Energy Audit Definition:Energy audit Types of energy audit, Understanding energy costs Bench marking Energy performance Fuel and energy substitution Energy audit instruments
Energy Audit Definition:Energy audit
Types of energy audit, Understanding energy costs
Bench markingEnergy performance
Fuel and energy substitution Energy audit instruments
Conversion Factors for MTOE
1 Kwh = 860 Kcal1 kg of coal/coke = GCV in Latest Certificates 1 kg FO/LSHS/Naptha = 10500 Kcal/kg (density = 0.93)1 kg HSD = 11840 Kcal (density = 0.82)1 kg Petrol = 11200 Kcal (density = 0.708)1 kg Kerosene = 11110 Kcal (density = 0.778)1 kg LPG = 12500 Kcal1 m3 of Natural gas = 8000-10500Kcal (actual as per
certificate) 1 kg of oil equivalent = 10,000 Kcal
Energy Conservation ActDesignated consumers : Central Govt. specify the
following criteria for energy Intensive Industries and other establishments. (As per EC Act 2001, Section 14(e)
For Industries
Electrical connected load -5000 KW and above
or
Annual energy consumption - 30,000 MTOE
For Commercial Buildings
Connected Load - 500 KW or 600 KVA
ELECTRICITY ACT 2001 MAIN FEATURES 1. Replaced all the previous three Electricity
Laws:– Indian Electricity Act 1910,
Electricity Supply Act 1948– Electricity Regulatory Commission
Act 1998 as amended from time to time
2. 100% metering is mandatory for 11 KV feeder
3. 100% Rural Electrification– Accelerated Rural electrification Program,
AREP)– PRIs & NGOs can be participated)– 80,000 villages yet to be electrified
ELECTRICITY ACT 2001(Contd..)
4. Private sector Investments is allowed in Renewable Energy Sources (Generation, Distribution, Supply area)– No license is required for generation and
distribution of power in Rural areas.
5. Participation in power transmission sector
6. More stringent provision for theft of electricity
ELECTRICITY ACT 2001(Contd..)
7. Delicensed for Captive power generation, Thermal power generation, Hydro power generation – can be sold directly to other consumers by
wheeling through the grid under open access
– Banking facility is provided to captive power plants
8. State Electricity Regulatory Commission is mandatory for all States
Definition of Energy Audit
As per the Energy Conservation Act, 2001, Energy Audit is defined as
“the verification, monitoring and analysis of use of energy including submission of technical report containing recommendations for improving energy efficiency with cost benefit analysis and an action plan to reduce energy consumption “
Objective of Energy ManagementTo achieve and maintain optimum energy
procurement and utilisation, throughout the organization
To minimise energy costs / waste without affecting production & quality
To minimise environmental effects.
TO KNOW TECHNICAL PERFORMANCE OF MAJOR EQUIPTMENT / SYSTEMS
TO IDENTIFY LOSS AREAS
TO ASSESS TECHNO ECONOMIC FEASIBILITY OF ENCON OPTIONS.
ENERGY AUDIT…..It’s a tech.Survey to analyze existing energy utilisation practice, pinpoint areas of wastage and to evolve energy saving schemes. •It is an organised and systematic exercise with top management support
•Energy audit addresses •House keeping •Operational improvement/retrofits•Capital projects requiring investment•New technology
•Energy audit helps to achieve “savings through invisibles”.
Types of Energy Audit
1.Preliminary energy audit
2.Detailed energy audit
Safety Considerations
The audit person or team should be thoroughly briefed on safety equipment and procedures
Adequate safety equipment should be worn at all appropriate times.
Auditors should be extremely careful making any measurements on electrical systems/on high temperature devices.
Preliminary Audit Site Survey:
Take a walk through survey /Observations Collection of existing energy and production
records of the entire plant and major energy consuming facilities and departments.
Brief data analysis and preparation of documentation.
Identification of preliminary energy saving measures, including an estimation of saving potentials and economic aspects
INDUSTRIAL ACTIVITIES
Final ProductFinal Product
Raw MaterialsFluids
Raw MaterialsFluids
ManpowerManpower
EnergyEnergy
Industrial Wastes
LIQUIDtoxic, inorganicand organicwastewaters
GASEOUSEmissionsSO2 , NOx,CO, etc.
SOLID WASTESwasted raw materialor product, sludge fromETP
DISCHARGE
ENERGYheated fluids,steam, hotemissions etc.
TYPICAL PLANT UTILITIES & SCOPE AREAS
BOILERS/FURNACES
PUMPS
FANS
AIR COMPRESSORS
A/C PLANTS
COOLING TOWER
TRANSFORMERS
MOTORS
DG SETS
LIGHTING
ELECTRIC HEATERS
Process Flow Diagram Spinning Mils
Raw Cotton
Blowroom
Carding
Drawing
Combing
Simplex
Ring framespinning
CheeseWinding
Doubling
Cone winding
Utility
Electricity
Humidifin..
