ENERGY_EFFICIENCY_IN_ELECTRICAL_UTILITIES (Chapter 8:Lightening System)

 

ENERGY_EFFICIENCY_IN_ELECTRICAL_UTILITIES   

(Chapter 8:Lightening System)

Introduction 

Most natural light comes from the sun, including moon light. Its origin makes it completely clean and it consumes no natural resources. But man-made sources generally require consumption of resources, such as fossil fuels, to convert stored energy into light energy. 

Light is usually described as the type of electromagnetic radiation that has a wavelength visible to the human eye, roughly 400 to 700 nanometers. Light exists as tiny “packets” called photons and exhibits the properties of both particles and waves. Visible light, as can be seen on the electromagnetic spectrum, as given in Figure 8.1, represents a narrow band between ultraviolet light (UV) and infrared energy (heat). These light waves are capable of exciting the eye’s retina, which results in a visual sensation called sight. Therefore, seeing requires a functioning eye and visible light. 

The lumen (lm) is the photometric equivalent of the Watt, weighted to match the eye response of the “standard observer”. Yellowish-green light receives the greatest weight because it stimulates the eye more than blue or red light of equal radiometric power: 
 1 Watt = 683 lumens at 555 nm wavelength 
The best eye sensitivity, as seen from Figure 8.2 is at 555 nm wavelength having greenish yellow colour with a luminous efficacy of 683 lm/Watt.  
Three primary considerations to ensure energy efficiency in lighting systems are:
1. Selection of the most efficient light source possible in order to minimize electricity consumption and cost.
ii. Matching the proper lamp type to the intended work task or aesthetic application, consistent with color, brightness control and other requirements. 
iii. Establishing adequate light levels without compromising productivity improve security and increase safety.

Basic Parameters and Terms in Lighting System 
Luminous flux: The luminous flux describes the quantity of light emitted by a light source. It is a measure of a lamp’s economic efficiency.  
The most common measurement or unit of luminous flux is the lumen (Im). The lumen rating of a lamp is a measure of the total light output of the lamp. Light sources are labeled with an output rating in lumens.

Illuminance (E): is the quotient of the luminous flux incident on an element of the surface at a point of surface containing the point, by the area of that element. The lighting level produced by a lighting installation is usually qualified by the illuminance produced on a specified plane. In most cases, this plane is the major plane of the tasks carried out in the interior and is commonly called the working plane. The illuminance provided by an installation affects both the performance of the tasks and the appearance of the space. Lux (Ix) is the metric unit of measure for illuminance of a surface. One lux is equal to one lumen per square meter. I!luminance decreases by the square of the distance (inverse square law).  
The inverse square law defines the relationship between the illuminance from a point source and distance. It states that the intensity of light per unit area is inversely proportional to the square of the distance from the source (essentially the radius). 
Where, E = Illuminance in lux (Im/m2), I = Luminous flux in lumen (Im) and d = distance in m An alternate form of this equation which is sometimes more convenient is: 
 Distance is measured from the test point to the first luminating surface - the filament of a clear bulb or the glass envelope of a frosted bulb. 

Example: The illuminance is 10 lm/m2 from a lamp at 1 meter distance. What will be the illuminance at half the distance?  
Average maintained illuminance: is the average of illuminance (lux) levels measured at various points in a defined area.  
Circuit Watts: is the total power drawn by lamps and ballasts in a lighting circuit under assessment.
Luminous Efficacy (Im/W);: is the ratio of luminous flux emitted by a lamp to the power consumed by the lamp. It is a reflection of efficiency of energy conversion from electricity to light form. Unit: lumens per lamp Watt (Im/W).   
Lamp Circuit Efficacy: is the amount of light (lumens) emitted by a lamp for each Watt of power consumed by the lamp circuit, i.e. including control gear losses. This is a more meaningful measure for those lamps that require control gear. Unit: lumens per circuit Watt (Im/W).  
Installed Load Efficacy: is the average maintained illuminance provided on a horizontal working plane per circuit watt with general lighting of an interior. Unit: lux per Watt per square metre (lux/W/m/2). 
Installed Power Density: The installed power density per 100 lux is the power needed per square metre of floor area to achieve 100 lux of average maintained illuminance on a horizontal working plane with general lighting of an interior. Unit: Watts per square metre per 100 lux (W/m7/100 lux) 

Color rendering index (CRI): is a measure of the effect of light on the perceived color of objects. To determine the CRI of a lamp, the color appearances of a set of standard color chips are measured with special equipment under a reference light source with the same correlated color temperature as the lamp being evaluated. If the lamp renders the color of the chips identical to the reference light source, its CRI is 100. If the color rendering differs from the reference light source, the CRI is less than 100. A low CRI indicates that some colors may appear unnatural when illuminated by the lamp.  
  
Luminaire: is a device that distributes filters or transforms the light emitted from one or more lamps. The luminaire includes all the parts necessary for fixing and protecting the lamps, except the lamps themselves. In some cases, luminaires also include the necessary circuit auxiliaries, together with the means for connecting them to the electric supply. The basic physical principles used in optical luminaire are reflection, absorption, transmission and refraction.  

Control gear: The gears used in the lighting equipment are as follows:
¢ Ballast is a current limiting device, to counter negative resistance characteristics of any discharge lamps. In case of fluorescent lamps, it aids the initial voltage build-up, required for starting. In an electric circuit the ballast acts as a stabilizer. Fluorescent lamp is basically an electric discharge lamp with two electrodes separated inside a tube with no apparent connection between them. When sufficient voltage is impressed on these electrodes, electrons are driven from one electrode and attracted to the other. The current flow takes place through an atmosphere of low-pressure mercury vapour. 
¢ Since the fluorescent lamps cannot produce light by direct connection to the power source, they need an ancillary circuit and device to get started and remain illuminated. The auxiliary circuit housed in a casing is known as ballast. 
¢ Ignitors are used for starting high intensity discharge lamps such as metal halide and sodium vapour lamps. Ignitors generate a high voltage pulse or a series of pulses to initiate the discharge. 

Light Source and Lamp Types 
Lamp is equipment, which produces light. Light is that part of the electromagnetic spectrum that is perceived by our eyes. A number of light sources are available, each with its own unique combination of operating characteristics viz., efficacy, colour, lamp life, and the percent of output that a lamp loses over its life. Based on the construction and operating characteristics, the lamps can be categorized into three groups: incandescent, fluorescent and high intensity discharge (HID) lamps. HID lamps can be further classified as sodium vapour, mercury vapour and metal halide lamps. The most commonly used lamps are described briefly as follows: 

1) Incandescent lamp 
The principal parts of an incandescent lamp also known as GLS lamp (General Lighting Service lamp) include the filament, the bulb, the fill gas or vacuum and the cap. Incandescent lamps (Figure 8.3 A&B) produce light by means of a wire or filament heated to incandescence by the flow of electric current  through it. The filament is enclosed in an evacuated glass bulb filled with inert gas such as argon, krypton, or nitrogen that helps to increase the brilliance of lamp and to prevent the filament from burning out.
Reflector lamps: Reflector lamps are basically incandescent, provided with a high quality internal mirror, which follows exactly the parabolic shape of the lamp. The reflector is resistant to corrosion, thus making the lamp maintenance free and output efficient. 

2) Halogen lamp 
It has a tungsten filament and the bulb filled with halogen gas (Figure 8.4). Current flows through the filament and heats it up, as in incandescent lamps. These lamps therefore generate a relatively large amount of heat. The use of halogen increases the efficiency and extends the service life compared with traditional incandescent lamps. Low-voltage types are very small and are ideal for precise direction of light, but they require a transformer. Tungsten atoms evaporate from the hot filament and move toward the cooler wall of the bulb. Tungsten, oxygen and halogen atoms combine at the bulb-wall to form tungsten oxyhalide molecules. The bulb-wall temperature keeps the tungsten oxyhalide molecules in a vapor. The molecules move toward the hot filament where the higher temperature breaks them apart. 
Tungsten atoms are re-deposited on the cooler regions of the filament - not in the exact places from which they evaporated. Breaks usually occur near the connections between the tungsten filament and its molybdenum lead-in wires where the temperature drops sharply.  

