Energy Auditing

CHAPTER -1

CHAPTER-1

INTRODUCTION:

With increase in demand in energy and deficient in power generation, the cost of

power is going to increase manifold. This will worsen the cost of lining if new technology

energy efficient fittings and machines are consuming more power. The energy savings can be

accomplished by efficient use of power and judiciously employing energy management

programmers. Energy Audit likes, a financial audit is a systematic and scientific process to

identify the potential for improvements in energy efficiency, to recommend the ways, with or

without financial investment, to achieve estimated savings in energy and energy cost. This

requires collection &analysis of existing energy usage data, careful study of existing

equipment and the process and then suggesting practical& economic ways for saving energy

&energy cost .The greatest malady that has plagued power supply utilities is the scourge of

transmission and distribution losses. Although the menace of transmission & distribution

losses in a power system in inevitable, yet these need to be continuously monitored and

mitigated to reasonable limits. Transmission & Distribution losses in power system account

for the energy lost in transit from the sending end to the receiving end. In the present era,

more generation of power is not sufficient; the prime concern is how we make power

available to the consumer that is reliable and at affordable cost.

Any changes in the power sector right from generation to transmission to distribution to the

consumer should focus on the customer.

CHAPTER -2

CHAPTER-2

2.0 COMPONENTS

2.1 Main Energy Consumptions:

Based on our data the main energy consumption in our college is

• Fans

• Tube lights

• CFL lights

• CRT monitors

• Air conditioners

• Printers

• Projectors

• Freezers

• Xerox machines

2.2 Instruments used for conducting energy audit:

Fig: 1

TABLE-1

2.3 EQUIPMENT WATTAGES:

Old equipment Total wattage New equipment Total wattage

Fans 40.8kw Low wattage fans 28.05kw

Fluorescent tubes 16.4kw Led tubes 6.15kw

CFL lamps 1.279kw Led lamps 0.425

CRT monitors 22.10kw Led monitors 11.05

LCD monitors 6.4kw Led monitors 4kw

AC’ s 40kw Low power Ac’s 30kw

TOTAL 126.97KW TOTAL 79.625KW

TABLE-2

CHAPTER -3

CHAPTER - 3

3.1 Definition:

Energy is the capacity of a physical system to perform work. Energy exists in several

forms such as heat, kinetic or mechanical energy, light, potential energy, electrical or other

forms. According to the law of conservation of energy, the total energy of a system remains

constant, though energy may transform into another form.

To minimize costs for energy.

To minimize operational costs.

To minimize costs for repairs and reconstruction increase quality of environment that

contributes to increased work productivity. Energy audit is a systematic study or survey to identify how energy is being used in a

building or plant, and identifies energy savings opportunities. Using proper audit

methods and equipment, an energy audit provides the energy manager with essential

information on how much, where and how energy is used within an organization

(factory or building).

This will indicate the performance at the overall plant or process level. The energy manager

can compare these performances against past and future levels for a proper energy

management. The main part of the energy audit report is energy savings proposals

comprising of technical and economic analysis of projects. Looking at the final output, an

energy audit can also be defined as a systematic search for energy conservation

opportunities.

This information can be transformed into energy savings projects. It will facilitate the energy

manager to draw up an action plan listing the projects in order of priority. He will then

present it to the organization's management for approval. Providing tangible data enables the

management to be at a better position to appreciate and decide on energy efficiency projects.

Adopting this activity as a routine or part of the organization's culture gives life to energy

management, and controlling the energy use by energy audit is what we refer to as Energy

Management by Facts

3.2 What Offers EA To The Customer?

Identifies highest achievable potential of energy and costs savings and its effort,

points out on often visible as well as hidden technical/hygienic/safety deficiencies of

buildings and building and production technology equipment,... recommends technical

parameters of measures, calculates investment needs of measures, their asset economical,

technical environmental, proposes procedure for realization of measures, it is very effective

technical, economical and management tool for investment decision processes going out of

economical modeling, it is solid basement for effective control of energy consumption and

herewith also operational costs.

3.3 Types Of Energy Auditing:

• Preliminary energy audit.

• Detailed energy audit.

• Targeted energy audit

Inputs and Outputs of Energy audit

3.3.1 Preliminary energy audit:

• Establish energy consumption in the organization.

• Estimate the scope for saving.

• Identify the most likely (and the easiest areas for attention.

• Identify immediate (especially no-/low-cost) improvements/savings.

• Set a ‘reference point’.

3.3.2 Detailed energy audit:

• Detail audit is carried out for the energy savings proposal recommended in walk-through or

preliminary audit.

