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