3) Fluorescent tube lamp (FTL) 
It works by the fluorescence principle. A fluorescent lamp (Figure 8.5 A&B) is a glass tube containing a small trace of a gas such as mercury vapor (for a white color), carbon dioxide (for green), neon (for red color), etc., with a special fluorescent / phosphorescent coating on the interior surface of the tube. It contains two filaments, one at each end of the tube and when the electrical supply is switched ON, the contacts of the starter open and the filaments glow to heat up the gas contained inside the tube. 

This action provides a voltage across its electrodes that set off an electric (gaseous mercury) arc discharge in the tube. This generates invisible UV radiation that is high enough to ionise the warmedup gas inside the tube. This ionised gas also called as “plasma”, excites the fluorescent coating so that it gives out visible light. Ballast is needed to start and operate fluorescent lamps, because of the characteristics of a gaseous arc. The luminous flux is highly dependent on the ambient temperature. Fluorescent Lamps are about 3 to 5 times as efficient as standard incandescent lamps and can last about 10 to 20 times longer. 
The different types of fluorescent lamps and their reference are given below: 
Linear tubes 
¢ T12-38 mm (1.5’diameter) 
¢ T8-25 mm (1”diameter) 
¢ T5 - 16mm (5/8”diameter) 
¢ T2-6mm (1/4’’ diameter) 

U-bent tubes 
¢ T12-38 mm (1.5”diameter)
¢ T8-25 mm (1” diameter)  

Circular tubes 
¢ T9-38 mm (1.5’diameter) 
¢T5 - 16 mm (5/8”diameter)  

These four lamps vary in diameter (ranging from 1.5 inches that is 12/8 of an inch for T12 to 0.625 or 5/8 of an inch in diameter for TS lamps). Efficacy is another area that distinguishes one from another. T5 & T8 lamps offer a 5-percent increase in efficacy over 40-watt T12 lamps, and have become the most popular choice for new installations.

4) Compact fluorescent lamp (CFL) 
Compact Fluorescent lamps (Figure 8.6) are compact / miniature versions of the linear or circular fluorescent lamps and operate in a very similar way. The luminous flux depends on temperature. CFL’s use less power and have a longer rated life compared to an incandescent lamp.  
They are designed to replace an incandescent lamp and can fit into most existing light fixtures formerly used for incandescent. CFL’s are available in screw type/ pin type which fit into standard sockets, and gives off light that is similar to common fluorescent lamps.

5) Sodium vapour lamp 
Low pressure sodium vapour lamp 
Although low pressure sodium vapour (LPSV) lamps (Figure 8.7) are similar to fluorescent systems (because they are low pressure systems), they are commonly included in the HID family. LPSV lamps are the most efficacious light  sources, but they produce the poorest quality light of all the lamp types. Being a monochromatic light source, all colours appear black, white, or shades of gray under an LPSV source. LPSV lamps are available in wattages ranging from 18-180.
LPSV lamp use has been generally limited to outdoor applications such as security or street lighting and indoor, low-wattage applications where color quality is not important (e.g. stairwells). However, because the color rendition is so poor, many municipalities do not allow them for roadway lighting.

High pressure sodium vapour lamp 
The high pressure sodium vapour (HPSV) lamp (Figure 8.8 A&B) is widely used for outdoor and industrial applications as the light  is yellowish. Its higher efficacy makes it a better choice than metal halide for these applications, especially when good color rendering is not a priority. HPSV lamps differ from mercury and metal-halide lamps in that they do not contain starting electrodes; the ballast circuit includes a high-voltage electronic starter. The arc tube is made of a ceramic material, which can withstand temperatures up to 1300 °C. It is filled with xenon to help start the arc, as well as a sodium-mercury gas mixture.   
6) Mercury vapour lamp 
In a mercury vapour lamp (Figure 8.9) electromagnetic radiation is created from discharge within mercury vapour, but the regime is different than that found in the normal fluorescent lamp. During operation, the pressure within the lamp is in the range of 200 — 400 kPa (compared with only 1 Pa). It is not possible to achieve the mercury vapour discharge in a cold lamp. For this reason, the lamp also includes argon, and the initial arc is struck as an argon arc. The energy from this discharge vapourises the mercury to get the main discharge going. 
The mercury vapour lamp produces a much greater proportion of visible light than fluorescent lamp and gives off a bluish white light. Phosphor coating can be given to improve the colour rendering index. 


7) Metal halide lamp: 
Metal halide lamp (Figure 8.10 A&B) can be considered as a variant of high pressure mercury vapour lamp (HPMYV). In addition to mercury vapour and argon, this lamp contains metal halide. The halides can be a mixture of rare earth halides, usually iodides or a mixture of sodium and scandium iodide. The mercury vapour radiation is augmented by that of the  metals.
A highly compact electric arc is produced in a discharge tube. A starter is needed to switch on the lamp. The use of ceramic discharge tubes further improves the lamp properties. The halides act in a similar manner to the tungsten halogen cycle. As the temperature increases there is disassociation of the halide compound releasing the metal into the arc. The halides prevent the quartz wall getting attacked by the alkali metals. By adding other metals to the mercury  different spectrum can be emitted. Some lamps use a third electrode for starting, but others, especially the smaller display lamps, require a high voltage ignition pulse. Metal halide lamps have a significantly better colour rendering index than mercury vapour and can be tailored by the choice of halides.
8) Light emitting diode (LED) lamp 
LEDs produce light in a very unique way; they produce light via a process called electro-luminescence (Figure 8.11), a process that starts by turning a semiconductor material into a conducting material. A semiconductor with extra electrons is called N-type (negative) material, since it has extra negativelycharged electrons. In N-type material, free electrons can move from a negatively-charged area to a positively charged area. A semiconductor with extra holes is called P-type (positive) material since it has extra positively-charged gaps called holes. When excited with current the negative electron leaves its atom and the P-type material’s positive attraction draws the free negative electron into its hole, and the hole also moves toward the electron, so on and so forth. As an electron travels to a hole, it carries energy, but in order to fit into the hole it must release any extra energy, and when it does, the extra energy is released in the form of light. When we maintain a steady flow of electrical current to the diode, it continues the process of allowing electrons to flow from the negative charged material and fall into the positive charged holes which maintains a steady stream of light out of the LED. The actual LED is quite small in size, usually less than one square millimeter. Additional optical components are added to shape and direct the light. LED’s are made of number of inorganic semiconductor materials, many of which produce different colour of light. 

The efficiency of LED’s has now risen sharply and is currently up to 200 lumens per watt in the laboratory and in some products available on the market (although more typical LED’s average output varies from 50 to 130 lumens per watt). Because of the low power requirement for LED’s, using solar panels becomes more practical and less expensive than running an electrical wire or using a generator. Hence LED with battery backup for remote application is very economical. 
They do not radiate light in 360 degrees as an incandescent does. The light will be bright wherever it is focused. Unlike incandescent and fluorescent lamps, LEDs are not inherently white light sources. Instead, LEDs emit nearly monochromatic light, making them highly efficient for colored light applications such as traffic lights and exit signs. 
However, to be used as a general light source, white light is needed. White light can be achieved with LEDs in three ways: Phosphor conversion, in which a phosphor is used on or near the LED to convert the colored light to white light; RGB systems, in which light from multiple monochromatic LEDs (red, green, and blue) is mixed, resulting in white light; and a hybrid method, which uses both phosphor-converted and monochromatic LEDs.  

Advantages of LED technology is as follows Low power consumption, Directional light output, High efficiency level, Long life: upto ~100,000 hour life if junction temperature can be controlled, Instant switching on with no warm up time, High resistance to switching cycles, High impact and vibration resistance, No UV or IR radiation, Color control ability, allows dimming and Mercury free 
LED’s also offer a number of promising environmental benefits, and they are often viewed as the future of green lighting.

9) Induction lamp 
Induction lamp is noted for ‘crisp white light output’. Uses a magnetic field to excite gases — has no lamp parts to wear out. It consists of two main components: ballast and a sealed gas-filled bulb. Light is produced via electromagnetic induction, without an electrode or any electrical connection inside the bulb. Instead, high frequency electromagnetic fields are induced from outside the sealed chamber. To produce light, the ballast supplies the electric coils with high frequency electrical current. The ferrite magnets on either side of the bulb then emit electromagnetic fields which excite electrons within the bulb.  

As the electrons accelerate inside the bulb, they collide with mercury atoms and produce ultraviolet (UV) light radiation. The UV light then causes the special phosphor coating inside the glass to react in a way that produces fluorescent light within the visible spectrum. The light produced by Induction Lighting (Figure 8.12) achieves good Color Rendering Index (CRI), with a Correlated Color Temperature. Advantages of Induction lamps is as follows long burning hours, very less maintenance required, instant on/ instant re-strike and energy efficient lighting. 

