075.00 1064.00
27-01-12 1102.00 21-02-12 616.00
1102.00 616.00
28-01-12 1299.00 22-02-12 964.00
1299.00 964.00
29-01-12 1083.00 23-02-12 665.00
1083.00 665.00
30-01-12 1036.00 24-02-12 654.00
1036.00 654.00
31-01-12 1271.00 25-02-12 631.00
1,271.00 631.00
01-02-12 1,241.00
1,241.00 450.00
1,127.00
Average 1,062.77 924.21
850.00
900.00
950.00
1,000.00
1,050.00
1,100.00
1
Un
its
Average consumption Before and After Stabilizer
Before After
Page | 41
Running load Study
Before installing Servo-stabilizer
Voltage Current
R Y B R Y B Running load (KVA) Running Load (KW)
230 230 230 40 52 35 28.68 28.35
After installing stabilizer:
Voltage Current
R Y B R Y B Running load( KVA) Running Load (KW)
202 202 202 38 48 29 22.97 22.7
Firstly the load was run after bye-passing the servo stabilizer. The running load came out to be
28.35KW on a voltage of 230V. Then the servo was taken into line and the voltage was reduced
down to 202V. A clear trend of falling KW was seen onto this voltage. This can be explained by
proportion of voltage to current, which led to decrease in the power used. Here it can be
observed that clearly the trend of falling running load can be observed.
Page | 42
Calculating Savings Generated as per running load
Reduction in load: 5.65 KW
Saving in 1 hour: 5.65 units
Saving in 10 hours: 339 INR (Assuming load runs from 9am to 7pm everyday)
Saving for 1 year: 1,23,735 INR (at Rs. 6 per unit)
Graphical analysis
0
5
10
15
20
25
30
Load before stabilizer Load after stabilizer
Load in KW
Load in KW
Page | 43
Consumption Analysis from SAP
Weekly analysis:
Before After
Week Units/day Week Units/day
Week 1 1044 Week 4 962
Week 2 1036 Week 5 994
Week 3 1109 Week 6 883
The servo-stabilizer was taken into line on 31st December 2012. A analysis was done to monitor
the per day consumption of IOL 3 weeks before and 3 weeks hence. The red line in the graph
shows the day of installation of the stabilizer. The trend had fallen by an average of around 100
units per day. This was something beyond our expectations from the running load analysis.
0
200
400
600
800
1000
1200
Week 1 Week 2 Week 3 Week 4 Week 5 Week 6
Series1
Installation of Stabilizer
Page | 44
Monthly analysis:
Month Units/day
December 1123
January 1076
February 918
March 684
April 936
Outcome:
The servo-stabilizer was taken into line on 31st December 2012. Another analysis was done to
monitor the per day monthly consumption of IOL before and hence. The red line in the graph
shows the day of installation of the stabilizer. The trend had fallen by an average of around 200
units per day. This was something beyond our expectations from the running load analysis. We
were expecting saving of around 60-70 units per day. But this was something beyond our
imagination.
0
200
400
600
800
1000
1200
December January February March April
Units
Page | 45
Savings as per SAP data
Saving in 1 day: 834 INR
Saving in 1 week: 5,838 INR
Saving in 1 month: 25,020 INR
Saving in 1 year: 3,05,244 INR
* This is way beyond Rs. 1,23,735 per annum we expected before for our running load study. It
was researched and thought why was the saving coming about three times than expected.
Page | 46
Why Data From SAP showing more saving than expected?
The Energy meter is connected at the incoming. Pump no. 4, Air conditioners and
Lighting supply all come under it.
Pump no. 4 was not used for few days. Instead of it pump no. 3 was used.
In march pump no. 4 was not used since it was out of order.
Air conditioners were not used in the winters. So a clear idea cannot be made
It cannot be compared with last year’s data because last year the connected load was too
less. Many offices have been opened recently.
Clearly the trend of energy consumption can still be observed. With the reduction in
running current by bye passing the servo once and then later taking it in line.
So, we would consider the running load analysis to be accurate enough to calculate our
savings.
Page | 47
Project 2: Installing a servo-stabilizer in Woodland Guest House
A servo-stabilizer installed Woodland Guest House lighting load.
Date: 24th February 2012
Capacity: 30 KVA
Company: Muskaan’s
Page | 48
History:
Servo was initially in line but after loading AC’s it was bye-passed.
Load Analysis of connected load was done.
Reason:
Installing AC’s in Woodland-boys could result in the over-loading servo, hence
resulting in a flash.