• It will provide technical solution option and economics analysis for the factory management

to decide project implementation or priority.

• A feasibility study will be required to determine the viability of each option.

3.3.3 Targeted energy audit:

Targeted energy audits are mostly based upon the outcome of the preliminary audit results. As

an example, an organization may target its lighting system or boiler system or compressed air

system with a view to bring about energy savings.

3.3.4Type of energy audit chosen depends on:

• Function and type of industry.

• Depth to which final audit is needed.

• Potential and magnitude of cost reduction desired.

3.5 Energy Audit:

An ideal way of identifying energy saving opportunities in your business is to conduct

an Energy audit. An energy audit is a fundamental part of any energy management

programme, which wishes to control its energy costs. Energy audits can be considered as a

first step understanding how energy is being used in a given facility. It indicates the ways in

which different forms of energy are being used and quantifies energy use according to

discrete functions .The energy audit is a balance sheet of energy inputs and outputs. The aim

of energy audit is to obtain a simple, but comprehensive photograph of the overall energy

flow situation within a declared system boundary, which may be a building, a factory, or a

product lane or an agricultural sector. This picture aids comprehension of the total overall

system activity, reveals inter-relations and allows priorities to be identified. It high lights

major areas where inefficiencies or waste occurs and allows economic estimates, leading to

fully reasoned investment decisions, to be considered. The energy audit enables analyzing the

data in meaningful manner to evolve measure to introduce checks and balances in the system.

3.5.1 Necessity:

Auditing of energy in electrical under taking has become increasingly important in

view of. Large energy shortages, mismatches in Demand and supply in all SEBs. Very low

sales & high T&D loss levels requiring identification of areas of rampant. Pilferage and

malpractices, due to organizational deficiencies. Deteriorating financial position, shortage of

funds for system improvement. Improving the efficiency of functioning of the power system

as also the personnel in the organization at each level. Analysis of expenditure/investment Vs

revenue. In any industry, the three top operating expenses are often found to be energy (both

electrical and thermal), labour and materials. If one were to relate to the manageability of the

cost or potential cost savings in each of the above components, energy would invariably

emerge as a top ranker, and thus energy management function constitutes a strategic area for

cost reduction. Energy Audit will help to understand more about the ways energy and fuel are

used in any industry, and help in identifying the areas where waste can occur and where

scope for improvement exists. The Energy Audit would give a positive orientation to the

energy cost reduction, preventive maintenance and quality control programmes which are

vital for production and utility activities. Such an audit programme will help to keep focus on

variations which occur in the energy costs, availability and reliability of supply of energy,

decide on appropriate energy mix, identify energy conservation technologies, retrofit for

energy conservation equipment etc. In general, Energy Audit is the translation of

conservation ideas into realities, by lending technically feasible solutions with economic and

other organizational considerations within a specified time frame. The primary objective of

Energy Audit is to determine ways to reduce energy consumption per unit of product output

or to lower operating costs. Energy Audit provides a “ bench-mark” (Reference point) for

managing energy in the organization and also provides the basis for planning a more effective

use of energy throughout the organization.

3.5.2 Energy audit is carried out with the following objectives:

Review and up gradation of procedure for energy accounting i.e., losses at various

levels. Review of technical efficiency of system elements in ST&D system by identification

of areas of technical & non technical losses. Suggest remedial action to reduce the losses by

various methods of system improvement, Conservation of energy, and load management,

curbing pilferage &plugging up leakages. Review of performance of equipment, meters and

distribution transformers etc. Analysis of the techniques for measuring energy received,

energy billed and revenue. To clearly audit the segregation of technical and non-technical

losses. Establishment of norms for checking the consumption of various categories of

consumers and overall energy balance.

3.5.3 The work undertaken during an audit may include:

Investigating the usage of all types of energy consumed and energy using equipment

within the building, complex or plant. Identifying the energy usage of all major heating and

cooling applications and its percentage against total energy use. Identifying cost-effective

measures to improve the efficiency of energy use. Estimating the potential energy savings,

indicative budget costs and payback periods. Reviewing energy management strategies,

including monitoring systems & evaluation process. The underlying current for the above

mentioned activities i.e., to get over all picture of energy availability and its use is to conduct

proper accounting.

3.5.4 Energy Accounting:

The energy accounting gives the overall picture of energy availability and its use.