Recommended Illuminance Levels for Various Tasks / Activities / Locations 
Recommendations on Illuminance
Scale of Tiluminance: 
The minimum illuminance for all non-working interiors, has been mentioned as 20 Lux (as per IS 3646). A factor of approximately 1.5 represents the smallest significant difference in subjective effect of illuminance. Therefore, the following scale of illuminances is recommended. 
 20—30—50—75—100—150—200-—300—500—750—1000—1500—2000, ...

Illuminance ranges: 
Lux Because circumstances may be significantly different for different interiors used for the same application or for different conditions for the same kind of activity, a range of illuminances is recommended for each type of interior or activity intended of a single value of illuminance. Each range consists of three successive steps of the recommended scale of illuminances. For working interiors the middle value (R) of each range represents the recommended service illuminance that would be used unless one or more of the factors mentioned below apply.  
The higher value (H) of the range should be used at exceptional cases where low reflectance or contrasts are present in the task, errors are costly to rectify, visual work is critical, accuracy or higher productivity is of great importance and the visual capacity of the worker makes it necessary. Similarly, lower value (L) of the range may be used when reflectances or contrasts are unusually high, speed and accuracy is not important and the task is executed only occasionally.

Recommended Illumination
The following Table 8.2 gives the recommended illuminance range for different tasks and activities for chemical sector. The values are related to the visual requirements of the task, to user’s satisfaction, to practical experience and to the need for cost effective use of energy (Source IS 3646 (Part I): 1992). For recommended illumination in other sectors, reader may refer illuminating Engineers Society Recommendations Handbook. 
Table 8.2 Recommended illuminance range for different tasks and activities for chemical sector .

Methods of Calculating illuminance - Lighting Design for Interiors
In order to design a luminaire layout that best meets the illuminance and uniformity requirements of the job, two types of information are generally needed: average illuminance level and illuminance level at a given point. Calculation of illuminance at specific points is often done to help the designer evaluate the lighting uniformity, especially when using luminaires where maximum spacing recommendations are not supplied, or where task lighting levels must be checked against ambient level. 
If average levels are to be calculated, two methods can be applied:
1. For indoor lighting situations, the Zonal Cavity Method is used with data from a coefficient of utilization table. 
2. For outdoor lighting applications, a coefficient of utilization curve is provided, the CU is read directly from the curve and the standard lumen formula is used. 

Zonal Cavity Method for Indoor Lighting Calculations 
The Zonal Cavity Method (sometimes called the Lumen Method) is the currently accepted method for calculating average illuminance levels for indoor areas, unless the light distribution is radically asymmetric. It is an accurate hand method for indoor applications because it takes into consideration the effect that inter-reflectance has on the level of illuminance.  
Although it takes into account several variables, the basic premise that foot-candles are equal to luminous flux over an area is not violated.

 The basis of the Zonal Cavity Method is that a room is made up of three spaces or cavities. The space between the ceiling and the fixtures, if they are suspended, is defined as the “ceiling cavity”; the space between the work plane and the floor, the “floor cavity”; and the space between the fixtures and the work plane, the “room cavity.”

Example: The step by step process of lighting design is illustrated below with the help of an example. The Figure 8.13 shows the parameters of a typical space.  
Step-1: Decide the required illuminance on work plane, the type of lamp and luminaire 
A preliminary assessment must be made of the type of lighting required, a decision most often made as a function of both aesthetics and economics. For normal office work, illuminance of 200 lux is desired. For an air conditioned office space under consideration, we choose 36 W fluorescent tube lights with twin tube fittings. The luminaire is porcelain-enameled suitable for the above lamp. It is necessary to procure utilisation factor tables for this luminaire from the manufacturer for further calculations.

Step-2: Collect the room data in the format given below 
Typical reflectance values for using in L5, L6, L7 are:
Step 4: Calculate the utilisation factor 
Utilisation factor is defined as the percent of rated bare-lamp lumens that exit the luminaire and reach the work plane. It accounts for light directly from the luminaire as well as light reflected off the room surfaces. Manufacturers will supply each luminaire with its own CU table derived from a photometric test report. Using tables available from manufacturers, it is possible to determine the utilisation factor for different light fittings if the reflectance of both the walls and ceiling is known, the room index has been determined and the type of luminaire is known. For twin tube fixture, utilisation factor is 0.66, corresponding to room index of 2.5. 
  
Step-5: To calculate the number of fittings required, the following formula is used  
Where, MF = Maintenance Factor 
Typical LLF values A

So, 6 Numbers of Twin Tube Fixtures are required. Total number of 36 W lamp is 12. 
Step 6: Space the luminaires to achieve desired uniformity 
Every luminaire will have a recommended space to height ratio. In earlier design methodologies, the uniformity ratio,which is the ratio of minimum illuminance to average illuminance, was kept at 0.8 and suitable space to height ratio is specified to achieve the uniformity. In modern designs incorporating energy efficiency and task lighting, the emerging concept is to provide a uniformity of 1/3 to 1/10 depending on the tasks. 
Recommended value for the above luminaire is 1.5. If the actual ratio is more than the recommended values, the uniformity of lighting will be less. For a sample of arrangement of fittings, refer Figure 8.14. The luminaire closer to a wall should be one half of spacing or less. 
Luminaire Spacing Spacing between luminaires = 10/3 = 333m 
Mounting height (L9-L8) = 2.0m 
Space to height ratio (SHR) = 3.33/2.0 = 1.66   

This is close to the limits specified and hence accepted. 
It is better to choose luminaires with larger SHR. This can reduce the number of fittings and connected lighting load.  

General Energy Saving Opportunities
Changing the light bulbs is not the only way to improve the use of lighting. Below are some examples of many other options available: 
a) Use natural day lighting 
The utility of using natural day lighting instead of electric lighting during the day is well known, but is being increasingly ignored especially in modern air-conditioned office spaces and commercial establishments like hotels, shopping plazas etc. Industrial plants generally use daylight in some fashion, but improperly designed day lighting systems can result in complaints from personnel or supplementary use of electric lights during daytime. 

Some of the methods to incorporate day lighting are:
i. North lighting by use if single-pitched truss of the saw-tooth type is a common industrial practice; this design is suitable for latitudes north of 23 i.e. in North India. In South India, north lighting may not be appropriate unless diffusing glasses are used to cut out the direct sunlight. 
 il. Innovative designs are possible which eliminates the glare of daylight and blend well with the interiors. Glass strips, running continuously across the breadth of the roof at regular intervals, can provide good, uniform lighting on industrial shop floors and storage bays. 
ill.A good design incorporating sky lights with FRP material along with transparent or translucent false ceiling can provide good glare-free lighting; the false ceiling will also cut out the heat that comes with natural light. 
 iV. Use of atrium with FRP dome in the basic architecture can eliminate the use of electric lights in passages of tall buildings. 
V.Natural Light from windows should also be used. However, it should be well designed to avoid glare. Light shelves can be used to provide natural light without glare. 
vi. Mounting Solar tube on the roof, with the help of advanced optics and special duct work to direct sunlight deep into the buildings and spreading out over large internal spaces providing heat and glare free daylighting for 8-10 hrs in a day.

b) De-lamping to reduce excess lighting 
De-lamping is an effective method to reduce lighting energy consumption. In some industries, reducing the mounting height of lamps, providing efficient luminaires and then de-lamping has ensured that the illuminance is hardly affected. De-lamping at empty spaces where active work is not being performed is also a useful concept.  

c) Task lighting 
Task Lighting implies providing the required good illuminance only in the actual small area where the task is being performed, while the general illuminance of the shop floor or office is kept at a lower level; e.g. Machine mounted lamps or table lamps. Energy saving takes place because good task lighting can be achieved with low wattage lamps. The concept of task lighting if sensibly implemented, can reduce the no of general lighting fixtures, reduce the wattage of lamps, save considerable energy and provide better illuminance and also provide aesthetically pleasing ambience.

d) Selection of high efficiency lamps and luminaries 
The details of common types of lamps are summarised in Table 8.1 above. It is possible to identify energy saving potential for lamps by replacing with more efficient types. The following examples of lamp replacements are common. There may be some limitations if colour rendering is an important factor. It may be noted that, in most cases, the luminaires and the control gear would also have to be changed. The savings are large if the lighting scheme is redesigned with higher efficacy lamps and luminaires. 