So it was avoided to jeopardize our servo. We did a load study before taking it back
into the line.
Load Analysis
Load Analysis of Woodland Guest House
Items Number Load
(Watts)
Total
Load
(Watts)
TV 18 120 2160
Fan 32 75 2400
Tube
lights
32 40 1280
Cooler 16 150 2400
Total Load 8240
Deductions:
Lighting load is under 30 KVA
A new cable was dug in and geysers and AC’s would be fed by it.
This cable would not be under Servo-stabilizer’s load.
Now only the lighting load of Woodland would be fed under a stabilizer.
Page | 49
Previous SLD of Woodland Supply
The bus bar to the woodland DB is charged by unit 1 supply. A cable picks up the charge. A
change over switch is there to choose whether want to keep the servo in line or use it in a bye-
pass mode. Initially it was in line but after the installation of air conditioners in woodland boys it
was decided to use it in bye-pass mode. This outgoing from servo used to feed boys and girls’
lighting and geyser loads. The capacity of the servo stabilizer is 30 KVA. The load onto the
servo stabilizer is under the total capacity. For this the total connected load should be less than
the capacity. However certain margin should be kept to consider overloading.
So a new 4 core cable was decided to be fed just for the geyser and the AC loads of the girls and
boys hostel.
Charged Bus-bar
Bus-bar charged
Boys lighting + geyser
Girls lighting + geyser
Servo-stabilizer
Page | 50
New SLD of Woodland Supply
This is what the new arrangement was transformed to. Now from now the new cable was feeding
boys’ and girls’ geysers and the air conditioners in boys’ guest house. Whereas the old cable
would be feeding the lighting loads. The servo was now taken into line via the changeover
switch. The bye-pass was still kept in case the servo fails sometime in future so that supply to
the guest house still continues.
The load balancing on each phase was also done from the woodland’s end. Initially more load
was on y phase which was balanced. Moreover the new cable was fed to the geyser and AC
loads.
Charged Bus-bar
Bus-bar charged
Boys lighting Girls lighting
Servo-stabilizer
Girls + Boys geyser/AC
Page | 51
Savings Calculations
Since there was no energy meter on the lighting load we decided to analyze the load from a load
manager. A three day study onto it was done. It was kept in mind that the analysis should be
done on weekdays. Since there used to be very marginal load on the weekends since very few
people used to be there in the hostel.
Comparison on behalf of 3 Day Load Manager Study
Consumption Before
Stabilizer
52 Units/day
Consumption After
Stabilizer
47 Units/day
Savings :
30 INR per Day
930 INR per Month
10,980 INR per Year
44
45
46
47
48
49
50
51
52
53
Units Comparison
Before
After
Page | 52
Project 3 – Reduction in Downtime via Thermography
Thermography has a long history, although its use has increased dramatically with the
commercial and industrial applications of the past fifty years. Government and airport personnel
used thermography to detect suspected swine flu cases during the 2009 pandemic.
1. Firefighters use thermography to see through smoke, to find persons, and to localize the
base of a fire. Maintenance technicians use thermography to locate overheating joints and
sections of power lines, which are a sign of impending failure. Building construction
technicians can see thermal signatures that indicate heat leaks in faulty thermal insulation
and can use the results to improve the efficiency of heating and air-conditioning units.
Some physiological changes in human beings and other warm-blooded animals can also
be monitored with thermal imaging during clinical diagnostics.
Page | 53
2. Specialized thermal imaging cameras use focal plane arrays (FPAs) that respond to
longer wavelengths (mid- and long-wavelength infrared). Their resolution is considerably
lower than that of optical cameras, mostly 160x120 or 320x240 pixels, up to 640x512 for
the most expensive models. Thermal imaging cameras are much more expensive than
their visible-spectrum counterparts, and higher-end models are often export-restricted due
to the military uses for this technology.
Thermal Energy
A thermal imaging camera is capable of performing algorithms to interpret that data and build an
image. Although the image shows the viewer an approximation of the temperature at which the
object is operating, the camera is actually using multiple sources of data based on the areas
surrounding the object to determine that value rather than detecting the actual temperature. This
phenomenon may become clearer upon consideration of the formula
Incident Energy = Emitted Energy + Transmitted Energy + Reflected Energy
Here Incident Energy is the energy profile when viewed through a thermal imaging camera.
Emitted Energy is generally what is intended to be measured. Transmitted Energy is the energy
that passes through the subject from a remote thermal source. Reflected Energy is the amount of
energy that reflects off the surface of the object from a remote thermal source.