Energy accounting involves preparation of energy accounts of the energy flow to various

segments of sub transmission and distribution system and supply to various categories of

consumers and how it has been consumed out of total available quantum over a specified

period. Preparation of electrical network database and documentation and consolidation of

consumer details would be the first step in energy accounting. In the area of energy

accounting, network metering and consumer metering system should be reviewed and

working, non-working, defective un-metered supply etc., should be documented for taking

corrective measures. It involves preparation of accounts of the energy flow to various

segments and various categories of consumers and how it has been consumed out of total

available quantum over a specified time period.

3.5.5 Objectives Of Energy Accounting:

Preparing an energy account on each feeder to record the quantum of energy received

and the quantum of energy supplied and billed to various categories of consumers.

Identifying areas where billing if revenue collection does not commensurate with energy

supplied. Improvement in metering, billing and revenue collection. Study & analysis of the

energy accounts to identify high loss areas. Segregation of energy losses in to technical losses

and non-technical/commercial losses. Identification of areas of high technical losses vis-à-vis

normal system losses. Identify remedial steps for reduction of both technical and commercial

losses. Constantly review, at least on a monthly basis, the progress made in regard to the

remedial action already initiated earlier.

3.6 Energy Accounting procedure:

The energy accounting is related to responsibility structure of SEB. Each junior

engineer has to be entrusted with responsibility of covering an 11KV feeder(s), which could

be feeding supply to number of consumers. He would be responsible to account for the

energy received by the feeder and proper billing of their connected consumers. Each

consumer should be identified with the. Distribution transformer through which he is fed, and

then each distribution transformer would be identified with the feeder on which the

transformer is installed. In turn, each 11kv feeder would be identified with the 33/11KV

substation from which feeder emanates and electric supply is received. The consumer

mapping is to be done by allotting a "code no." to each consumer, which would be his

"technical address" on the energy bill. The bill should also include the identification of meter

reader and application tariffs. Computerized billing software placed at division level should

be designed to capture the concept of tracking the consumers to the electrical network and

meter reader. Management information system reports of each feeder have to be generated

through suitable financial energy management system software package developed to meet

specific needs of circle. Proper and accurate precision meters and metering system is essential

for effective and correct energy accounting.

3.7 Metering System:

Realizing the importance of metering in establishing the energy accounting and

improved billing and revenue collection, it was decided at the government of India level in

Feb 2000 to have time-bound program for 100% metering up to consumer level by

December, 2001.Subsequently, in the meeting conducted by the minister of power on May

23, 2000, it was agreed to implement the program in two phases-(i) To 11kv level &H.T.

consumers by mar 2001(ii) consumer level by Dec 2001.

3.7.1 System Metering:

The metering plan for an effective energy accounting system should cover the input

points of the circle and identify receiving and transfer points at different voltage levels to

ultimately enable measurement of energy input to a 11kv feeder and thereafter to the ultimate

consumers.

3.7.2 Consumer Metering:

The consumer metering should be tamper proof and appropriate accuracy class meters

should be deployed for different categories of consumers:

(i.) Industrial consumers: Electronic meters of accuracy class 0.2 to 1.0 are recommended for

replacing the electro-mechanical meters.

(ii)Use of electronic TOD (time of day) maximum demand meters (M D): The electro

mechanical MD meters should be replaced with electronic MD meters, since MD reset

operation in electromechanical meters involves human interaction. This operation provides

scope for manipulations. The electronic meters with auto MD resets facility are also capable

of computing cumulative maximum demand provides solution for prevention of such

manipulations.

3.7.3 Improved Metering:

Installation of tamper-proof meter boxes and use of tamper-proof numbered seals.

• Providing cut-outs/MCBs after the meter as per sanctioned load & use of multi-core

PVC.

• Installation of tamper-proof electronic energy meters.

• Providing adequate meter testing facilities. A time bound program should be chalked-

out. For checking the meters with tested meters.

• Pilot studies for introduction of modern technologies such as pre paid meters, remote

metering, automatic billing etc.

• Difference of energy input measured at feeder end & the recorded consumption, is

total loss.

3.8 Scope and methodology adopted for evaluation of losses:

From net input in to system the total sales are subtracted & over all losses are

evaluated as net input:

• Input and output feeder wise power supply points to be identified for the state grid

and for all the circles (also divisions, sub divisions, sections/towns) for all lines

crossing the boundaries of respective jurisdictions at all voltage levels.

• Sending ends are taken as metering points and readings taken on every 25th at

24.00hrs every month and net input is arrived at .Sending and measurement enables

inclusion of losses in the line segments as also cross checking with inputs arrived by

measurement done at generating station end.