e) Reduction of lighting feeder voltage 
Figure 8.15 shows the effect of variation of voltage on light output and power consumption for fluorescent tube lights. Similar variations are observed on other gas discharge lamps like mercury vapour lamps, metal halide lamps and sodium vapour lamps (Table 8.3 summarises the effects). Hence reduction in lighting feeder voltage can save energy, provided the drop in light output is acceptable. In many areas, night time grid voltages are higher than normal; hence reduction in voltage can save energy and also provide the rated light output. Some manufacturers are supplying reactors and transformers as standard products. A large number of industries have used these devices and have reported saving to the tune of 5% to 15%. Industries having a problem of higher night time voltage can get an additional benefit of reduced premature lamp failures. 
f) Electronic ballasts
Conventional electromagnetic ballasts (chokes) are used to provide higher voltage to start the tube light and subsequently limit the current during normal operation. Electronic ballasts are oscillators that convert the supply frequency to about 20,000 Hz to 30,000 Hz. The basic functions of electronic ballast are: 
¢ To ignite the lamp
¢ To stabilize the gas discharge 
¢ To supply the power to the lamp

The losses in electronic ballasts for tube lights are only about 1 Watt, in place of 10 to 15 Watts in standard electromagnetic chokes. The additional advantage is that the efficacy of tube lights improves at higher frequencies, resulting in additional savings if the ballast is optimised to provide the same light output as with the conventional choke. Hence a saving of about 15 to 20 Watts per tube light can be achieved by use of electronic ballasts. With electronic ballast, the starter is eliminated and the tube light lights up instantly without flickering.

g) Lighting controllers 
Automatic control for switching off unnecessary lights can lead to good energy savings. This includes dimmers, motion & occupancy sensors, photosensors and timers.  

h) Lighting maintenance 
Maintenance is vital to lighting efficiency. Light levels decrease over time because of aging lamps and dirt on fixtures, lamps and room surfaces. Together, these factors can reduce total illumination by 50 percent or more, while lights continue drawing full power. The basic maintenance includes cleaning of lamps and fixtures, cleaning and repainting interiors, relamping etc 

Energy Efficient Lighting Controls 
Occupancy Sensors 
Occupancy-linked control can be achieved using infra-red, acoustic, ultrasonic or microwave sensors, which detect either movement or noise in room spaces. These sensors switch lighting on when occupancy is detected, and off again after a set time period, when no occupancy movement detected. They are designed to override manual switches and to prevent a situation where lighting is left on in unoccupied spaces. With this type of system it is important to incorporate a built-in time delay, since occupants often remain still or quiet for short periods and do not appreciate being plunged into darkness if not constantly moving around. 

Timed Based Control
Timed-turnoff switches are the least expensive type of automatic lighting control. In some cases, their low cost and ease of installation makes it desirable to use them where more efficient controls would be too expensive.

Types and features
The oldest and most common type of timed-turnoff switch is the “dial timer,” a spring-wound mechanical timer that is set by twisting the knob to the desired time. Typical units of this type are vulnerable to damage because the shaft is weak and the knob is not securely attached to the shaft. Some spring wound units make an annoying ticking sound as they operate. Newer types of timed-turnoff switches are completely electronic and silent. Electronic switches can be made much more rugged than the spring-wound dial timer. These units typically have a spring-loaded toggle switch that turns on the circuit for a preset time interval. Some electronic models provide a choice of time intervals, which you select by adjusting a knob located behind the faceplate. Most models allow occupants to turn off the lights manually. Some models allow occupants to keep the lights on, overriding the timer. Timedturnoff switches are available with a wide range of time spans. The choice of time span is a compromise. Shorter time spans waste less energy but increase the probability that the lights will turn off while someone is in the space. Dial timers allow the occupant to set the time span, but this is not likely to be done with a view toward optimising efficiency. For most applications, the best choice is an electronic unit that allows the engineering staff to set a fixed time interval behind the cover plate.

Daylight Linked Control
Photoelectric cells can be used either simply to switch lighting on and off, or for dimming. They may be mounted either externally or internally. It is however important to incorporate time delays into the control system to avoid repeated rapid switching caused, for example, by fast moving clouds. By using an internally mounted photoelectric dimming control system, it is possible to ensure that the sum of daylight and electric lighting always reaches the design level by sensing the total light in the controlled area and adjusting the output of the electric lighting accordingly. If daylight alone is able to meet the design requirements, then the electric lighting can be turned off. The energy saving potential of dimming control is greater than a simple photoelectric switching system. Dimming control is also more likely to be acceptable to room occupants.  

Localized Switching 
Localized switching should be used in applications which contain large spaces. Local switches give individual occupants control over their visual environment and also facilitate energy savings. By using localized switching it is possible to turn off artificial lighting in specific areas, while still operating it in other areas where it is required, a situation which is impossible if the lighting for an entire space is controlled from a single switch.  

Street Lighting Systems and Controls 
Street lighting /Public lighting is one of the major electrical loads in municipal areas. Number of street lights used in a Municipal area varies from 20000 — 50000 in numbers depending on the kilometers of road illuminated within the municipal limits. Typical electrical load of municipal lighting system varies 2MW to 7 MW. The type of lamps used in Municipal area includes Fluorescent Tube light/ Mercury Vapor Lamps/ Sodium Vapor Lamps and Metal Halide Lamps. High Mast towers are also used at strategic junctions in the Municipal area. LEDs are also used for traffic signaling purpose in municipal areas. Following controls are adopted to reduce energy consumption in street lighting system: 
1. Timer control (Switch ON/OFF as per set timing)
2. Day light control(Based on illumination level)
3. Selective switching/Alternate switching of street lights low traffic density areas (after midnight).  
4. Switching control based on lux levels. (after midnight)
5. Installations of Voltage controllers to be operated after midnight. 
6. Installation of PLC controlled Lighting panels for effective control and monitoring. 

Standards and Labeling Programs for FTL Lamps
Considering the large number of fluorescent lamps (FTL) in usage, BEE has included FTL under Standard and Labeling Programme (S&L). The S&L Programme covers 4 feet tubular fluorescent lamps (101mm) for wattages up to 40W. The S&L programme includes 6500K colour temperature for halo-phosphates and 6500K, 4000K & 2700K for tri-phosphate category. The star rating scheme for FTL is given in Table 8.4. Table 8.4 Star Rating scheme for FTL (101 mm)
Lighting Case Study 
Replacement of existing T12 Fluorescent lamps in street lighting system with LED lamps
Existing: Fluorescent lamp (T12) fixture of 40 numbers is connected to the entire campus for security purpose. All the lights remain in operation for around 12 hours at night (6 p.m. to 6 am) every day throughout the year. All the light fixtures are equipped with electromagnetic ballast which consumes around 12 to 14 watt of additional power while in operation. Hence the power consumption of a single fluorescent light fixture considering minimum ballast loss is 40+12=52 watts. The total light output of all the fluorescent light fixtures is around 2400 lumen.  

Proposed: It was proposed to replace existing lamps with high efficient LED lamps of 18 W with a luminous efficacy of around 120-140 Im/w. The total luminous output of these lamps is around 2340 lumen. 
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ENERGY_EFFICIENCY_IN_ELECTRICAL_UTILITIES (Chapter 7:Cooling tower)

 

ENERGY_EFFICIENCY_IN_ELECTRICAL_UTILITIES  

 (Chapter 7:Cooling tower)

Introduction 

Cooling towers are a very important part of many chemical plants. The primary task of a cooling tower is to reject heat into the atmosphere. They represent a relatively inexpensive and dependable means of removing low-grade heat from cooling water. The make-up water source is used to replenish water lost to evaporation. Hot water from heat exchangers is sent to the cooling tower. The water exits the cooling tower and is sent back to the exchangers or to other units for further cooling. Typical closed loop cooling tower system is shown in Figure 7.1.

Cooling Tower Types 
Cooling towers fall into two main categories: Natural draft and Mechanical draft. Natural draft towers use very large concrete chimneys to introduce air through the media. Due to the large size of these towers, they are generally used for water flow rates above 45,000 m*/hr. These types of towers are used only by utility power stations. Mechanical draft towers utilize large fans to force or suck air through circulated water. The water falls downward over fill surfaces, which help increase the contact time between the water and the air - this helps maximise heat transfer between the two. Cooling rates of Mechanical draft towers depend upon their fan diameter and speed of operation. Since, the mechanical draft cooling towers are much more widely used; the focus is on them in this chapter.  