If the object is radiating at a higher temperature than its surroundings, then power transfer will be
taking place and power will be radiating from warm to cold following the principle stated in the
Second Law of Thermodynamics. So if there is a cool area in the thermogram, that object will be
absorbing the radiation emitted by the warm object. The ability of both objects to emit or absorb
this radiation is called emissivity. Under outdoor environments, convective cooling from wind
may also need to be considered when trying to get an accurate temperature reading.
Page | 54
Use in the industries for Electrical circuits
The thermo gram shows a fault with an industrial electrical fuse block. The thermal imaging
camera would next employ a series of mathematical algorithms. Since the camera is only able to
see the electromagnetic radiation that is impossible to detect with the human eye, it will build a
picture in the viewer and record a visible picture, usually in a JPG format. In order to perform the
role of noncontact temperature recorder, the camera will change the temperature of the object
being viewed with its emissivity setting. Other algorithms can be used to affect the measurement,
including the transmission ability of the transmitting medium (usually air) and the
temperature of that transmitting medium. All these settings will affect the ultimate output for the
temperature of the object being viewed. This functionality makes the thermal imaging camera an
excellent tool for the maintenance of electrical and mechanical systems in industry and
commerce. By using the proper camera settings and by being careful when capturing the image,
electrical systems can be scanned and problems can be found. Faults with steam traps in steam
heating systems are easy to locate.
Difference between infrared film and thermography
IR film is sensitive to infrared (IR) radiation in the 250°C to 500°C range, while the range of
thermography is approximately -50°C to over 2,000°C. So, for an IR film to show something, it
must be over 250°C or be reflecting infrared radiation from something that is at least that hot.
Night vision infrared devices image in the near-infrared, just beyond the visual spectrum, and
can see emitted or reflected near-infrared in complete visual darkness. Starlight-type night vision
devices generally only magnify ambient light.
Advantages of thermography
It shows a visual picture so temperatures over a large area can be compared
It is capable of catching moving targets in real time
It is able to find deteriorating, i.e., higher temperature components prior to their failure
It can be used to measure or observe in areas inaccessible or hazardous for other methods
It is a non-destructive test method
For electrical circuits one does not have to swtich them off.
It can be used to find defects in shafts, pipes, and other metal or plastic parts
It can be used to detect objects in dark areas
Page | 55
Limitations of thermography
Quality cameras often have a high price range, the one used in trident was Rs. 10 lakh
(Flir make)
Accurate temperature measurements are hindered by differing emissivity and reflections
from other surfaces
Most cameras have ±2% accuracy or worse in measurement of temperature and are not as
accurate as contact methods
Only able to directly detect surface temperatures (So one cannot see if there is a
hotspot inside the equipment. E.g. transformer)
What is thermography from electrical point of view?
Hot-spots are analyzed via an infra-red camera.
All the lose worn connections get heated up.
Reason: (Current/cross section area) becomes less leading to heating up.
We know,
R α L/A
Where L is the length and A is the cross section area. Since here A is less the resistance
increases.
Heating power P α R (P=I*I*R)
Hence, the hot-spot gets heated.
Page | 56
How are Hotspots detected?
Every body in this universe emits an infra-red radiation proportional to the amount of
heat it has.
IR camera picks up the radiations and tells the temperature of the body
It hence displays the temperature on its screen.
Reasons To Remove them?
So-called hot spots are hot terminal connections that negatively affect your electrical
system in several ways.
First is wasted energy: Hot spots bleed electrical current, reducing the efficiency of
the system and costing you more.
When the electrical connection actually fails, and the connections separate, an arc
will melt most metals.
Why not a laser gun?
A laser gun shows average temperature over a range of area. It cannot detect hotspots.
Moreover range of laser gun(1 m) is very less as compared to that of an IR camera
(10 m)
What can be scanned during a thermography inspection?
• Electrical switch gear, breakers, bus connections, and contacts
• Transformer connections
• Mechanical couplings on rotating equipment
• Process piping and heat exchangers
• Compressor heads
• Motor and generator connections, windings, feeders and excitors
• Bearings
• Friction in drive gears and drive belts
• Refractory systems
• Steam traps and piping insulation
• Tank levels and insulation problems
Page | 57
Thermography at Trident
On 23rd February 2012 a service Engineer from Masibus Co. was hired to do the 3 day Thermography
study. The cost of the camera is around Rs. 10 lakh. Thermography is usually done once a year.It was
also a sample testing of the camera as it was a new thing, it was also learnt how to use it.