• The circle wise totaled net input of the state is cross checked net energy pumped into

grid i.e., generation less auxiliary consumption plus imports/ purchases and also with

the total billed units to AP TRANSCO by AP GENCO and others.

3.9 SCALES:

3.9.1 Metered sales:

HT (recorded units but not billed units) & LT (billed units) metered scales are taken

from ERO.

3.9.2 Un-metered sales:

Average consumption of the sampled services is extrapolated to obtained mandal wise

agricultural consumption and the mandal wise consumption is summed up to arrive at the

agricultural consumption at each level i.e., section sub division, circle and state.

3.9.3 Losses:

The total losses at any level are the net input minus the metered plus un metered sales

put together in that area of network. The difference of total loss obtained from simulation

studies (Technical loss) is a indication of non technical loss i.e., commercial loss and together

are called T&D losses. The typical/optimum level of losses in various segments of the system

Areas are as under-the losses depend on pattern and nature of demand, load density and the

capability and configuration of system, equipment used and vary for various system elements.

However, system where total percentage loss lie beyond aforementioned values, should

become a matter of serious concern.

3.10 Limitations in Accuracy of accounting of energy losses:

• Different billing cycles (HT, High value, monthly, bi monthly) adopted.

• Important assessment of consumption in respect of stuck up, burnt meter cases and

door lock cases.

• Non apportionment assessed energy in respect of pilferage, back billing cases and

revision of bills on subsequent dates etc to the corresponding monthly sales.

• Difficulties in adjusting billing errors.

• Limited sample size as basis for estimating agricultural consumption.

• Shortages of qualified personnel as meter readers, limitations in their physical abilities

(old age, bad vision etc).

• Inaccessibility to meters, table readings etc.

3.11 Activities of Energy Auditing:

• Obtaining Energy Audit reports & data from field officers and registers and

maintaining data bank.

• State wide overall system losses and circle wise system losses and state wide EHT

losses are to be evaluated monthly.

• Evaluating sub transmission (33kv) prim and secondary (11kv& LT) distribution

losses.

• Arrive circle wise, division wise, sub division wise, section wise system losses.

• Assess month wise agricultural consumption through sample meters installed.

• Energy audit for selected distribution transformers feeding exclusively agricultural

loads/urban loads.

• The field reports received are to be registered analyzed, review and remarks

communicated to the field officers for taking remedial actions.

• Obtaining exceptional reports & review replacement of defective meters etc.

• Watching variations in specific consumptions of domestic, commercial and industrial.

• Watching the Indices prescribed and evaluates field officers performance from the

section to the circle level.

• Expedite 100% sealing of all meters of consumers.

• To facilitate distribution transformer wise audit, codification of transformers

structures.

• Preparation of monthly circle wise and state wise losses analysis reports for review

indicating the comparative performance during the current month & cumulative with

reference to corresponding period in the previous year etc.

• Circle wise discrepancies are set right and uniform billing, accounting procedures are

ensured throughout the state.

• Responsibilities are to be & norms are formulated for officers at different levels for

maintenance & reviewing various registers , conducting intensive raids, review of

Meter.

• Reading books, inspection of sub stations/subordinate offices maintenance of meter

issue/utilization / registers, expedition of pending assessment cases in respect of back

billing, pilferage etc.

• All revenue matters all reviewed and various instructions issued from time to time and

brought out in a book let and made available the lowest level officer concerned to set

right various discrepancies noticed during the review & of revenue officer and section

officers.

3.12 Energy Losses:

Energy loss in any industrial process or plant is inevitable; it is a foregone conclusion.

But its economic and environmental impacts are not to be taken lightly, thus explaining the

growing need for industrial energy efficiency. Put simply, the level of energy efficiency a

plant or process can achieve is inversely proportionate to the energy loss that occurs; the

higher the loss, the lower the efficiency. Energy loss in any industrial process or plant is

inevitable; it is a foregone conclusion. But its economic and environmental impacts are not to be taken

lightly, thus explaining the growing need for industrial energy efficiency. Put simply, the level of

energy efficiency a plant or process can achieve is inversely proportionate to the energy loss that

occurs; the higher the loss, the lower the efficiency. Overall energy losses in a plant can result from

losses due to designs that do not incorporate energy efficient specifications such as heat recovery

option; operations that run on inefficient methods; and poor or

Non-energy efficiency-conscious maintenance programme. Reducing these losses will

substantially increase the plant's efficiency, but we need data to identify and quantify the losses and

subsequently suggest suitable techno-economic solutions to minimize the losses. This data can be

acquired through energy audits.

