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"Power Optimisation" is utilizing the available power to the maximum extent by monitoring operational load parameters of the entire plant to achieve ideal voltage at which the energy losses are minimum, and plant performance at peak.
Induction Motors in any industry operate at partial load / low load and the average operating efficiency of the induction motors is very low. Voltage control helps improvement of efficiency to its design maximum value and also improves Power Factor.
Research Studies:
During 1990-91, while the Power Tariff was frog leaping, a lot of research studies were carried out to identify the Saving potential due to Voltage reduction to suit the operating conditions of the drive motors. This was not welcomed by many of the electrical dept. heads due to inadequate knowledge of benefit of Voltage Optimization. A few enthusiastic Electrical Engineers, who tried Voltage Optimization faced some problems and have given-up the trial and reverted the rated designed parameters.
In recent years some of the plants adopted some trial and error methods to achieve saving due to voltage and have assumed they have done the optimization of voltage.
Principle of Power Optimisation:
Induction motor has poor efficiency and low power factor (PF) at lightly loaded condition even when it has an energy efficient design. When a motor operates at full voltage at lightly loaded condition, core loss will be large. Reduction in voltage to optimum level (i.e., till current is not in increasing trend due to reduced voltage) will reduce core loss by a larger amount. That means by reducing the operating voltage, the low load efficiency of the motor will be improved.
In any industry, many induction motors operate at below 50% of their rated capacity for a significantly long duration, whereas replacement by lower capacity motors may not be viable, as the motors would be required to take a full load occasionally. By scientific method, the optimum voltage at different sections of the plant can be found. Optimum voltage operation helps improvement in both efficiency and power factor.
Power Optimization is one and half decades old concept but coming to light very slowly due to the requirements to fulfill and the difficulties experienced in implementing the method.
Energy Services Group (ESG) / AGS-Energy Conservation Pvt. Ltd (AGS-EC) had analyzed the reasons for the failure of achieving the optimum voltage by plant personnel and had identified the reasons, which are mainly due to the relation between Voltage, Current, and Power Factor -- that is complicated and iterative.
Energy Audit is a Physician's job and Fine-tuning (to achieve Power Optimization) is that of the Surgeon gifted with varied experience and exceptional skills.
ESG / AGS-EC has the capability to do both the Physician's and the Surgeon's jobs, and have received kudos aplenty in India, the Clients having benefited by marked Savings in Power Cost, consequently reducing the Manufacturing Cost and so becoming competitive in the market.
All our clients, who utilized our services for Power Optimization, have achieved the estimated saving and issued testimonials also.
The saving on account of our services can be noticed very clearly from the following:
1) The Daily / Monthly Power Consumption Reports.
2) Units / Hour Consumption
3) Instantaneous changeover from the tuned parameters to earlier parameters.
Energy Services Group