The picture above shows one of the transmission and distribution towers tested during
thermography. On the left is the normal photograph of the tower. On the tigt we can see the
thermography analysis of the tower. The square box is the analyzer box, this is the area which is
monitored for hot spot. The red cursor automatically points at the most heated point in the box.
On the top we can see the value of the temperature of the hotspot. Here is the example the value
105 degree Celsius is flashed. On the right hand side the key for variation of colors with respect
to the temperature is shown.
The spectrum and amount of thermal radiation depend strongly on an object's surface
temperature. This makes it possible for a thermal imaging camera to display an object's
temperature. However, other factors also influence the radiation, which limits the accuracy of
this technique. For example, the radiation depends not only on the temperature of the object, but
is also a function of the emissivity of the object. Also, radiation originates from the surroundings
and is reflected in the object, and the radiation from the object and the reflected radiation will
also be influenced by the absorption of the atmosphere.
Page | 58
Areas covered:
The study was done at :
PSPCL power T&D towers
Dhaula power T&D Towers
Major equipment like CTs, PTs, Isolators, Bus bar joints were covered
All joint in Panels of Unit 1,2,3,4 and 5 were also covered.
Why was the camera rented?
The cost of the camera is around Rs. 10 lakh
Thermography is usually done once a year.
It was also a sample testing of the camera as it was a new thing, it was also learnt how to
use it
Major findings during Thermography Survey ( Feb 22nd~24th,2012)
Temperature
S.
No. Description Location R Y B
1 Tower 45 (jumper towards Malwa) PSEB transmission Line 17 120 20
2 Tower 45 (jumper towards Trident) PSEB transmission Line 23 103 23
3 Tower 18 Dhaula Transmission Line 20 20 37
4
Tower 18- gantry between TW 18
and TW19 (the one towards tower
18) Dhaula Transmission Line 20 64 20
Findings:
These were the major findings from the thermography. The tower no. 45 of PSPCL was
found to be at a critical situation. Y-phase’s jumper had 3 hotspots.
Tower no. 18’s gantry was found to have a hotspot on it had a hot spot on its Y-phase.
Page | 59
Report of the PSPCL Tower no.45 as per Masibus Company
What if it had failed?
The jumper could have failed leading to PSPCL failuire.
We rely on 50% of our energy requirement(8.5 MW) on PSPCL at de-coupled mode.
This would have brought a downtime of at least 2.5 hours.
Page | 60
Condition of the jumper captured with wide-range digital camera
One of the major hotspot findings was found at PSPCL ‘s Tower no. 45
The temperature of Y- phase jumper was found abnormally high
Conclusion:
The ambient temperature that day was 17 degrees Celsius.
On R and B phase it showed a temperature of 18 degrees while on Y-phase a temperature
of 115.2 degree Celsius was indicated.
Page | 61
Other Hotspots Findings:
S. No. Description Location R Y B
1 Comp. and seiger and 66 KV panel Unit 1 50 45 81
2 Air washer 5,6,7,8 (back) Unit 1 76 61 45
3 Air washer 5,6,7,8 (cable-back) Unit 1 45 68 43
4 Main Incomer Transformer no. 3 Unit 1 43 52 74
5
Admin Block, gate complex, canteen, OAT (DG cater pillar) (front- bulb interior element) Unit 1 190
6 LR Blow Room 1and 2ONO line card (1/3 15-4), (DB3- B2) -(back) Unit 1 41 41 62
7 Incoming Transformer 2 (back) Unit 1 119 108 105
