BEE Presentation (DT & FTL) 1310200401

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    BEE - S & L ProgramDistribution Transformers & Fluorescent Tube Lamps

    PRESENTED AT THE WORKSHOP

    ON

    ENERGY EFFICIENCY STANDARDS & LABELING

    BANGALORE13, 14 OCTOBER, 2004Shri. S. Ramaswamy, GTZ

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    Distribution Transformers

    S & L Program

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    Technical Committee

    Mr. K. Venkata Narayana : CPDCAP

    Mr. P.N. Gopinath : NDPL

    Mr. Tirupathi : TNEB

    Mr. Alok Kr. Chattopadhyay : WBSEB

    Mrs. Rajani Menon : E.R.D.A.

    Mr. Vijay Kolambekar : E.R.D.A.

    Mr. A.B. Bhatia : Crompton Greaves Ltd

    Mr. D.J. Ramesh : Vijai Electricals Ltd

    Mr. Nitin Nayak : El-Tra Equipment Co.

    Mr. K.V.S.S.R. Venugopal : ABB Ltd.

    Mr. Manoj Mishra : ABB Ltd.Mr. Y.S. Shingne : Danke Products

    Dr. H.M. Gupta : IIT, Roorkee

    Mr. Mayur Karmarkar : ICPCI

    Mr. Avinash Barve : IEEMA

    Mr. S. Ramaswamy : BEE

    CONSUMERS

    Testing Institution

    Manufacturers

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    Technical Committee: Responsibilities

    Identify technical parameters

    Study & validate test procedures for adoption

    Define criteria for Laboratories (NABL)

    Identify & recommend Laboratories for testing ?

    Decide on label rating plan ?

    Decide parameters on label ?

    Design label

    Decide on enforcement mechanism and work out protocol

    Carry out economic analysis for MEPS

    Recommend MEPS

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    Recommendation

    Reduce temperature rise limits Due to frequent overloading in service, life

    deteriorates.

    Contributes to poor reliability.

    The current temperature rise limits 50/550C over theambient of 500C of top oil and winding respectively.

    Temperature rise limits revised to 35/400C over the

    ambient of 500C of top oil and winding respectively.

    Implication on cost average of 3%.

    Similar changes helped GEB to reduce failure rate

    from 27% to 20%.

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    Basis for Star rating plan

    Case Basis of losses (Total at 50% Load

    Condition)

    Base case Star 1 Current purchasing practice (IS 1180 Max

    Losses)

    Star 2 Some utility purchase specs like AP, NDPL

    Star 3 Losses from TOC design (Moderate)

    Star 4 Losses from lowest TOC design

    Star 5 High efficiency design

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    X axis is PU Load & Y axis price in Rs.

    Optimum eff Vs cost for various designs - 100 kVA

    0

    20000

    40000

    60000

    80000

    100000

    120000

    140000

    160000

    180000

    0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

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    Star 3 -100 kVA

    0.0

    500.0

    1000.0

    1500.0

    2000.0

    2500.0

    3000.0

    120% 115% 110% 105% 100% 95% 90% 85% 80% 75% 70% 65% 60% 55% 50% 45% 40% 35% 30% 25% 20% 15% 10% 5%

    Loading

    TotalLossesatrespectiveloadin

    Watts

    M3Al

    M4Cu

    M3Cu

    M5Cu

    ZDMHCu

    ZDMHAl

    AMTCu

    AMTAl

    Limits at 100% load

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    Recommendation

    Star rating plan

    The star rating represents the loss level and will

    represent the efficiency status.

    Star 1 is current IS level and Star 5 will be

    lowest loss specifications.

    Star rating will represent total losses at 50% &100% loads and at 750C.

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    Recommendation

    kVA Star Rating

    Max

    Lossesat 50%

    (Watts)

    Max Losses at

    100% (watts)

    16 1 200 555

    2 165 520

    3 150 480

    4 135 440

    5 120 400

    25 1 290 785

    2 235 740

    3 210 695

    4 185 655

    5 160 615

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    Recommendation3

    kVA Star Rating

    MaxLosses

    at 50%

    (Watts)

    Max Losses at 100%

    (watts)

    63 1 490 1415

    2 430 1335

    3 380 1250

    4 330 1170

    5 280 1100

    100 1 700 2020

    2 610 1910

    3 520 1800

    4 440 1700

    5 360 1600

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    Recommendation3

    kVA Star Rating

    Max

    Losses

    at 50%

    (Watts)

    Max Losses

    at 100%

    (watts)