Mechanical draft towers

Mechanical draft towers are available in the following airflow arrangements: 

1. Counter flows induced draft.

2. Counter flow forced draft. 

3. Cross flow induced draft. 

In the counter flow induced draft design, hot water enters at the top, while the air is introduced at the bottom and exits at the top. Both forced and induced draft fans are used. In cross flow induced draft towers, the water enters at the top and passes over the fill. The air, however, is introduced at the side either on one side (single-flow tower) or opposite sides (double-flow tower). An induced draft fan draws the air across the wetted fill and expels it through the top of the structure.

The Figure 7.2 illustrates various cooling tower types. Mechanical draft towers are available in a large range of capacities. Normal capacities range from approximately 10 tons, 2.5 m3/hr flow to several thousand tons and m3/hr. Towers can be factory built or field erected — for example concrete towers are only field erected. 

Many towers are constructed so that they can be grouped together to achieve the desired capacity. Thus, many cooling towers are assemblies of two or more individual cooling towers or “cells.” The number of cells they have, e.g., a eight-cell tower, often refers to such towers. Multiple-cell towers can be lineal, square, or round depending upon the shape of the individual cells and whether the air inlets are located on the sides or bottoms of the cells. 

Components of Cooling Tower

The basic components of an evaporative tower are: Frame and casing, fill, cold water basin, drift eliminators, air inlet, louvers, nozzles and fans. 

Frame and casing: Most towers have structural frames that support the exterior enclosures (casings), motors, fans, and other components. With some smaller designs, such as some glass fiber units, the casing may essentially be the frame. 

Fill: Most towers employ fills (made of plastic or wood) to facilitate heat transfer by maximising water and air contact. Fill can either be splash or film type. 

With splash fill, water falls over successive layers of horizontal splash bars, continuously breaking into smaller droplets, while also wetting the fill surface. Plastic splash fill promotes better heat transfer than the wood splash fill. 

Film fill consists of thin, closely spaced plastic surfaces over which the water spreads, forming a thin film in contact with the air. These surfaces may be flat, corrugated, honeycombed, or other patterns. The film type of fill is the more efficient and provides same heat transfer in a smaller volume than the splash fill. 

Cold water basin: The cold water basin, located at or near the bottom of the tower, receives the cooled water that flows down through the tower and fill. The basin usually has a sump or low point  for the cold water discharge connection. In many tower designs, the cold water basin is beneath the entire fill.

In some forced draft counter flow design, however, the water at the bottom of the fill is channeled to a perimeter trough that functions as the cold water basin. Propeller fans are mounted beneath the fill to blow the air up through the tower. With this design, the tower is mounted on legs, providing easy access to the fans and their motors. 

Drift eliminators: These capture water droplets entrapped in the air stream that otherwise would be lost to the atmosphere. 

Air inlet: This is the point of entry for the air entering a tower. The inlet may take up an entire side of a tower—cross flow design— or be located low on the side or the bottom of counter flow designs. 

Louvers: Generally, cross-flow towers have inlet louvers. The purpose of louvers is to equalize air flow into the fill and retain the water within the tower. Many counter flow tower designs do not require louvers. 

Nozzles: These provide the water sprays to wet the fill. Uniform water distribution at the top of the fill is essential to achieve proper wetting of the entire fill surface. Nozzles can either be fixed in place and have either round or square spray patterns or can be part of a rotating assembly as found in some circular cross-section towers. 

Fans: Both axial (propeller type) and centrifugal fans are used in towers. Generally, propeller fans are used in induced draft towers and both propeller and centrifugal fans are found in forced draft towers. Depending upon their size, propeller fans can either be fixed or variable pitch. 

A fan having non-automatic adjustable pitch blades permits the same fan to be used over a wide range of kW with the fan adjusted to deliver the desired air flow at the lowest power consumption. 

Automatic variable pitch blades can vary air flow in response to changing load conditions.  

Tower Materials

In the early days of cooling tower manufacture, towers were constructed primarily of wood. Wooden components included the frame, casing, louvers, fill, and often the cold water basin. If the basin was not of wood, it likely was of concrete. 

Today, tower manufacturers fabricate towers and tower components from a variety of materials. Often several materials are used to enhance corrosion resistance, reduce maintenance, and promote reliability and long service life. Galvanized steel, various grades of stainless steel, glass fiber, and concrete are widely used in tower construction as well as aluminum and various types of plastics for some components. 

Wood towers are still available, but they have glass fiber rather than wood panels (casing) over the wood framework. The inlet air louvers may be glass fiber, the fill may be plastic, and the cold water basin may be steel. 

Larger towers sometimes are made of concrete. Many towers—casings and basins—are constructed of galvanized steel or, where a corrosive atmosphere is a problem, stainless steel. Sometimes a galvanized tower has a stainless steel basin. Glass fiber is also widely used for cooling tower casings and basins, giving long life and protection from the harmful effects of many chemicals.

Plastics are widely used for fill, including PVC, polypropylene, and other polymers. Treated wood splash fill is still specified for wood towers, but plastic splash fill is also widely used when water conditions mandate the use of splash fill. Film fill, because it offers greater heat transfer efficiency, is the fill of choice for applications where the circulating water is generally free of debris that could plug the fill passageways. 

Plastics also find wide use as nozzle materials. Many nozzles are being made of PVC, ABS, polypropylene, and glass-filled nylon. Aluminum, glass fiber, and hot-dipped galvanized steel are commonly used fan materials. Centrifugal fans are often fabricated from galvanized steel. Propeller fans are fabricated from galvanized, aluminum, or molded glass fiber reinforced plastic.

Fanless Cooling Towers

Basis of Theory

Fanless cooling tower (Figure 7.3) takes advantage of the water pressure of the existing water circulation pump forming a water screen with specially designed ejection headers. As the water flows through the  nozzles at high velocity, based on a ejector principle, low pressure is created which sucks the ambient cold air into the tower. The kinetic energy of Water entering the cooling tower is converted into kinetic energy of the air by the use of specially designed ejector nozzles. Water Pressure required in the Jet Ejector Nozzles is min. 0.5 Bar. 

The incoming air passes through the fills at the bottom while the ejected water falls on the fills thus enabling a counter current heat exchange between water and air. Drift eliminators are provided to contain the drift losses. 

Features of Fanless Cooling Tower 

Energy saving 

Since fans are not used in this type of cooling there is a considerable saving of power even though marginally higher power consumption is required for the pump. 

Low noise 

The noises of traditional cooling tower originate from the operating fans and motors. Further the vibration caused by these transmission units reinforces the noise resonance. This problem is eliminated in fanless cooling tower since no fan/motor is used. 

Water saving

The velocity of water is less than that in conventional cooling tower. In combination with high efficiency drift eliminators this can reduce the drift loss to 0.001% which is much less than that for a conventional tower. Since the water droplets will be less than 50 micron it evaporates immediately without causing any pollution nearby 

Low maintenance cost 
Since the fanless cooling tower has no mechanical equipment such as fan, motor, gearbox etc. there is hardly any maintenance required, provided the quality of circulation water is kept clean and well maintained. 