8 Card LC 300 A 1-14 blow Room Trumac CVT-3 line Unit 1 41 82 41
9 Ring Frame No. 3 Unit 1 87 59 52
10 Ring Frame No. 3 - Contractor -fan motor (Overload) Unit 1 102 102 102
11 Ring Frame no. 5 (main switch) Unit 1 79 69 60
12 Ring Frame no. 7 Unit 1 62 63 70
13 Ring Frame no. 11 (C-2 contractor) Unit 1 63 90 68
14 Ring Frame no. 11 (Fan Contractor) Unit 1 135
15 Ring Frame no. 12 (C2 contractor) Unit 1 69 79 64
16 Ring Frame no. 14 (main motor overload) Unit 1 156
17 Ring Frame no. 20 (Input) Unit 1 61 61 76
18 Ring Frame no. 20 (Main Motor)- drive end Unit 1 53.9
19 Ring Frame no. 20 (Main Motor)- body Unit 1 57
20 Card no. 4 (Top) Unit 1 58
21 Card no. 4 (Bottom) Unit 1 76
22 Card no. 4 (Gear motor) Unit 1 57
23 Card no. 4 (Main Motor) Unit 1 71
24 Card no. 4 (Doffer Motor) Unit 1 66
25 Main Incomer Winding DB- switch no. 7 (front) Unit 1 41 44 66
26 Main Incomer Winding DB- feeder no. 2 - Incomer Unit 1 77 58 50
Page | 62
Temperature
S. No. Description Location R Y B
27 Main Busbar Feeder no. 2- Fingframe G5/1 DB (front) Unit 1 49 81 49
28 Carding DB - main switch Unit 1 93 46 73
29 Blow Room DB Room, comber(1-8) Unit 1 75 76 96
30 Blow Room DB Room, feeder 2 Unit 1 68 85 64
31 Air washer Filter main motor- body Unit 1 100
32 Card no. 5 Main switch Unit 1 97 161 92
33 VXL electrical panel Unit 1 123 49 41
34 Main Supply incoming from LT room Feeder no.15 Unit 2 78 67 80
35 Sub DB Ring Frame 1 Unit 2 41 41 84
36 Energy meter (no. 9 machine) Unit 2 52 52 75
37 Energy meter (switch 17) Unit 2 59 65 50
38 Feeder no. 3 winding DB main Switch Unit 2 61 70 113
39 Feeder no. 6 F1 A/C 8,9 Unit 2 82 82 65
40 Winding No. 16 main panel Unit 2 96
41 Winding No. 16 main panel -KM9 botom connection Unit 2 100
42 Ring Frame DB no. 3 (Main Switch) Unit 2 72 75 97
43 Main switch Feeder no. 6 Unit 2 109 91 110
44 Transformer no. 4 L.V. Bus Duct Unit 2 145
45 Incomer Insulator- PCC Unit 2 130
46 Seiger Air compressor (Front side) Unit 2 62 44 40
47 P2 DB-2 comber, RSB, D06, Unilap (back) Unit 2 52 113 61
48 Air washer No. 7 Unit 2 75 66 62
49 P1 DB 1, S/F, RSB (back) Unit 2 63 42 42
50 Airwasher no. 3, ring frame, DB2, 10-18 (back) Unit 2 65 70 68
51 Transformer no. 5 incomer( back) Unit 2 75 86 78
52 L.V. Bus Duct Transformer no. 5 (outside temp) Unit 2 66
Page | 63
Temperature
S. No. Description Location R Y B
53 Feeder No. 8 (T.F. Incomer) Unit 3 62 97 63
54 Feeder no. 10 (T/F Incomer) Unit 3 85 68 64
55
56 Feeder 1- Blow Room, H Plant Unit 4 30 65 30
57 Feeder 7- Incomer Unit 4 81 86 71
58 Feeder 21 (servo 3) Unit 4 60 61 67
59 Feeder 21 (pump House) Unit 4 56 37 57
60 Feeder 30 (Prep H plant) Unit 4 44 56 43
61 PCC 3 (Bus Duct) Unit 4 64
62 Ring Frame no. 24 (Main Switch) Unit 4 (Inside) 53 53 64
63 MLDB-N-LDB no.7 (panel no. 3) Unit 5 46 85 43
64
MLDB(Lighting)-S-LDB no.3 (MN0103) -[FAULT IN NEUTRAL WITH TEMPERATURE 96] Unit 5 64 46 43
65 USDB DB-2 (MN0110) Unit 5 38 92 43
66 Transformer no. 1 Unit 5 47 52 59
67 Transformer no. 2 Unit 5 58 67 69
68 Transformer no. 3 Unit 5 41 41 44
69 Transformer no. 4 Unit 5 59 69 72
70 Transformer no. 5 Unit 5 54 74 74
71 Transformer no. 6 Unit 5 47 50 50
Page | 64
Savings Calculations
Fact
Total load on PSPCL 8.5 MW when de-coupled.
At coupled condition the load is 5 MW
Considering shutdown taken and few units run on Diesel generators
Load loss per hour 30000 INR
Breakdown on transmission
line will create breakdown for
hours:
2.5 Hours
Total savings 75,000 INR
Hence, for future we have saved a downtime of 2.5 hours.