3.13 A Guide for Conducting Energy Audit at a Glance:

Industry-to-industry, the methodology of Energy Audits needs to be flexible. A

comprehensive ten-step methodology for conduct of Energy Audit at field level is presented

below. Energy Manager and Energy Auditor may follow these steps to start with and

add/change as per their needs and industry types.

3.14 CONVERSION OF POWER UNITS:

Power is the time rate at which work is done or energy is transferred.

Units of power:

1 horsepower =760 watts

1 kilowatt =1000 watts

1 watt =1 joule/second

1 watt =3.412 btu/hr

1000 Watts = 1 kilowatt (kW)

Fig: 2

Ten Steps Methodology

for Detailed Energy

Audit Step No

PLAN OF ACTION PURPOSE / RESULTS

Stages of Energy Audit

Step 1 Step 2 Step 3 Step 4 Step 5

Phase I –Pre Audit Phase • Plan and organise • Walk through Audit • Informal Interview with Energy Manager, Production / Plant Manager • Conduct of brief meeting / awareness programme with all divisional heads and persons concerned (2-3 hrs.)

Phase II –Audit Phase • Primary data gathering, Process Flow Diagram, & Energy Utility Diagram • Conduct survey and monitoring • Conduct of detailed trials /experiments for selected energy guzzlers

• Resource planning, Establish/organize a Energy audit team • Organize Instruments & time frame • Macro Data collection (suitable to type of industry.) • Familiarization of process/plant activities • First hand observation & Assessment of current level operation and practices • Building up cooperation • Issue questionnaire for each department • Orientation, awareness creation • Historic data analysis, Baseline data collection • Prepare process flow charts • All service utilities system diagram (Example: Single line power distribution diagram, water, compressed air & steam distribution. • Design, operating data and schedule of operation • Annual Energy Bill and energy consumption pattern (Refer manual, log sheet, name plate, interview) • Measurements : Motor survey, Insulation, and Lighting survey with portable instruments for collection of more and accurate data. Confirm and compare operating data with design data. • Trials/Experiments: - 24 hours power monitoring (MD, PF, kWh etc.).

- Load variations trends in

pumps, fan

TABLE: 3

CHAPTER -4

CHAPTER-4

4.1 Observations of Energy audit:

• Due to various constraints the losses can be given as a range only and not exactly to a

decimal.

• The EHT, Sub transmission, HT&LT losses are higher than assessed.

• The Assessment of losses is very largely dependent up on the Agricultural sampling

method employed .Defective meters, street lighting consumption; un-metered services

affect the losses greatly.

• Pilferage is one item long neglected and often not taken seriously by the organizations

and this is the major cause of financial erosion of the Electrical utilities. Firm and

concerted and action will correct the existing situations.

4.2 Benefits of energy auditing:

There is a lot of potential for energy savings from energy audits.. Technical solutions

proposed in the energy audits show massive potential for energy savings in every sub-sector

with an average of almost ten percent of the energy usage. However, this can only materialize

through replication at other factories within the respective sub-sector

4.3 Results of Energy auditing:

• Much improvement is noticed in metering, billing of energy and revenue collection

activity on such an implementation.

• LT demand is registering steady increase in addition to improvement in LT metered

sales & LT revenue.

• Performance at all levels has shown improvement.

• Defective meters are brought down substantially.

• Registering and reporting system has been streamlined.

4.4 Constraints in conducting Energy Audit:

Several unavoidable errors occur in the process metering energy due to inherent

errors/accuracy limits in meters, CT’s , PT’s(especially due to large multiplying factors) and

inaccuracies due to variations in voltage, frequency, low power factor, changes in system

configuration( for feeding loads ) to suit operational exigencies, all readings not being taken

simultaneously, problems associated with the assessment of un metered agricultural

consumption.

4.5 Parameters to be measured:

Energy consumption pattern of pumps (daily / monthly /yearly consumption)

Motor electrical parameters (kW, kVA, Pf, A, V, Hz, THD) for individual pumps

Pump operating parameters to be monitored for each pump

Discharge Flow, Head (suction & discharge), Valve position, Temperature, Load

variation, Simultaneous power parameters of pumps, Pumps operating hours and operating

schedule, Pressure drop in the system (between discharge and user point), Pressure drop and

temperatures across the users (heat exchangers, condensers, etc), Pump /Motor speed, Actual

discharge pressure and required / prevailing pressure at the user end, User area pressure of

operation and requirement.

