‘'Good practices in energy management

and efficient execution with Automation'.

Shibu George

Apollo Tyres Ltd

‘E’nergy - Fest 2012

•Energy Prices have Risen to an all time high...

•Result the companies are spending Millions of

dollars more Electricity cost for same Product

output.

•Important for improving profitability and reducing

pollution by minimising the emissions of greenhouse

gases and other polluting gases.

•The latest department of Energy study said that

electric motors consume nearly 63 % of electricity

used by industry .

Why Energy Management

Good Practices In Energy Management

1. Upgrade to premium efficient motors .

2. Plan and use VFD for all the pump & fan

application .

3. Do complete Motor Survey of the facility.

4. Use " Right " motor size for the application .

5. Turn off motors when they are not needed ----

Myth that this will reduce the life of motor is

incorrect unless it exceeds the design -starting

specification.

6. Turn off lights when not required.

Good Practices In Energy Management

7. Integrate Electrical Automation with process automation system.

8. Consistently monitor energy prices and energy consumption .

9. Building accountability into your organizational metrics and provide useful reporting and analysis tools for accurate budgeting and allocations.

10. Set Specific Power consumption targets for each process & plan control action.

• Automating as many of these activities as

possible to ensure energy management is

a repeatable, documented business

process.

Tyre Industry Power Requirement

Utility

• Usage of VFD for all the Pump & Fan Application.

Throttling or VFD Usage ?

Controlling the flow with a throttling valve is like modulating the

speed of a car using only the brake pedal.

• Power usage is directly proportional to the cube of

the pump/ Fan speed.

• For eg. reducing speed by 50% requires only 12.5%

of the power needed at full speed

VFD – Vacuum Pump System,

Feed water system , Blowers

Production Review

Nerve Centre

Plant Floor

Usage of Data Collection

Secure Remote Access Power

Consumption

chart

SCADA

• “Energy cannot be controlled if it is not monitored

• Automatic Data logging system in a PC (SCADA) has been designed and developed right from the project stage to have an effective control in the use of energy

• Energy Monitoring SCADA:

Energy Data from all the energy Meter is being recorded in this SCADA continuously ( BU wise )

• Instrumentation SCADA:

– Steam, Air, Water, and Oil consumption has been continuously recorded and monitored in the SCADA System.( BU wise )

–

Sample of Consumption report

13698 KW

Thank You

Electrical Power distribution& Lighting

• Distributed Substation.

• Cable sizing.

• Energy efficient light – T5 Tube Light w.r.t Energy & Lux Level.

• Tuned filter/ Harmonic Filter are used to avoid loss.

• Solar street light for external areas.

• Movement sensors in all the Control Rooms , CFT Offices for Switching ON AC/ Lighting .

• LDR sensor for External Street Light Switching ON / OFF.

• Effective usage of Day light by Polycarbonate Roof sheet

14

Green IT- Typical Energy Flow/Use

Server Load/

Computing

Operations

Cooling

Equipment

Power

Conversion &

Distribution

Delivered

Power

Electricity

Generation &

Transmission

Losses

Fu

el B

urn

ed

at

Po

we

r P

lan

t

15

Will reduce cooling needs

Typical Energy Flow/Use

Server Load/

Computing

Operations

Cooling

Equipment

Power

Conversion &

Distribution

Reducing server power requirements

Lowering power conversion losses

Electricity

Generation &

Transmission

Losses

Delivered

Electricity

…ultimately reducing fuel burned at the power plant Reducing power demand and losses

Fu

el B

urn

ed

at

Po

we

r P

lan

t

On-Site Generation further

reduces losses and emissions!

Traditional Architecture

UPS

Standard PC

Clients

DC Thin Client Architecture

Battery Back-Up

Charge Controller Grid-Tie Inverter

Charger

4 to 8 times

Less Power than

Standard PC’s

Challenges faced • Effect of interferences of Equipment Wifi with the

Office Data Wifi .

• Unstable Ethernet network causing disturbance

to Production Equipment and also vise versa.

Plans –

1. Equipment Wifi Channels will be on separate

channel frequency.

2. VLAN creation and Network Architecture will be

designed with equipment.

3. Equipment layer on different communication

layer i.e. Control net & Device net instead of

Ethernet.

Typical Plant Level Equipment

Networking

Thank You