Comp.air
Lighting
Production
Yarn
Power Consumption Pattern in Spinning Mills
15%
45%
10%
18%
7%
5%
Pre Spinning
Spinning
Post Spinning
Humidification
Compressor
Lighting
Typical Specific Energy Consumption Norms in Textile Industry
COMPOSITE MILLS Thermal Energy = 19.0 Kg Steam /Kg of cloth Electrical Energy = 2.2 Kwh /Kg of cloth
SPINNING MILLS Electrical Energy = 3.6 Kwh /Kg of yarn (UKG adjusted to 40 counts)
Preliminary Energy Audit Methodology
It uses existing and easily obtained data Establish energy consumption patternEstablishes base line dataIdentify the most likely areas for attention/savingsIdentify immediate(no/low-cost) improvementsIdentify areas for more detailed study/measurementHelps in planning for Detailed audit(Team/instrument/Duration required)
Detailed Energy Audit
Evaluates all energy using system, equipment and include detailed energy savings and costs
Different phases of Detailed Audit– Pre-audit Phase (Preliminary audit)– Audit Phase (Instrumented/Comprehensive)– Brief presentation,Report Preparation/Vendor details
collection– Draft Report presentation and Final Presentation– Post-Audit
PLANT ENERGY AUDIT COVERS
ENERGY GENERATING EQUIPMENTS ENERGY DISTRIBUTION NETWORK END USE EQUIPMENTS.
OPERATIONAL FEATURES PLANT.
1. CONTINUOUS PROCESS PLANT
2. ONE/TWO SHIFT OPERATION
3. INTERMITTENT.
????????????????? What type of energy used How much energy is used? How much does it cost? Where it is used? How efficiently it is used? How can it be managed more efficiently
and effectively?
This is identified through carrying out ENERGY AUDITs
STEPS INVOLVED IN ENERGY AUDIT.
1. Data Collection
2. Efficiency Evaluation
3. Loss Quantification
4. Operational Improvement Measures
5. Techno Economic Evaluation of Projects.
6. Designing Energy Data Report System
7. Instrumentation Requirement
8. Action Plan For ENCON Implementation
9. Review --Setting Up of Target
SCOPE OF “DEA” TO INDICATE
CAPABILITIES & EFFICIENCY OF EQUIPMENT
NEED FOR AUTOMATIC CONTROLS
ADEQUACY OF MAINTENANCE
NEED FOR IMPROVED INSTRUMENTATION
SCOPE AREAS FOR ENERGY SAVING
COST BENEFITS OF SPECIFIC MEASURES IN SHORT /
MEDIUM / LONG TERM
MECHANISM OF MONITORING
VENDOR INFORMATION
INCENTIVE SCHEMES / PROVISIONS
Detailed Energy audit tasks:-
1. Elaboration and discussion of audit methodology.
2. Selection of plants items to be audited.3. Collection of more detailed energy and
production data.4. Comprehensive measurements at
selected plants items.• Process flow and utility diagram• Measurement survey/performance trials
5. Data analysis and calculations6. Elaboration of energy and material
balance for the audited plant items.
7. Investigation of energy saving options (improved maintenance of equipment, improved energy management, modification or rationalization of process configuration, improved insulation/ control of refrigeration, etc.)
8. Recommendation of feasible energy efficiency measures.
9.Financial analysis of recommended measures, including cost benefit calculation.
10.Ranking of measures and elaboration of an energy saving action plant
11.Reporting 12.Presentation to plant management
DATA COLLECTIONHow Much Data ?
What Data ?
Data Availability –Plant Records-metering
How To Proceed In Case Of Data Not Available
To Know Source of Information
Experience To Device Data From Secondary Information
Planning For Field Trials And Observation
Plant data
Present landed cost of all types of energy used in the plant.
Types of energy used :Electricity, Fuel oil , Coal, Gas
Annual energy consumption and cost for all purchased and internal fuel .(3 years)Monthly purchased electricity & self generated.
• Month,kva,kwh,PF,bill amount. (Grid Power)• Month,kva,kwh,PF,fuel cons.(Captive power plant)
Annual Production for Past 3 Financial Year To know seasonal variation to know production and energy trend
Electricity Tariff StructureWhat are the elements of Electricity Bill ?