4.6 Wattages of different lamps used to be replaced:Incandescent lamp CFL lamp LED Lumens

40 8-12 6-9 400-500

60 13-18 8-12.5 650-900

75-100 18-22 13+ 1100-1750

100 23-30 16-20 1800+

150 30-55 25-28 2780

TABLE: 4

4.7 Identification of Energy Conservation Opportunities:

4.7.1Fuel substitution:

Identifying the appropriate fuel for efficient energy conversion

4.7.2 Energy generation :

Identifying Efficiency opportunities in energy conversion equipment/utility such as

captive power generation, steam generation in boilers, thermic fluid heating, optimal loading of

DG sets, minimum excess air combustion with boilers/thermic fluid heating, optimizing existing

efficiencies, efficient energy conversion equipment, biomass gasifies, Cogeneration, high

efficiency DG sets, etc.

4.7.3 Energy distribution:

Identifying Efficiency opportunities network such as transformers, cables, switchgears

and power factor improvement in electrical systems and chilled water, cooling water, hot water,

compressed air, Etc.

4.7.4 Energy usage by processes:

This is where the major opportunity for improvement and many of them are hidden.

Process analysis is useful tool for process integration measures.

4.7.5 Technical and Economic feasibility:

The technical feasibility should address the following issues

• Technology availability, space, skilled manpower, reliability, service etc

• The impact of energy efficiency measure on safety, quality, production or process.

• The maintenance requirements and spares availability

The Economic viability often becomes the key parameter for the management

acceptance. The economic analysis can be conducted by using a variety of methods.

Example: Pay back method, Internal Rate of Return method, Net Present Value method

etc. For low investment short duration measures, which have attractive economic

viability, simplest of the methods, payback is usually sufficient. A sample worksheet for

assessing economic feasibility is provided below:

4.7.6 Sample Worksheet for Economic Feasibility :

Name of Energy Efficiency Measure :

1. Investment

• Equipments

• Civil works

• Instrumentation

• Auxiliaries

2. a2.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

4.8Understanding Energy Costs:

Understanding energy cost is vital factor for awareness creation and saving

calculation. In many industries sufficient meters may not be available to measure all the

energy used. In such cases, invoices for fuels and electricity will be useful. The annual

company balance sheet is the other sources where fuel cost and power are given with

production related information.

4.9 Energy invoices can be used for the following purposes:

They provide a record of energy purchased in a given year, which gives a base-line

for future reference

Energy invoices may indicate the potential for savings when related to production

requirements or to air conditioning requirements/space heating etc.

When electricity is purchased on the basis of maximum demand tariff

They can suggest where savings are most likely to be made.

In later years invoices can be used to quantify the energy and cost savings made

through energy conservation measures

4.10 Fuel Costs:

A wide variety of fuels are available for thermal energy supply. Few are listed below:

Coal18%Lignite4%Furnace Oil11%HSD1%Power36%LECO fines30%Total Energy

Bill -Rs. 6Crores/annum Figure 3.2: Annual energy bill

• Fuel oil

• Low Sulpher Heavy Stock (LSHS)

• Light Diesel Oil (LDO)

• Liquefied Petroleum Gas (LPG)

• COAL

• LIGNITE

• WOOD ETC.

Understanding fuel cost is fairly simple and it is purchased in Tons or Kiloliters. Availability,

cost and quality are the main three factors that should be considered while purchasing. The

following factors should be taken into account during procurement of fuels for energy

efficiency and economics.

• Price at source, transport charge, type of transport

• Quality of fuel (contaminations, moisture etc)

• Energy content (calorific value)

4.11 Power Costs:

Electricity price in India not only varies from State to State, but also city to city and

consumer to consumer though it does the same work everywhere. Many factors are involved

in deciding final cost of purchased electricity such as:

• Maximum demand charges, kVA

(i.e. How fast the electricity is used? )

• Energy Charges, kWh (i.e., How much electricity is consumed? )

• TOD Charges, Peak/Non-peak period

(i.e. When electricity is utilized ?)

• Power factor Charge, P.F

(i.e., Real power use versus Apparent power use factor )

• Other incentives and penalties applied from time to time

• High tension tariff and low tension tariff rate changes

• Slab rate cost and its variation

• Type of tariff clause and rate for various categories such as commercial, residential,

industrial, Government, agricultural, etc.

• Tariff rate for developed and underdeveloped area/States

• Tax holiday for new projects

4.12 Benchmarking and Energy Performance:

Benchmarking of energy consumption internally (historical / trend analysis) and

externally (across similar industries) are two powerful tools for performance assessment and

logical evolution of avenues for improvement. Historical data well documented helps to bring

out energy consumption and cost trends month-wise / day-wise. Trend analysis of energy

consumption, cost, relevant production features, specific energy consumption, help to

understand effects of capacity utilization on energy use efficiency and costs on a broader

scale. External benchmarking relates to inter-unit comparison across a group of similar units.