Cooling Tower Performance 
The important parameters, from the point of determining the performance of cooling towers, are: 
    
i) “Range” is the difference between the cooling tower water inlet and outlet temperature. (see Figure 7.4).
ll) “Approach” is the difference between the cooling tower outlet cold water temperature and ambient wet bulb temperature. Although, both range and approach should be monitored, the ‘Approach’ is a better indicator of cooling tower performance. (see Figure 7.4). 
111) Cooling tower effectiveness (in percentage) is the ratio of range, to the ideal range, i.e., difference between cooling water inlet temperature and ambient wet bulb temperature, or in other words it is = Range / (Range + Approach). 
Iv) Cooling capacity is the heat rejected in kcal/hr or TR, given as product of mass flow rate of water, specific heat and temperature difference. 
v) Evaporation loss is the water quantity evaporated for cooling duty and, theoretically, for every 10,00,000 kcal heat rejected, evaporation quantity works out to 1.8 m3. An empirical relation used often is: 
 *Evaporation Loss (m3/hr) = 0.00085 x 1.8 x circulation rate (m3/hr) x (T1-T2)   
T1-T2 = Temp. difference between inlet and outlet water. 
 *Source: Perry’s Chemical Engineers Handbook (Page: 12-17) 
vi) Cycles of concentration (C.O.C) is the ratio of dissolved solids in circulating water to the dissolved solids in make up water.
vil)  Blowdown losses depend upon cycles of concentration and the evaporation losses and is given by relation: 
Blow Down = Evaporation Loss / (C.O.C. — 1)  
viii)  Liquid/Gas (L/G) ratio, of a cooling tower is the ratio between the water and the air mass flow rates. Against design values, seasonal variations require adjustment and tuning of water and air flow rates to get the best cooling tower effectiveness through measures like water box loading changes, blade angle adjustments. 
Thermodynamics also dictate that the heat removed from the water must be equal to the heat absorbed by the surrounding air: 

Factors Affecting Cooling Tower
Performance Capacity 
Heat dissipation (in kcal/hour) and circulated flow rate (m3/hr) are not sufficient to understand cooling tower performance. Other factors, which we will see, must be stated along with flow rate m*/hr. For example, a cooling tower sized to cool 4540 m3/hr through a 13.9°C range might be larger than a cooling tower to cool 4540 m3/hr through 19.5°C range.  

Range 
Range is determined not by the cooling tower, but by the process it is serving. The range at the exchanger is determined entirely by the heat load and the water circulation rate through the exchanger and on to the cooling water.  
Range °C = Heat Load in kcal/hour / Water Circulation Rate in LPH

Thus, Range is a function of the heat load and the flow circulated through the system. Cooling towers are usually specified to cool a certain flow rate from one temperature to another temperature at a certain wet bulb temperature. For example, the cooling tower might be specified to cool 4540 m3/hr from 48.9°C to 32.2°C at 26.7°C wet bulb temperature. 
Cold Water Temperature 32.2°C — Wet Bulb Temperature (26.7°C) = Approach (5.5°C) 

As a generalization, the closer the approach to the wet bulb, the more expensive the cooling tower due to increased size. Usually a 2.8°C approach to the design wet bulb is the coldest water temperature that cooling tower manufacturers will guarantee. Ifflow rate, range, approach  and wet bulb had to be ranked in the order of their importance in sizing |a tower, approach would be first with flow rate closely following the range and wet bulb would be of lesser importance. 
Heat Load 
The heat load imposed on a cooling tower is determined by the process being served. The degree of cooling required is controlled by the desired operating temperature level of the process. In most cases, a low operating temperature is desirable to increase process efficiency or to improve the quality or quantity of the product. In some applications (e.g. internal combustion engines), however, high operating temperatures are desirable. 
The size and cost of the cooling tower is proportional to the heat load. If heat load calculations are low undersized equipment will be purchased. If the calculated load is high, oversize and more costly, equipment will result. 
Process heat loads may vary considerably depending upon the process involved. Determination of accurate process heat loads can become very complex but proper consideration can produce satisfactory results. On the other hand, air conditioning and refrigeration heat loads can be determined with greater accuracy. 
Information is available for the heat rejection requirements of various types of power equipment. A sample list is as follows: 

 Air Compressor 
- Single-stage                                                        - 129 kcal/kW/hr
- Single-stage with after cooler                             - 862 kcal/kW/hr 
- Two-stage with intercooler                                 - 518 kceal/kW/hr 
- Two-stage with intercooler and after cooler       - 862 kcal/kW/hr 
- Refrigeration,Compression                                 - 63 kcal/min/TR 
- Refrigeration, Absorption                                    - 127 kcal/min/TR
-Steam Turbine Condenser - 555 kcal/kg of steam 
-Diesel Engine, Four-Cycle, Supercharged - 880 kcal/kW/hr 
- Natural Gas Engine, Four-cycle - 1523 keal/kW/hr
 (18 kg/cm2 compression)  

Wet Bulb Temperature 
Wet bulb temperature is an important factor in performance of evaporative water cooling equipment. It is a controlling factor from the aspect of minimum cold water temperature to which water can be cooled by the evaporative method. Thus, the wet bulb temperature of the air entering the cooling tower determines operating temperature levels throughout the plant, process, or system. Theoretically, a cooling tower will cool water to the entering wet bulb temperature, when operating without a heat load. 
However, a thermal potential is required to reject heat, so it is not possible to cool water to the entering air wet bulb temperature, when a heat load is applied. The approach obtained is a function of thermal conditions and tower capability. Initial selection of towers with respect to design wet bulb temperature must be made on the basis of conditions existing at the tower site. The temperature selected is generally close to the average maximum wet bulb for the summer months. An important aspect of wet bulb selection is, whether it is specified as ambient or inlet. The ambient wet bulb is the temperature, which exists generally in the cooling tower area, whereas inlet wet bulb is the wet bulb temperature of the air entering the tower. 
The later can be, and often is, affected by discharge vapors being recalculated into the tower. Recirculation raises the effective wet bulb temperature of the air entering the tower with corresponding increase in the cold water temperature. Since there is no initial knowledge or control over the recirculation factor, the ambient wet bulb should be specified. The cooling tower supplier is required to furnish a tower of sufficient capability to absorb the effects of the increased wet bulb temperature peculiar to his own equipment. 
It is very important to have the cold water temperature low enough to exchange heat or to condense vapours at the optimum temperature level. By evaluating the cost and size of heat exchangers versus the cost and size of the cooling tower, the quantity and temperature of the cooling tower water can be selected to get the maximum economy for the particular process. The Table 7.1 illustrates the effect of approach on the size and cost of a cooling tower. 
The towers included were sized to cool 4540 m*/hr through a 16.67°C range at a 26.7°C design wet bulb. The overall width of all towers is 21.65 meters; the overall height, 15.25 meters, and the pump head, 10.6 m approximately.  
Approach and Flow 
Suppose a cooling tower is installed that is 21.65 m wide x 36.9 m long x 15.24m high, has three 7.32 m diameter fans and each powered by 25 kW motors. The cooling tower cools from 3632 m*/hr water from 46.1°C to 29.4°C at 26.7°C WBT dissipating 60.69 million kcal/hr. The Table 7.2 shows what would happen with additional flow but with the range remaining constant at 16.67°C. The heat dissipated varies from 60.69 million kcal/hr to 271.3 million kcal/hr. 
For meeting the increased heat load, few modifications would be needed to increase the water flow through the tower. However, at higher capacities, the approach would increase.

Range, Flow and Heat Load
Range is a direct function of the quantity of water circulated and the heat load. Increasing the range as a result of added heat load does require an increase in the tower size. If the cold water temperature is not changed and the range is increased with higher hot water temperature, the driving force between the wet bulb temperature of the air entering the tower and the hot water temperature is increased, the higher level heat is economical to dissipate. 
If the hot water temperature is left constant and the range is increased by specifying a lower cold water temperature, the tower size would have to be increased considerably. Not only would the range be increased, but the lower cold water temperature would lower the approach. The resulting change in both range and approach would require a much larger cooling tower.  

Approach & Wet Bulb Temperature 
The design wet bulb temperature is determined by the geographical location. Usually the design wet bulb temperature selected is not exceeded over 5 percent of the time in that area. Wet bulb temperature is a factor in cooling tower selection; the higher the wet bulb temperature, the smaller the tower required to give a specified approach to the wet bulb at a constant range and flow rate. 
A 4540 m3/hr cooling tower selected for a 16.67°C range and a 4.45°C approach to 21.11°C wet bulb would be larger than a 4540 m3/hr tower selected for a 16.67°C range and a 4.45°C approach to a 26.67°C wet bulb. Air at the higher wet bulb temperature is capable of picking up more heat. Assume that the wet bulb temperature of the air is increased by approximately 11.1°C. 
As air removes heat from the water in the tower, each kg of air entering the tower at 21.1°C wet bulb would contain 18.86 kcals and if it were to leave the tower at 32.2°C wet bulb it would contain 24.17 kcal per kg of air. In the second case, each kg of air entering the tower at 26.67°C wet bulb would contain 24.17 kcal and were to leave at 37.8°C wet bulb it would contain 39.67 kcal per kg of air. 
In going from 21.10C to 32.20C, 12.1 kcal per kg of air is picked up, while 15.5 kcal/kg of air is picked up in going from 26.67°C to 37.8°C. 