    160 1 1000 28002 880 2550

    3 770 2200

    4 670 1950

    5 570 1700

    200 1 1130 3300

    2 1010 3000

    3 890 2700

    4 780 2400

    5 670 2100

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    0.9650

    0.9700

    0.9750

    0.9800

    0.9850

    0.9900

    0.9950

    16 25 63 100

    kVA

    %

    IS - 100%

    BEE 100%

    IS 50

    BEE - 50

    Existing & Proposed efficiency levels

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    Impact of star 3 on cost & material

    kVA Star 1 Star 3

    Design

    Material

    Ex-works

    price (Rs)

    Design

    Material

    Ex-works

    price (Rs)

    25 M6Al 18,382 M3Al/M4Cu 20,941

    63 M5Al 32,904 M3Al/M4Cu 41,400

    100 M6Al 47,149 M3Al/M4Cu 60,236

    160 M4Al 68,100 M3Al/M4Cu 85,572

    200 M4Al 82,182 M3Al/M4Cu 102,164

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    PAY BACK PERIOD

    Pay-back Period for 100 kVA

    0

    2

    4

    6

    8

    10

    12

    14

    16

    18

    AMTCu

    M3Cu

    ZDMHCu

    M3Al

    ZDMHAl

    M4Cu

    M5Cu

    AMTCu

    AMTAl

    ZDMHCu

    M3Cu

    ZDMHAl

    AMTCu

    AMTAl

    ZDMHCu

    Star 3 Star 3 Star 3 Star 3 Star 3 Star 3 Star 3 Star 4 Star 4 Star 4 Star 4 Star 4 Star 5 Star 5 Star 5

    Years

    Pay Back Period at 30% Load Pay Back Period at 50% Load Pay Back Period at 100% Load

    STAR - 3 LEVEL

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    Energy saving potential in 1styear

    Transform

    ersize(kVA)

    % Of

    Total Saleupto

    200kVA

    Purchase

    s

    Annual

    Sales(MVA)

    Average

    No LoadLosses

    (W)

    Average

    LoadLosses

    (W)

    Effective

    LoadFactor

    Annual

    EnergyLosses

    (kWH)

    Annual

    Loss perkVA

    (kWh)

    Annual

    loss(Million

    kWh)

    Energy

    Saving in

    1st Year

    (Million

    kWh)

    25 6% 863 86 620 0.5 1808 72.30 62.39

    63 25% 3760 173 1180 0.5 3510 55.71 209.49

    100 44% 6667 250 1710 0.5 5081 50.81 338.77

    160 3% 398 395 2370 0.5 7406 46.29 18.42200 14% 525 425 2960 0.5 8738 43.69 22.94

    652.01

    25 6% 863 66 571 0.5 1566 62.63 54.05 8.35

    63 25% 3760 141 951 0.5 2841 45.09 169.54 39.95

    100 44% 6667 218 1201 0.5 3887 38.87 259.14 79.63

    160 3% 398 259 2035 0.5 5758 35.99 14.32 4.10

    200 14% 525 311 2304 0.5 6653 33.26 17.46 5.47514.51 137.50

    25 6% 863 75 335 0.5 1191 47.63 41.10 21.29

    63 25% 3760 114 659 0.5 2091 33.18 124.77 84.71

    100 44% 6667 157 804 0.5 2685 26.85 179.01 159.76

    160 3% 398 229 1359 0.5 4266 26.66 10.61 7.81

    200 14% 525 283 1542 0.5 5014 25.07 13.16 9.77

    368.65 283.35Total

    Purchase

    s of year

    2001-2002

    Conservat

    ion case

    with Star

    3

    Conservat

    ion case

    with Star

    5

    Total

    Total

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    Recommendation

    Energy efficiency labels

    Manufacturers would conduct the test as per the

    approved procedure register with BEE &display label on the transformer.

    Label will display rated capacity, star rating and

    maximum total losses at 50% and 100% loads.

    No positive tolerance on the displayed label

    value.

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    Sample DT label

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    Recommendation5

    Utility purchases

    Utility to improve MEPS from star 1(IS-1180)

    to Min star 3.

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    Fluorescent Tube Lights

    S & L Program

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    Lighting industry in India

    Total lighting market : Rs. 18,000 M ; Growth : 12% p.a.

    Lamps : Rs. 10,800 M : Growth : 10% p.a.

    GLS : Rs. 4,500 M (435 M units) ; Growth : 5% p.a.

    Tube lights : Rs. 4,200 M (136 M units) ; Growth : 10% p.a.

    HID : Rs. 1650 M ( 4 M units) ; Growth : 20% p.a.

    CFL : Rs. 450 M ( 1 M units) ; Growth : 15% p.a.

    Luminaires : Rs. 7,200 M ; Growth : 15% p.a.

    (Ballasts, fixtures & accessories)

    Unorganised sector accounts for 35% of the total lighting market (value

    terms)

    Around 440 unorganised players

    Around 20 organised players

    Lighting accounts for 17% of total electricity consumed in India

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    Work on BEE S & L programme on FTL was initiated on

    08 September 2002.

    ELCOMA was requested to spearhead the BEE S & L

    Programme.