However, it would be important to ascertain similarities, as otherwise findings can be grossly

misleading. Few comparative factors, which need to be looked into while benchmarking

externally are:

• Scale of operation

• Vintage of technology

• Raw material specifications and quality

• Product specifications and quality

Benchmarking energy performance permits

• Quantification of fixed and variable energy consumption trends vis-à-vis production levels

• Comparison of the industry energy performance with respect to various production levels (capacity utilization)

• Identification of best practices (based on the external benchmarking data)

• Scope and margin available for energy consumption and cost reduction

• Basis for monitoring and target setting exercises.

The benchmark parameters can be:

• Gross production related

e.g. kWh/MT clinker or cement produced (cement plant)

e.g. kWh/kg yarn produced (Textile unit)

e.g. kWh/MT, KCal/kg, paper produced (Paper plant)

e.g. KCal/kWh Power produced (Heat rate of a power plant)

e.g. Million kilocals/MT Urea or Ammonia (Fertilizer plant)

e.g. kWh/MT of liquid metal output (in a foundry)

• Equipment / utility related

e.g. kW/ton of refrigeration (on Air conditioning plant)

e.g. % thermal efficiency of a boiler plant

e.g. % cooling tower effectiveness in a cooling tower

e.g. kWh/NM3 of compressed air generated

e.g. kWh /litre in a diesel power generation plant.

While such benchmarks are referred to, related crucial process parameters need mentioning

for meaningful comparison among peers. For instance, in the above case:

• For a cement plant – type of cement, blaine number (fineness) i.e. Portland and process

used (wet/dry) are to be reported alongside kWh/MT figure.

• For a textile unit – average count, type of yarn i.e. polyester/cotton, is to be reported

along side kWh/square meter.

• For a paper plant – paper type, raw material (recycling extent), GSM quality is some

important factors to be reported along with kWh/MT, kCal/Kg figures.

• For a power plant / cogeneration plant – plant % loading, condenser vacuum, inlet

cooling water temperature, would be important factors to be mentioned alongside heat

rate (kCal/kWh).

• For a fertilizer plant – capacity utilization (%) and on-stream factor are two inputs worth

comparing while mentioning specific energy consumption.

• For a foundry unit – melt output, furnace type, composition (mild steel, high carbon steel/cast iron etc.) raw material mix, number or power trips could be some useful operating parameters to be reported while mentioning specific energy consumption data.

• For an Air conditioning (A/c) plant – Chilled water temperature level and refrigeration load (TR) are crucial for comparing kW/TR.

• For a boiler plant – fuel quality, type, steam pressure, temperature, flow, are useful comparators alongside thermal efficiency and more importantly, whether thermal efficiency is on gross calorific value basis or net calorific value basis or whether the computation is by direct method or indirect heat loss method, may mean a lot in benchmarking exercise for meaningful comparison.

• Cooling tower effectiveness – ambient air wet/dry bulb temperature, relative humidity, air and circulating water flows are required to be reported to make meaningful sense.

• Compressed air specific power consumption – is to be compared at similar inlet air temperature and pressure of generation.

• Diesel power plant performance – is to be compared at similar loading %, steady run condition etc.

4.13Plant Energy Performance:

Plant energy performance (PEP) is the measure of whether a plant is now using more

or less energy to manufacture its products than it did in the past: a measure of how well the

energy management programme is doing. It compares the change in energy consumption

from one year to the other considering production output. Plant energy performance

monitoring compares plant energy use at a reference year with the subsequent years to

determine the improvement that has been made.

However, a plant production output may vary from year to year and the output has a

significant bearing on plant energy use. For a meaningful comparison, it is necessary to

determine the energy that would have been required to produce this year production output, if

the plant had operated in the same way as it did during the reference year. This calculated

value can then be compared with the actual value to determine the improvement or

deterioration that has taken place since the reference year.

4.14 Production factor:

Production factor is used to determine the energy that would have been required to

produce this year’s production output if the plant had operated in the same way as it did in the

reference year. It is the ratio of production in the current year to that in the reference year.