A loss of Rs. 75,000has been saved
Page | 65
Project 4: Reduction in Downtime via Interlocking
A tripping occurred since the Areva panels had a tripping command system if the DC supply
failed. This was removed by removing that function from the panel and an alarm using a
contractor with a reset operation was made. For future purposes a downtime of 60 minutes was
avoided.
On 3rd March 2012 DC input supply had failed. There was no alarming system to indicate this
fault. There is a emergency battery tank to supply DC in case the DC input fails. So that day the
battery started to discharge. When the battery was discharged no DC supply was going. The
areva Panels had a protection system to trip in case there is no DC supply. So the master relay of
all the Areva panels tripped. The main amongst them was the Unit 5 south and Incomer no 3
panels. Incomer 3 was the main feeder of the PSPCL., which had tripped now. The load was now
directly on the Dhaula supply now. Since all the units were now loaded on Dhaula, it went
overloaded. So the bus coupler tripped off to avoid overloading. It was now running in Decouple
mode.
Load put on PSPCL and Dhaula when
Decoupled
Unit 1 PSPCL
Unit 2 PSPCL
Unit 3 Dhaula
Unit 4 Dhaula
Unit 5 (north) PSPCL
Unit 5 (south) PSPCL
Gyanpeeth PSPCL
So there was now no supply to Unit 1,2,5 south and gyaanpeeth. They were shut down, while
unit 3 and unit 4 operated normally as before.
Implications:
There was a downtime of about 60 minutes.
Now it was decided to make a hooter alarm to indicate a fault if DC fails in future.
Page | 66
Chart how the failure happened
Page | 67
SLD of The Prepared Hooter Circuit
Page | 68
Hooter Installed
Page | 69
Circuit Working
K1 is contactor connected to the MCB output. As soon as the DC fails the K1 gets picked
up.
Now the hooter circuit is fed by UPS supply which is always there.
Both K1 and K2 are normally closed so the hooter starts ringing.
To accept the fault there is a push button which is normally open.
Now as soon as we push the button it becomes closed and contactor K2 gets picked up
Since k2 is normally closed it now the hooter stops to ring.
The entire circuit is restored to original position.
Savings Calculations
Now if the DC fails the Hooter will show the fault.
There is also a ‘Reset Button’ to accept the fault and bring it back to normal condition.
This is not a onetime saving it is applicable for the future also.
Load loss per hour 70,000 INR
Breakdown on
transmission line will
create breakdown for
hours:
60 minutes
Total savings 70,000.00 INR
Now Downtime of Unit 1, 2, 5 and Gyaanpeeth from DC failure can be avoided.
Hooter would run and action can be taken in time.
For future purposes a downtime of 60 minutes was avoided.
A a reset operation is introduced to accept the fault.
Page | 70
Project 5: Reduction in Power consumption of H-plant in Unit 5
Unit 5 produces cotton yarn. The temperature controlling is very important. For making thread
out of cotton, it is important that the cotton has long fibers. So while brushing the cotton a little
hot temperature is required for the strength purposes of the cotton fiber. To control it there is a
H-plant which regulates the temperature and the humidity of the unit. We can now control it.
An effort was made to reduce the power consumption of the H-plant.
Page | 71
Introduction
IMPORTANCE OF RH AND TEMPERATURE:
The atmospheric conditions with respect to temperature and humidity play very important part in
the manufacutring process of textile yarns and fabrics. The properties like dimensions, weight,
tensile strength, elastic recovery, electrical resistance, rigidity etc. of all textile fibre whether
natural or synthetic are influenced by Moisture Regain. Moisture regain is the ratio of the
moisture to the bone-dry weight of the material expressed as a percentage. Many properties of
textile materials vary considerably with moisture regain, which in turn is affected by the ambient
Relative Humidity (RH) and Temparature. If a dry textile material is placed in a room with a
particualr set of ambient conditions, it absorbs moisture and in course of time, attains an
equilibrium. Some physical properties of textile materials which is affected by RH is given
below:
Strength of COTTON goes up when R.H.% goes up
Strength of VISCOSE goes down when R.H.% goes up
Elongation %ge goes up with increased R.H.% for most textile fibers
the tendency for generation of static electricity due to friction decreases as RH goes up
At higher levels of RH , there is also a tendency of the fibers to stick together
Temperature alone does not have a great effect on the fibers. However the temperature
dictates the amount of moisture the air will hold in suspension. Therefore, temperature
and humidity must be considered together.