Fill Media Effects 
In a cooling tower, hot water is distributed above fill media which flows down and is cooled due to evaporation with the intermixing air. Air draft is achieved with use of fans. Thus some power is consumed in pumping the water to a height above the fill and also by fans creating the draft.
An energy efficient or low power consuming cooling tower is to have efficient designs of fill media with appropriate water distribution, drift eliminator, fan, gearbox and motor. Power savings in a cooling tower, with use of efficient fill design, is directly reflected as savings in fan power consumption and pumping head requirement.  

Function of Fill media in a Cooling Tower
Heat exchange between air and water is influenced by surface area of heat exchange, time of heat exchange (interaction) and turbulence in water effecting thoroughness of intermixing. Fill media in a cooling tower is responsible to achieve all of above.  

Splash and Film Fill Media: 
As the name indicates, splash fill media generates the required heat exchange area by splashing action of water over fill media and hence breaking into smaller water droplets. Thus, surface of heat exchange is the surface area of the water droplets, which is in contact with air. 

Film Fill and its Advantages
In a film fill, water forms a thin film on either side of the fill sheets. Thus area of heat exchange is the surface area of the fill sheets, which is in contact with air. Typical comparison between various fill media is shown in Table 7.3. 

Due to fewer requirements of air and pumping head, there is a tremendous saving in power with the invention of film fill. Recently, low-clog film fills with higher flute sizes have been developed to handle high turbid waters. 
For sea water, low clog film fills are considered as the best choice in terms of power saving and performance compared to conventional splash type fills.  

Choosing a Cooling Tower 
The counter-flow and cross flows are two basic designs of cooling towers based on the fundamentals of heat exchange. It is well known that counter flow heat exchange is more effective as compared to cross flow or parallel flow heat exchange. 
Cross-flow cooling towers are provided with splash fill of concrete, wood or perforated PVC. Counterflow cooling towers are provided with both film fill and splash fill. 
Typical comparison of Cross flow Splash Fill, Counter Flow Tower with Film Fill and Splash fill is shown in Table 7.4. The power consumption is least in Counter Flow Film Fill followed by Counter Flow Splash Fill and Cross-Flow Splash Fill. 

Efficient System Operation 
I  Cooling Water Treatment 
Cooling water systems is one of the Critical utility in Power plants, process industries and in Airconditioning systems. The power plant performance, Chiller performance have direct effect on energy consumption, based on Cooling water temperatures which in turn is maintained by good cooling water treatment. The various problems in Cooling water system and the corrective measures required are discussed below.  

a) Water Side Problems 
Usually the typical problems that any (Open) cooling system meets with are:
 © Corrosion and/or Scale formation
 © Biological/Micro-biological fouling  

Corrosion: 
Corrosion, being not a precisely understood phenomenon, is a function of various factors of which the following are the main factors responsible for promoting corrosion in the system; high salinity of the water, low PH, low Alkalinity, presence of corrosive gases (mainly oxygen and CO,), dissimilarity of the metals etc. 
Corrosion can either lead to failure of the metallurgy (leakages in the heat exchangers) and/or deposit formation of corrosion products.  

Scale Formation: 
The main sources for the scale formation in the Open Evaporative Condenser circuit are: Hard water containing, high levels of Calcium and Magnesium, high level of PH and Alkalinity. An open evaporative cooling systems (condenser water systems) operated on softened water can meet with severe scaling problems when 
¢ PH of the circulating water is above 9.0
¢The total Alkalinity as CaCO, is above 550 ppm 
¢ Temporary hardness in the sources of make-up is above 200 ppm

Biological/Micro-Biological Fouling 
Systems exposed to sunlight (mainly cooling tower) often meet with severe problem of algae formation. Other problems associated with algae are slime mass, fungi and various species of bacteria. 

Bacteria being miniature bodies, of which growth is not controlled, can lead to the formation of fine masses of suspended particles that lead to fouling and deposit formation. Algae obviously block the nozzles of the cooling tower and thus reduce temperature drop across the tower. Slime masses again are responsible for fouling and deposit formation.  

Deposit Formation: 
Foreign matter such as; turbidity, sand, silt, mud, air borne debris and other suspended impurities are the sources of deposits formation. Corrosion products that are formed also add to the deposit formation. 

b) Energy Losses: 
Regardless of the type of system, be it open or closed, if it meets with any of the above problems, either the cooling tower nozzles are blocked resulting in reduced Delta ‘T’ and/or the deposits/scales are formed on the heat transfer surfaces. 
For example, the energy losses due to scale and deposit formation in a cooling water circuit of a refrigeration system are significant as shown in Table 7.5. The scale and deposit on the heat transfer area In process equipment can also cause production loss. 
c) Solution to the Problems 
ON line / OFF Line Chemical Cleaning
Depending on the criticality the plant management may adopt ON line/ OFF line cleaning systems.

Preventive Treatment 
For preventive treatment, a wide range of chemicals are available in the market and formulations manufactured by reputed companies are generally very safe to use in the system.  

Corrosion/Scale Inhibitors 
To control corrosion and scale formation depending upon the severity of each of the problem, either or both chemicals should be used and the selection of the chemicals should be made in accordance with the quality of the make-up water available for plant operation.  

Dispersants (For Deposit Formation) 
Suitable dispersants help in controlling the deposit formation and selection of the dispersants is made in accordance with the nature of suspended solids/deposits forming particulate present in the water. 

Side Stream Filter
Circulating water having very high levels of turbidity and/or suspended impurities should be facilitated with side stream filters. Side stream filters are generally selected to handle 2% to 5% of the total rate of circulation, but to ensure that the total water content in the system (hold-up volume) is filtered approximately once in 12 hours.

Bio Dispersants and Biocides 
To combat problems arising due to the growth of biological and micro biological species, such as algae, fungi, slime, bacteria etc. It is very essential to select a combination of oxidizing and nonoxidizing biocides. Bio-dispersants are used to remove the upper layer of the biological masses and allow better penetration of biocides in the lower layers of bio-masses. 

Chlorination 
Chlorination is the most effective and most economical oxidizing biocide. Chlorination for the smaller systems may be done with hypo chlorite based products and for the larger systems having hold-up volume in excess of 100 m? be done with suitable gas chlorinators. The safest gas chlorination equipment are vacuum gravity feed type which can be easily installed on either 50 kg or 100 kg chlorine cylinders. 

Drift Loss in the Cooling Towers 
It is very difficult to ignore drift problem in cooling towers. Now-a-days most of the end user specification calls for 0.02% drift loss. With technological development and processing of PVC, manufacturers have brought large change in the drift eliminator shapes and the possibility of making efficient designs of drift eliminators that enable end user to specify the drift loss requirement to as low as 0.003 — 0.001%.

Cooling Tower Fans 
The purpose of a cooling tower fan is to move a specified quantity of air through the system, overcoming the system resistance which is defined as the pressure loss. The product of air flow and the pressure loss is air power developed/work done by the fan; this may be also termed as fan output and input kW depends on fan efficiency. 
The fan efficiency in turn is greatly dependent on the profile of the blade. An aerodynamic profile with optimum twist, taper and higher coefficient of lift to coefficient of drop ratio can provide the fan total efficiency as high as 85-92 %. However, this efficiency is drastically affected by the factors such as tip clearance, obstacles to airflow and inlet shape, etc. 
As the metallic fans are manufactured by adopting either extrusion or casting process it is always difficult to generate the ideal aerodynamic profiles. The FRP blades are normally hand moulded which facilitates the generation of optimum aerodynamic profile to meet specific duty condition more efficiently. Cases reported where replacement of metallic or Glass fibre reinforced plastic fan blades have been replaced by efficient hollow FRP blades, with resultant fan energy savings of the order of 20-30% and with simple pay back period of 6 to 7 months. 
Also, due to lightweight, FRP fans need low starting torque resulting in use of lower HP motors. The lightweight of the fans also increases the life of the gear box, motor and bearing is and allows for easy handling and maintenance. 