4.15 Reference Year Equivalent Energy Use:

The reference year’s energy use that would have been used to produce the current year’s

production output may be called the “reference year energy use equivalent” or “reference

year equivalent” for short. The reference year equivalent is obtained by multiplying the

reference year energy use by the production factor (obtained above)

Reference year equivalent = Reference year energy use x Production factor

The improvement or deterioration from the reference year is called “energy performance”

and is a measure of the plant’s energy management progress. It is the reduction or increase in

the current year’s energy use over the reference, and is calculated by subtracting the current

year’s energy use from the reference years equivalent. The result is divided by the reference

year equivalent and multiplied by 100 to obtain a percentage.

CHAPTER -5

CHAPTER -5

5.1 Analysis Of Energy Bills:

o The audit must begin with a detailed analysis of the energy bills for the

previous twelve months. This is important because:

o The bills show the proportionate use of each different energy source when

compared to the total energy bill.

o An examination of where energy is used can point out previously unknown

energy wastes.

o The total amount spent on energy puts an upper limit on the amount of money

that can be saved.

5.2 By replacing fluorescent tubes with led tubes the savings are as follows:

1 Led tube wattage =20watts and the cost is Rs.1000/-

1 fluorescent tube wattage =40watts and the cost is Rs.200/-

Extra amount invested =Rs.800/-

Power saving =20 watts

Total lamps =240 lamps

Power saving =240*20

=4800 watts

Per day consuming hours =5 hours (approx)

Total consuming days =20 days/month

Total energy saving /month =4800*5*20

=480000 WH

=480 KWH

Amount saving /month =480*9

=Rs.4320/-

Amount saving/year =4320*12

=Rs.51,840/-

Extra amount invested =240*800

=Rs.1,92,000/-

Pay back period =extra amount invested/amount saving per year

=192000/51840

=3.70 years

In a period of 5 years saving =amount return due to power saving- amount invested

=51840*5-192000

After 5 Years amount saving =Rs.67,200/-

Fig: 3

CHAPTER -6

CHAPTER -6

ENERGY SAVINGS AND TECHNIQUES:

Replacement of fluorescent tubes with led tubes.

Replacement of CFL lamps with led lamps.

Replacement of fans with low wattage fans.

Replacement of CRT monitors with led monitors.

Replacement of air conditioners with 5star ac’s.

5 watts led tube is equal to 40 watts fluorescent tube.

2watts led tube is equal to 15watts CFL bulbs.

By replacing all these equipments with above devices we can save up to 15% of

energy consumption.

Replacing of all these equipment involves a lot of money investment .but in due

course we can achieve in payback period. After that it is very economical.

Fig: 4

CHAPTER -7

CHAPTER-7

7.1 Conclusion:

The benefits of Energy Audit and Accounting are inter-related and outcome of a study

shall form the basis for detailed and complete evaluation of the system, which is need of the

hour. The adoption of proper energy accounting would ultimately facilitate increased revenue

realization for the energy supplied to the consumers, identification of areas and causes of

high energy losses and cutting down on its own expenses on account of the operational

inefficiencies.

7.1.1 The implementation of a structured energy audit offers numerous benefits to the

enterprises including:

Improved energetic efficiency;

Reduced energy bills;

Reduced environmental impact;

Reduced maintenance costs;

Improvement of working conditions and safety;

Greater organizational involvement and competency concerning.

7.2 The outcome of energy accounting and audit are:

Estimation of technical losses, Estimation of commercial losses, their causes and a

proper database to evolve strategy for elimination of avoidable and undesired losses,increase

in billing and revenue collection and finally improvement is ought to bereflected in financial

performance of utility.

Proper energy accounting and audit would also facilitate in a database as input for up

gradation of distribution system.

Finally it can be concluded that energy accounting and audit is very essential for reducing the

T & D loss within optimum permissible limits, for which targets are to be fixed and

concerned efforts are to be made to plug the leakages in the ST & D system so that revenue

collection of SEB increases which in turn will give a face-lift to the SEB s and improve their

financial health.

7.3 High Efficiency, 3rd Gen. or Super T-8s:

• Excellent efficacy up to 95 l/w at mean life

• Good lumen maintenance 93% at 12,000 hrs

• Long lamp life in excess of 18,000 hours

• CRI 80 or better

This new fluorescent lamp type is the only T-8 linear fluorescent that qualifies for PG&E’s

Deemed Incentive Program.

CHAPTER-8

CHAPTER-8

Reference:

1. NPC energy audit manual and reports

2. Energy management handbook, John Wiley and Sons - Wayne C. Turner

3. Guide to Energy Management, Cape Hart, Turner and Kennedy

4. Cleaner Production – Energy Efficiency Manual for GERIAP, UNEP, Bangkok

prepared by National Productivity Council

www.eeca.govt.nz

www.energyusernews.com/