The following components are a must in a Humidification system:
Return Air and Supply Air fans
Air washer
Exhaust damper
Fresh air damper
Supply air fan
Reverse air fan
Page | 72
Diagram How Air Temperature is controlled
R.A. fans stands for reverse Air fans
S.A. fans stands for supply air fans
Working
The volume of air rejected from unit 5 is E and the volume of air taken from H-plant to unit is B.
C is the reverse air that is redirected again into unit 5. D is the volume of air rejected from h-
plant into the environment. Whereas A is the fresh air which is taken from the surroundings into
the H-plant. There are dampers between the environment and H-plant whose angles determine
how much fresh air would be taken in. B is the air which is cumulative of C and A. A is
determined by the angle of opening of dampers and C is regulated by the R.A. fans. So the
temperature inside the unit is regulated.
Unit 5
H-plant
Outside
S.A. Fan
R.A. Fan
A
B
D
C E
Air Volume A = D
B = E
Page | 73
Example
If we want the emperature inside the unit to be 40degrees, the temperature outside in the
environment is 20 degrees and the temperature of ait through reverse fan is 50 degrees. We
would set the dampers in such a way that the the ratio of volume of C to A would be 0.66
40 = 50x + 20(1-x)
x=0.66
So more of reverse air would be taken and less of supply air.
Temperature controlling parameter
The drives were used in a periodic manner. The temperature was cooled first. When it
exceeded the set-point it would shut down. Again when temperature increased it would
start.
So tuning was decided to be done to use the it in a uniform manner.
RPM = 120f/p
o RPM= 120f/2
RPM α f
Hence the temperature is controlled
So it was decided to vary frequency and use it in uniform manner.
For Humidity
Humidity was controlled by sprinklers after the S.A fan there was a Chamber from
where the air passes. Water is sprinkled onto it via a pump to control the moisture
level in the air.
This also brings some amount of temperature change in the air.
This effect is also considered on setting down the ratio of air to be taken from the
outside to the reverse air.
For R.H. the pump is used at same frequency.
Hence there is no effect in the humidity.
The entire system would now run in more of a systematic pattern.
Page | 74
Savings Calculations
The frequency of the R.A fan was changed from 45Hz to 38Hz.
This brought a change of 7.1KW on the running load of one fan.
The frequency of the S.A fan was changed from 46Hz to 42Hz.
This brought a change of running load of 5KW on running load of one fan.
A total saving of 48.4KW was done on the running load.
This is a breakthrough in saving power consumption.
Department Fan Qty. Previous Frequency
New Frequency
Previous KW New KW
Saving in KW
Prep. S.A. Fan 4 46 42 18.9 13.9 20
R. A. Fan 4 45 38 18.9 11.8 28.4
Saving In KW
48.4
Now calculating savings with current future trends.
6,969.60 INR per Day
2,11,992 INR per Month
25,43,904 INR per Year
A total of Rs. 25,43,904 is expected to be the profit at the end of the year.
This is also not a onetime saving. It would be applicable for the future also.
Result:
1. Reduction in variation of temperature and humidity.
2. Reduction in power Consumption.
3. Reduction in frequent operation of dampers.
Page | 75
Project 6- Self-made load manager
Page | 76
What is a load Manager?
A load manager is like a portable digital energy meter. In industry it is very important to monitor
the energy parameters to use machines at full efficiency. But it is not possible to install an energy
meter everywhere. So a load manager is used to monitor the energy parameters. It has a main
screen head where all the parameters are displayed, 3 current transformers, and 3 crocodile clips
connected with main head through connecting wires for voltage monitoring.
The parameters monitored are:
Volt line to line
Voltage line to neutral
Amperes
P.F. /cos∅
kW
kVA
kVAR
Hz
kWh
kvarh
Peak kVA
Total harmonic distortion in voltage
Total harmonic distortion in current
Total KVAh consumption
Total KWh consumption
Total KVARh consumption.
All of these monitoring is done on each phase i.e R,Y,B and even average value is also
accounted. The values are viewed on the main head.
Page | 77
Main Features:
AC and DC Measurements.
Built-in printer for measurements and graphs.
Integrated Harmonic Analysis up to the 24th order.
Integrated 1 Mb Flash Memory
RS 232 port for PC connection
Windows software included
High accuracy (class 1.0)
Mains or Battery operation.
Graphical view of all the waves (current, voltages)
Page | 78
Advantages
There are many diverse advantages of a portable analyzer for the user. The most important is
information.
With the information from a single entry, we can find out:
Habits of use to ensure that the contracted tariffs are the most suitable.
