TECHNICAL NOTE REGARDING COST SAVING BENEFIT OF OUR SERVO STABILISER
Voltage fluctuation is a common phenomenon all over the country. Generally voltage is very low during daytime and high during night hours. Therefore, Industrial Units running round the clock, face the problem of both Low and High Input Voltage. Also, voltage fluctuation is a seasonal phenomenon and increases in summer season. Moreover on holidays, peak hours, rainy days and when the agricultural load is switched off, the voltage rises sharply in the feeder lines. There are few consumers of electricity, in these days, there is comparatively lesser voltage drop in the feeder lines as a result consumers suffer from high voltage which is more dangerous.

Electrical equipment are designed for 230 volts (single-phase) or 400 volts (3-phase) and operate with optimum efficiency at its rated voltage 90% of industrial load consists of motors. Electric motor draws considerably high current at high voltage and increases energy consumption, increases MDI and reduces power factor etc. These excessive power losses of motors generated at higher voltage results in premature failure of electrical equipments.

Similar is the case with bulbs and tubes, when voltage increases above 230 volts. For example, at 270 volts, the power consumption of 60W bulb increase by almost 40% and the life of the bulb reduces from normal 1000 Hours to mere 100 Hours only (as per analysis report of ISI marked bulb manufacturers).

We have done an analysis on electrical equipments such as motors, bulbs, tubes etc. for variation in current drawn at different voltage. It is found in the analysis that with the increase in the voltage above 390/400 vots, the current drawn by the electrical equipments increases sharply, thereby resulting in breakdown of electrical equipment, increases energy consumption, increases MDI and reduces power factor etc.

You can verify these facts in your premises by nothing down hourly readings of voltage and current on particular motor having constant load on them for few days.

HOW TO ASSESS POSSIBLE SAVINGS:

You must be having Electronic Energy Meter installed in your works, you can easily verify and ascertain the ENERGY savings possible by recording the periodic (hourly) readings of KW and KVA corresponding to voltage.

From the recoded readings-different input voltages can be segregated in bands and the corresponding KW consumption. For example, 320-330V, 330-360V, 350-390V, 390-400, 400-410, 410-420, 420-430……. 450-460 volts (voltage readings in steps of 10 vots bands) and the relevant KW consumption reading, The sum total of different KW consumption readings of particular voltage band can be divided with number of readings taken-to arrive at the average KW consumption at that voltage band.

From this data-sheet, you will find that overall KW consumption at 390-400 volts input voltage band will be minimum. Similarly, the overall KW consumption at other High/Low input voltage conditions will be high and it can be saved by maintaining 390/400 volts by installing the Servo Voltage Stabilizer.

NOTE:

You may strike out the abnormally High/Low KW consumption readings from data-sheet, because these may be due to different load conditions than normal running load. This will give more precise and accurate analysis.

Also, you can workout the average monthly failure rate of electrical equipments e.g. electric motors, bulbs, tubes, mercury lights, contactor coils and electronic circuits etc. and the expenses incurred on repair/replacement of them.

We have installed number of Automatic Voltage Controllers to different type of industries throughout India and our customers have confirmed substantial advantages after installing the Automatic Voltage controllers Following data gives an approximate quantitative advantage of Voltage Stabiliser at various levels of voltage fluctuations:

1.   REDUCTION IN BREAKDOWN OF ELECTRICAL EQUIPMENTS:
      60-80% depending upon the input voltage variation and working hours of the plant.

2.   ENERGY SAVING:
      5-10% depending upon the Input voltage variation and working hours of the plant.

3.   REDUCTION IN MDI:
      There will be definite reduction in MDI by 10-15% after the installation of the equipment.

4.   IMPROVEMENT IN POWER FACTOR:
      There will be definite improvement in the power factor by 10-15% after the installation of the equipment.

5.   Depreciation allowance @ 100% as per income Tax Act.

6.   Uniform Quality of End Products.


PAYBACK PERIOD OF 500 KVA CAPACITY SERVO VOLTAGE STABILIZER:

Owing to its high efficiency and associated benefits, the payback period of SUVIK's Servo Voltage Stabilizer is within 10-18 months and depends upon the input variation and the number of working hours.

The cost of our 500 KVA Stabilizer with input 360-460 Volts & output 400 Volts is Rs. 3,50,000/-.

Approximate Power Bill of the 500 KVA stabilizer considering 50% running load and assuming that the plant is running 20 hours daily for 25 days in a month and the tariff is charge @ Rs. 3.50 per Unit will be Rs. 4,00,000/-.

1. 5% Saving in Power Bill on account of voltage fluctuation The Power saving can be 10%, : Rs. 20,000/-
if you are getting higher voltage most of the time
2. As per the customer feed back the failure rate of their Electrical equipments reduced upto : Rs. 10,000/-
80% after installing the stabilizer. Thereby saving in the cost of repairs/replacement of
burnout equipment.
3. Better production in plant due to lesser breakdown in production will generate additional earning. : Rs. 10,000/-
  TOTAL SAVING PER MONTH   : Rs. 40,000/-

In addition to the above there are certain over heads such as staff to purchase above material, maintain and install the above material.

From the above it is clear that cost of equipment will be recovered with in a period of 10-12 months and in subsequent years it will give you additional earning of approx Rs. 40,000/- per month.