    T-8 ( 36W ) & T-5 ( 28 watt ) Triband offers lumen

    efficacy of 85 lumen per watt

    VISION OF S & L PROGRAMME

    Lighting industry should strive to improve lumen efficacy

    of over 70 lumens per watt in about 5 years time.

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    In order to create market pull, the government could

    buy only star rated products, i.e. the highest energy

    efficiency products.

    The standards should be futuristic since there is also

    a time frame required for phasing out old products

    and introduction of efficient products. A time frame of

    2-3 years was suggested.

    Labeling would be the first activity to be taken up in

    these products.

    VISION OF S & L PROGRAMME

    ( CONTINUED)

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    MEETINGS

    In first meeting of steering committee held on 27

    September 2002,it was decided to form a Technical

    Committee having following compositions:

    Mr. R.Nandakishoreconvener, Philips India Limited

    Mr. R.S.Mandal, Osram India Private Limited

    Mr. S.K.Neogi, Phoenix Lamps India Limited

    Mr. S.Ramasubramanian, Surya Roshni LimitedMr. Ramaswamy, BEE

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    The task of Technical Committee is to finalise:

    a. Testing protocol

    b. Technical parameters along with weightages forlabeling

    c. Label design

    d. Test laboratoriese. Challenge & Check testing protocol.

    Tasks of Technical Committee

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    FTL Technical Committee Recommendations

    For energy labeling 3 parameters should be considered which

    would provide efficacy from both efficiency as well as life:

    Lumens at 100 hrs.(initial lumens) Lumen/watt

    Lumen depreciation @ 2000 hours Lumen/watt

    Lumen depreciation @ 70 % life (3500) hours Lumen/watt.

    Test Procedure: relevant BIS test procedures including

    amendments

    meet all the minimum requirements of BIS to qualify for labelling

    BIS certification or a quality control certification, a

    prequalification for labelling

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    For 18W we have considered 940 lumens in place of 1015lumens inBIS since this has been agreed in the last

    meeting of the BIS.

    Based on the visit of the technical team to the four

    Laboratories, the recommendations of the technical

    committee is to go for testing at NPL & ERDA after

    ascertaining Proficiency testing in both the Laboratories.

    Accreditation of NPL with NABL is under process.

    The 3200 lumen output lamps (Triband) was also

    included for testing and BIS has also agreed to go in for

    the standards in the last meeting

    FTL Technical Committee Recommendations

    ( Continued)

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    10 lamps were tested at manufacturers laboratory as

    well as ERDA to get comparative readings/calibration

    before full scale testing begins (Proficiency Testing).

    There were certain differences in the optical

    measurements in the three laboratories but these are with

    in the z score of proficiency testing.

    Since the measurements are against a standard

    reference lamp, it was felt necessary to ensure thequality of reference lamp. BEE to take up with NPL

    The lighting industry had agreed to align with ERDA

    laboratory

    FTL Technical Committee Recommendations

    ( Continued)

    Re ised Star rating Plan

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    Revised Star rating Plan( This would need another meeting with stakeholders)

    Starlevels

    100 hrsefficacy

    Lumens/W

    2000 hrsefficacy

    Lumens/W

    3500 hrs

    efficacy

    Lumens/W

    1 >47 & < 54 >40 & =38 & =54 & = 46 & = 43 & = 60 & = 51 & = 48 & = 69 & = < 85 >59 & = < 72 >55 & = < 68

    5 > 85 > 72 > 68

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    Basis

    Values for the 100 hours efficacy was worked out taking intoconsideration that all Wattages and their energy efficacy isreflected the star rating plan.

    The values of IS with permissible tolerances for different

    wattages were used to arrive at the boundaries.

    Efforts were made to differentiate 20 W & 18 W, 40 W & 36W and halo phosphates and Tri phosphates

    Star rating plan would ensure efficiency purchases.

    The cut off % for these categories have been fixed in such away the categories of lamps operating with good qualitycontrol as well as above the minimum threshold would fall inthe appropriate levels.

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    Energy Label

    INTERNATIONAL COMPARISON

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    INTERNATIONAL COMPARISON

    MEPSCURRENT INDIAN STANDARD

    Lamp type Minimum average lamp efficacy (lm/W)

    India

    ( Lamp only)

    India

    ( Lamp &

    ballast)

    Australia Canada USA Korea

    600mm - 20 W

    51 36 70 64 64 55600 mm - 18W 56 42

    600 mm - 18 W HL 72 59

    1200mm - 40 W 61 47 75 75 75 66

    1200 mm36 W 67 51

    1200 mm - 36 W HL 90 81

    MEPS ALSO TALKS OF LUMEN MAINTANANCE AT 70% OF LIFE

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