Response of an installation's load to see how it affects the rest of the installation, startup, shutdown or normal operation of the various charges.
Angles of each of the loads for the analysis of reactive power, therefore avoiding penalties.
Measuring leakage currents that trigger unwanted tripping of the differential current protection relays.
Measurement of the harmonics.
Getting to know the demand for our installation to determine if the power that the user has contracted is suitable.
Save on electrical energy costs.
Prevent shut-downs of the installation.
- Market bought load managers look like this.
CTs Main screen/Head
Page | 79
Testing the Self-Made Load Manager
Comparison
A test was done on Woodland Guest house D.B. Both company made load manager and self-made load
manager were applied and the values of parameters were compared. For the self-made load manager the
voltage was measured using connecting wires and crocodile clips. The auxiliary supply for the energy
meter was picked up in a loop from one of the phase. The CTs were also enclosed around the Bus bar.
Same thing was done for the load manager bought from the company. The company made load manager
had a plug for its auxiliary supply. The company made load manager even had a battery for its auxiliary.
It was kept connected for 3 days. It was kept in mind that a weekend didn’t come during one of the load
study day.
There currents and voltages were compared with an actual load manager.
There results were not same, but still close.
Observations
Current (A) Error %
Voltage (V) Error %
Current on load manager 10 10 220 0
Current on self made Load manager
9 220
Implications:
Voltages shown were identical.
Current readings did not match.
Current fluctuated sometimes and gave a zero reading.
Page | 80
So don’t we have buy Load Managers Anymore?
No, we still have to buy load managers. The customization available in a company’s load manager a lot
than we have it coming on the self-made load manager. In a company’s load manager we have graphical
analysis of every parameter. Moreover, data can be saved onto it. On the other hand in the self-made load
manager there is a single button to scroll along the parameters. A graphical solution is not available here
and no data can be saved onto it.
Savings Calculations
S. no. Items used Cost (INR)
1 Digital Energy meter 10,000
2 Cts(3 nos.) 9,000
Total 19,000
This is when we buy all the equipment required new from the market. Here in my case the load
manager was made out of old items.
Cost of Load manager in market 50000 INR
Cost of Making our own Load
manager
19000 INR
Expected savings 31000 INR
Profit comparison
0
10000
20000
30000
40000
50000
60000
Cost of Load manager in market Cost of Making our own Load manager
Cost in INR
Cost in INR
Page | 81
Summary
Pictures showing test on self-made load manager
Disadvantages:
Its readings cannot be relied on. (Error of 10%)
Cannot replace a load manager.
Customization available on a company made load manager is not available.
Advantages:
But it is good for checking/monitoring purposes.
A good replacement when a load manager is not available.
Easy to take from one place and connect to other.
Page | 82
Total Overall Savings
Total savings in 4 months
Project Savings (INR)
Stabilizer in IOL 41,086.80
Stabilizer in Guest House 2,220.00
Reduction in Downtime via
Thermo graphy
75,000.00
Reduction in Downtime via
Interlocking
70,000.00
Reduction in Power
consumption H-plant Unit 5
3,27,571.20
Self-made load manager 31,000.00
Total Savings 5,46,878
Total Annual savings
Project Savings (INR)
Stabilizer in IOL 1,48,888.8
Stabilizer in Guest House 10,980.00
Reduction in Downtime via
Thermo graphy 75,000.00
Reduction in Downtime via
Interlocking 70,000.00
Reduction in Power
consumption H-plant Unit 5 25,43,904.00
Self-made load manager 31,000.00
Total Savings 28,79,773.00
Calculating EVA= (546878-160000)/160000 =2.41
Page | 83
References
1. www.tridentindia.com
2. Conzerv EMS helpbook
3. www.wikipedia.org
4. www.wiki.answers.com
5. www.voltage.ezinemark.com
6. SAP values entered – Trident
7. www.xnet.rrc.mb.ca
8. www.flir.com
9. www.infraredthermography.com
10. www.allaboutcircuits.com
11. www.answers.yahoo.com
12. www.industrial-cooling-towers.com
13. www.naacenergy.com
14. http://www.hortica-insurance.com/publishedarticles/hotspots.pdf
15. http://www.thermalmoistureimaging.com/industrial_services.html
16. http://www.norantel.com/products/power-distribution-products/21-prouducts/power-
distribution-products/breaker-panels/30-stand-alone-breaker-panels
17. http://www.lumenindustries.net/servo-stabilizer.html