Performance Assessment of Cooling Towers
In operational performance assessment, the typical measurements and observations involved are: 1.Cooling tower design data and curves to be referred to as the basis. 
2. Intake air WBT and DBT at each cell at ground level using a whirling pyschrometer.
3. Exhaust air WBT and DBT at each cell using a whirling psychrometer. 
4.CW inlet temperature at risers or top of tower, using accurate mercury in glass or a digital thermometer. 
5.CW outlet temperature at full bottom, using accurate mercury in glass or a digital thermometer.
6.Process data on heat exchangers, loads on line or power plant control room readings, as relevant.
7.CW flow measurements, either direct or inferred from pump motor kW and pump head and flow characteristics. 
8. CT fan motor amps, volts, kW and blade angle settings 
9.TDS of cooling water. 
10.Rated cycles of concentration at the site conditions. 
11.Observations on nozzle flows, drift eliminators, condition of fills, splash bars, etc. 
The findings of one typical trial pertaining to the Cooling Towers of a Thermal Power Plant 3 x 200 MW is given below:

Observations 
Unit Load 1 & 3 of the Station                      = 398 MW 
Mains Frequency                                           = 49.3
Inlet Cooling Water Temperature °C             = 44 (Rated 43°C) 
Outlet Cooling Water Temperature °C           = 37.6 (Rated 33°C) 
Air Wet Bulb Temperature near Cell °C        = 29,3 (Rated 27.5°C) 
Air Dry Bulb Temperature near Cell °C        = 40.8°C
Number of CT Cells on line with water flow = 45 (Total 48) 
Total Measured Cooling Water Flow m3/hr   = 70426.76 
Measured CT Fan Flow m3/hr                       = 989544  
Comments 
¢ Cooling water flow per cell is much lower, almost by 16.5%, need to investigate CW pump and system performance for improvements. Increasing CW flow through cell was identified as a key result area for improving performance of cooling towers. 
¢ Flow stratification in 3 cooling tower cells identified.
¢ Algae growth identified in 6 cooling tower cells. 
¢ Cooling tower fans are of GRP type drawing 36.2 kW average. Replacement by efficient hollow FRP fan blades is recommended.

Flow Control Strategies
Control of tower air flow can be done by varying methods:
1.Starting and stopping (ON-OFF) of fans, 
2. Use of two- or three-speed fan motors,
3.Use of automatically adjustable pitch fans, and 
4.Use of variable speed fans. 
ON-OFF fan operation of single speed fans provides the least effective control. Two-speed fans provide better control with further improvement shown with three speed fans. Automatic adjustable pitch fans  and variable-speed fans can provide even closer control of tower cold-water temperature. In multi-cell towers, fans in adjacent cells may be running at different speeds or some may be on and others off depending upon the tower load and required water temperature. Depending upon the method of air volume control selected, control strategies can be determined to minimise fan energy while achieving the desired control of the Cold water temperature.

Energy Saving Opportunities in Cooling Towers
— Follow manufacturer’s recommended clearances around cooling towers and relocate or modify structures that interfere with the air intake or exhaust.
- Optimise cooling tower fan blade angle on a seasonal and/or load basis. 
— Correct excessive and/or uneven fan blade tip clearance and poor fan balance. 
- On old counter-flow cooling towers, replace old spray type nozzles with new square spray ABS practically non-clogging nozzles.
— Replace splash bars with self-extinguishing PVC cellular film fill. 
- Install new nozzles to obtain a more uniform water pattern 
— Periodically clean plugged cooling tower distribution nozzles. 
- Balance flow to cooling tower hot water basins. 
- Cover hot water basins to minimise algae growth that contributes to fouling.
- Optimise blow down flow rate, as per COC limit.
- Replace slat type drift eliminators with low pressure drop, self extinguishing, PVC cellular units.
— Restrict flows through large loads to design values.
- Segregate high heat loads like furnaces, air compressors, DG sets, and isolate cooling towers for sensitive applications like A/C plants, condensers of captive power plant etc. A 1°C cooling water temperature increase may increase A/C compressor kW by 2.7%. A 1°C drop in cooling water temperature can give a heat rate savings of 5 kcal/kWh in a thermal power plant. 
— Monitor L/G ratio, CW flow rates w.r.t. design as well as seasonal variations. It would help to increase water load during summer and times when approach is high and increase air flow during monsoon times and when approach is narrow. 
- Monitor approach, effectiveness and cooling capacity for continuous optimisation efforts, as per seasonal variations as well as load side variations. 
- Consider COC improvement measures for water savings. 
- Consider energy efficient FRP blade adoption for fan energy savings. 
- Consider possible improvements on CW pumps w.r.t. efficiency improvement.
— Control cooling tower fans based on leaving water temperatures especially in case of small units.
- Optimise process CW flow requirements, to save on pumping energy, cooling load, evaporation losses (directly proportional to circulation rate) and blow down losses. 

Case Study: Application of VFD for Cooling Tower (CT) Fan 
The rating (KW) of the CT fan is selected for the worst case wet and dry bulb temperatures. In areas where such temperature conditions occur for a small portion of the year & which require maximum air flow for this condition, 
it is possible to improve energy efficiency by reducing the speed of the fan (to obtain reduced air flow), using a VFD. It is therefore necessary to obtain data for the variations in wet and dry bulb temperatures on an annual basis to arrive at estimates for the energy saved through use of VFD. Alternatively, it is also possible to install a VFD on a trial basis on the CT fans and measure the electrical power consumed with and without VFD. 
The relationship between the power consumed by the CT fan and the airflow delivered by it follows a cube law. The potential for energy savings exists if a proper analysis of the cooling system is made. 

Implementation with VFD 
An energy efficient system with VFD can be realized through the use of closed loop control. In this control method, the return or cold water temperature is used as the feedback signal to the PID controller which is a standard control block in the drive. 


The highlights of control with temperature feedback and drive can be summarized below: 
1.An RTD sensor, installed at the CT outlet generates a 4-20 mA current signal as the feedback to the integrated Process PID Controller in the drive. 
2.The set point for the cooled water temperature is entered in engineering units (°C or °F) in the drive controller.
3.Any error between the set point and the feedback signal (temperature in this case) will be integrated by the PID controller so that the same, after correction, is zero. For example, if there is an increase in the outlet temperature (due to wet bulb temperature increase or due to an increase in plant load), the feedback exceeds the set point & the error A becomes negative. The PID controller output will now try to increase the drive frequency so that the fans deliver more cooling air for evaporation. This has the effect of bringing down the outlet temperature. The correction continues till the feedback signal matches the set point. A similar correction takes place when the outlet temperature reduces. In that case, the CT fan motor speed is reduced to bring the A value to zero.
4.This design therefore permits precise control of outlet temperature and conserves energy.
5.In the event of drive failure, the CT fans can still be operated through an optional built-in bypass circuit which will transfer the power source to the mains supply, thereby ensuring uninterrupted operation.

Use of VFD for CT fan motors in Ingot manufacturing plant 
An aluminium ingot manufacturing plant requires large amounts of water for cooling of the ingots. Hence cooling tower fans are required to cool the water from the ingot plant. The salient features of the application are as given below: 
1.Drives have been installed on two Cooling Towers. 
2. Details of drives supplied as follows:

Details of control and power consumption The previous method of control employed a digital temperature controller to switch ON & OFF the CT Fans depending upon the basin temperature. A typical daily regimen employed for CT#1 was as follows: 
(a) 3 Nos. CT Fans running for 8 Hours. 
(b) 2 Nos. CT Fans running for 8 Hours.
(c) 1NoCT Fan running for 5 hours.
Trials were taken with the VFD (common to 3 nos. drive motors as shown in Figure 7.6 below) installed in CT  and run for a period of one month to ascertain the power consumption with and without the drive.
It was compared with the power consumed with manual operation (as described above) on a daily basis. It yielded a significant result in terms of power saved daily.

Savings calculation with VFD operation:  
Energy consumed daily with manual control (kWh)      = 392 
Energy consumed daily with VFD control (kWh)          = 254 
Energy saved on daily basis with VFD control (kWh)   = 138 
Energy saved on daily basis with VFD control (%)        = 35.2 
Unit energy cost (INR)                                                    = 5 
Number of days of running of fans in a month                = 26 
Number of months in a year                                             = 12 
Annual savings due to VFD operation (INR)                  = 215280
Average price of drive panel (INR)                                  = 250000 
Payback period (Year)                                                      = 1.16 
*Data for savings extrapolated for annual estimates 

In practice, the power saved with VFD operation would also depend upon the wet bulb temperature which would vary on a seasonal basis. In case of higher temperatures, the VFD would be required to run at maximum speed during which period, the savings would be negligible. Hence the average annual savings would reduce depending upon the site environmental conditions. The quantum of savings can be optimized by having a closed loop system as shown above which will track the outlet water temperature and determine the drive motor speed accurately. 

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