| CASE STUDY |
An Engineering company saves 17% of energy consumed by metallic fans - investment of Rs. 5 lakh pays back in 1.5 years. |
| DEMONSTRATION SITE |
| An automobiles component manufacturing in Bangalore has 8 DG Sets (2x2,260kVA & 2,260, 4x860 kVA) to serve its entire captive power generation requirements. The plant management identified an air-cooled fluid cooler of 2,260 kVA Conex DG set for the purpose of the Energy Saving Demonstration Project. |
| PILOT PROJECT |
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One of the 2260 kVA DG sets was selected for evaluating the performance of high efficiency aerofoil fan. The 2260 kVA DG set has 2 numbers of FC-W-140 air-cooled fluid coolers for heat dissipation. Together these 2 fluid coolers have 5 fans made of stainless steel and are connected to motors of 5.5 kW each. This DG set operates on an average of about 4,500 hours in a year. The company has monitored the performance of aerofoil fans after installation. The investment is Rs. 1.35 lakh, and the annual energy savings is to the tune of 0.18 lakh kWh. PERFORMANCE EVALUATION 5 sets of aerofoil fan blades made of PAG material were installed as replacement to the existing SS fans for the 2260kVA DG set under trail. All necessary parameters, viz. energy consumption, fan operating hours, were monitored over a period of time. All the data were downloaded and analyzed. Following table compares the existing SS and the retrofitted aerofoil fan: |
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| Note: The most important parameter for this investigation is the heat dissipation by the forced air-cooled of the fluid cooler (radiator) fans. The heat dissipation is directly proportional to the product of airflow rate and air enthalpy gain. What is required of the aerofoil fan is to dissipate equal or higher heat from the circulating cooling water at lower power consumption. It was observed that the aerofoil fans have achieved the job they are intended for. As can be seen, the aerofoil fan is found to be delivering 6,150 m3/h of additional air (15% more) compared to the existing SS fans besides savings 17% of energy. |
This
Demonstration case study is supported by the Indo-German Energy project
- a joint initiative of Government of India and Germany, and implemented
by Tata Energy Research Institute, Bangalore Center. The key objective of this programme is to promote cost effective energy saving retrofits and products based on new innovations, technologies and ideas and also those technologies/devices that are cost effective, but do not have the required market penetration due to lack of information about the product. The promotion of these will be through information dissemination and wide distribution of practical case to the potential users. The case studies' results are based on close monitoring of the installation at site over a period, and hence the savings potential and other parameters are those actually realized. |
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