Elements TNEB APSEB KEB Gujarat / Maharashtra
MD Charge Rs.300/KVA RS.117/KVA <1000 kwMinimum 90% of CMD RS.116/KVA 1000-3000
Rs.115/kva > 3000 KwMD Penalty Rs 600/Kva Rs. 225/Kva
Energy 3.5.00 P/Unit Rs.1.8 <400 kwhcharges Rs.1.6 >400 kwh
TOD Tariff 6 - 9 AM/PM 10AM-6PM Oct-Feb 20% more 2 PM-10PM Mar- Sep 20paise /unit more
PF minimum 0.9 0.85
PF Penalty <.9 2P unit for each 1% decrease in PF below .85
SPECIFICATION OF MAJOR ENERGY CONVERSION EQUPT. • BOILERS• HEATERS• FURNACES• THERMIC FLUID HEATER• POWER GENERATING UNITS
DETAILS OF MAJOR UTILITIES(PUMPS/FANS/COMPRESSORS)• MAKE • TYPE• CAPACITY• SINGLE STAGE/MULTISTAGE• FLOW, HEAD• DESIGN KW – EFFICIENCY• CAPACITY CONTROL METHOD• ACTUAL REQUIREMENTS• ANNUAL OPERATING HOURS• Operating Schedule(Design and Operating parameters)
Benchmarking • Internal Benchmarking
• Historical and trend analysis
• External Benchmarking Across similar industries
•kWh/MT Cement produced (Cement Industry)
•kWh/MT Paper produced (Paper Industry)
•kWh/ton of refrigeration (AC&R PLANT) /kWh /litre (DG Sets)
Energy cost as a percentage of total
manufacturing cost - 30 to 60 %
Generally a decreasing trend in specific energy consumption
Specific power consumption varies from 66 to 127 kWh per tonne of cement
Specific thermal energy consumption varies from 692 to 879 kCal/kg clinker
Energy Conversion
Boiler efficiency,Quality of Fuel used,
Maintenance
EnergyTransfer
Insulation of Steam piping,Jackets for hot fluid pipes to
prevent losses
EnergyUtilization
Equipment efficiency, Maintenance,
Energy Recovery
Waste heat exchangers,
Energy Conservation
Product
Waste
Raw materials
Separation EquipmentSeparation EquipmentHeat Recovery
Heat Recovery
By ProductMaterialbalance
Cause and Effect AnalysisCost-benefit analysis
Brainstorming
Process 2Process 2Process 1Process 1
Recovery
Recycle, Reuse and Recovery
Fuel and Energy Substitution
Fuel substitutionReplacement of coal by Agro fuelsReplacement of LDO by LSHS
Energy substitutionElectric heaters by steam heatersSteam based hot water by solar
systems
ENERGY AUDIT REPORT1. ACKNOWLEDGEMENT2. CONTENTS3. EXECUTIVE SUMMARY4. SUMMARY OF SAVINGS5. INTRODUCTION6. PLANT ENERGY SYSTEM7. ENERGY USAGE PATTERN8. ENERGY INDICATORS9. ENERGY SAVING
OPTIONS/RECOMMENDATIONS10.ANNEXURE/PLANT BASE LINE DATA
Filed observation and savings calculations.List of suppliers .Action plan for ENCON implementation
Technical and Economic feasibility Name of Energy Efficiency Measure 1. Investment
Equipments Civil works Instrumentatio
n Auxiliaries
2. Annual operating costs Cost of capital Maintenance Manpower Energy Depreciation
3. Annual savings Thermal Energy Electrical
Energy Raw material Waste disposal
Net Savings /Year (Rs./year) = (Annual savings-annual operating costs) Payback period in months = (Investment/net savings/year) x 12
Energy Audit Instruments
Electrical Measuring Instruments: These are instruments for measuring major electrical parameters such as kVA, kW, PF, Hertz, kvar, Amps and Volts. In addition some of these instruments also measure harmonics. These instruments are applied on-line i.e on running motors without any need to stop the motor. Instant measurements can be taken with hand-held meters, while more advanced ones facilitates cumulative readings with print outs at specified intervals.
POWER ANALYSERS
Measurement Technology
-Measures @256 samples/cycle for better accuracy even on non-linear waveforms
-Continuous & simultaneous sampling on all 6 channels for accurate readings on dynamic loads
Accuracy far superior when compared to conventional analyzers with low sampling rate
New Generation Measurement Techniques
Application – Textile Mill Study
Readings of KRYKARD Load Manager ALM 30
Readings of Low & non-continuous sampling meter
THD in % P.F THD in %
KWh (% error)
P.F
8% 0.882
15% 0.837
36% 0.864 36% -1.2% 0.82
52% 0.881 46% -2.77% 0.74
74% 0.880 81% -8.2% 0.68
This picture is taken using the Screen shot feature of ALM/3032. You can see that the ALM 30/32 is highly accurate even on non-linear loads thanks to the new generation measuring techniques used by it.
FLUE GAS ANALYSERS
TEMPERATURE MEASURMENTS
FLOW MEASURMENTS – AIR ,WATER
Portable Instruments Budget Price (Rs)
1
Three phase Power Analyzer. (V, A, KW, KVA, KVAR, PF,
HZ and THD)
2,60,000
2 Single Phase Power Analyzer with THD
90,000
3 Megger & Resistance Meter 50,000
4 Lux Meter (Digital) 7,000
5 Ultrasonic Flow Meter 4,00,000
6 Pitot Tube & Monometer 60,000
7 Digital Animometer 15,000
8 Hot Wire Animometer 7,000
9 Contact & Non-Contact Tachometer (Speed)
5,000
10
Thermal :Flue Gas Analyzer
(O2, CO and Template)
1,50,0
00
11 Humidity Meter (Digital) - For Aircondition Space Survey
12,000
12 Leaf Probe Surface Temp. Indicator
6,000
13 Stroboscope 5,000
14 Thermocouple for Liquid Gas and High Temp.(0-100oC, 0-500oC, 2000oC)
30,000