ENERGY AUDIT OF KYAMBOGO UNIVERSITY MECHANICAL WORKSHOP & CLASSROOM

BLOCK

By

Kyambadde Francisco11/U/44/APD/GV

Supervised by: Mr. Kakebe RobertWednesday, 26th May, 2015

Background

• Limited funds and high expenditures are some of the causes of slow or no development of Kyambogo University. Any endeavor to cut down costs and realize some savings can greatly improve the university.

• Since the Mechanical Workshop and Classroom block are some of the main energy consumption areas in the university, conducting an energy audit to identify energy savings is one step to cut down the University costs.

• Also energy costs are spirally increasing day-by-day. According to UMEME End-User Tariffs and Charges of 2014, the current tariff for small scale industries is 474 Ugx/kWh, in January 2015 it was increased to 484.6Ugx/kWh. And fuel costs have increased by more than 100% since 2002.

• However, various studies in different countries have shown that significant energy efficiency improvements exist in the industrial sector, many of which are cost effective..

• The workshop management is not aware of these energy efficiency improvement potentials. Therefore, conducting an energy audit is the first step in identifying these potentials.

Problem Statement

• Wastage of energy needs to be avoided to cut down energy costs of the workshop and the university. It is therefore, necessary to conduct an energy audit covering analysis and evaluation of all equipment, operations and system components which have bearing on energy consumption, and identify scope for reduction in energy cost.

General Objective• To understand how energy is used within the workshop

and classroom block and to find opportunities for improvement and energy saving.

Specific Objectives• To clearly identify and acquire data on types and costs of

energy use of the mechanical workshop and classroom block.

• To analyse and calculate energy consumption pattern of the workshop based on results of the first objective.

• To identify and analyse efficiency energy conservation measures (ECMs)

• To carryout a cost-benefit analysis on the above identified measures.

Scope of the Study

• Geographical Scope: The project will confine itself to Kyambogo University Mechanical workshop.

• Subject Scope: The main focus of this project is to study and identify how and where energy is being used and possibly wasted in the workshop, and identify energy saving opportunities.

• Time scope: The project will be conducted with a period of seven months, that is from November 2014 to May 2015.

Significance

• The university will be able to save on energy costs from electricity and fuel.

• The study can also be adapted for homes to improve their energy efficiency and reduce energy bills.

• Environmental benefits will also be realized owing to reduction in the pollutants.

• Improved efficiency of energy consuming utilities in the workshop.

Justification of the Study

• The costs of electricity and fuel impact greatly on the Workshop and University expenditure, yet alternatives sources of energy like solar and biogas are less efficient and have high up-front costs.

• There is lack of awareness on the energy saving potential of Mechanical workshop and University at large.

MethodologySpecific Objective Methods Used

1. To clearly identify and acquire data on types and costs of energy use of the mechanical workshop and classroom block.

• Walk Through Inspection and Observation; this was done to get information about workshop layout and identify areas of energy consumption. Also to acquire data on types of energy use.

• Recording; this enabled me to capture information relating to Power rating of equipment using a digital camera and noting them down.

• Interviewing; acquired some information on energy usage and condition of equipment by interviewing some key individuals

• Measurements; carried out some measurements on a few motors using a cramp tool to obtain power consumption

2. For analyzing data to calculate energy consumption pattern of the workshop.

• Clusters; calculated energy consumption basing on Lighting, Machines, Computers e.t.c for each specific area.

• Determined the Total Load and Made Use of Time Differentiation

Methodology ContinuedSpecific Objective Methods Used

3. For identifying Energy Conservation measures

• Desk Research; this involved the Internet mainly and use of the library to find better alternatives for the components that have impact on power

• Cross Cutting Energy Efficient Measures; from motors, Lighting and electrical appliances.

• Consultation; I consulted key players in the industry regarding components to acquire more knowledge about available technologies in the market and pricing.

4. For carrying out a cost-benefit analysis on the identified ECMs.

• Compute Annual Savings;

• Simple Pay back period; this is the ratio of investment to the savings per year. This gives the time it will take to recover initial investment through realised energy savings.

• Savings to Investment ratio; this ratio helped determine whether the potential savings of the project justifies the initial investment.

Findings1. To clearly identify and acquire data on types and costs of energy use of the

mechanical workshop and classroom block

• The Mechanical Workshop Uses two sources of Energy, Electricity and Diesel Fuel to run the generator in cases of load shedding.

• Energy is mainly used by Machine tools, Lighting, and Electrical Appliances; Computers, Photocopiers and Printers

• The Main energy consumption areas are the Machine Shop and Classroom block since the Auto Vehicle Shop and Spraying Shop has been closed for more than a semester now.

• The Kyambogo University energy consumption is metered basing on time differentiation (off-peak, shoulder, peak) and then Maximum demand.

• Under the UMEME User Tariff 2015, Kyambogo University is rated under Medium Industrial Code 20 and the Tariffs are; Average – 461.6 Ugx/kWh, Peak(18.00hrs-23.00hrs) – 570.1 Ugx/kWh, Shoulder(05.00-18.00hrs) – 461.9 Ugx/kWh, Off-Peak(23.00hrs-05.00hrs) – 314.5 Ugx/kWh

2. To analyze data and calculate energy consumption pattern of the workshop

• Energy Consumption of The Mechanical Classroom Block based on Rooms

ROOM/OFFICE EQUIPMENT/LOAD NO OF LOADS INDIVIDUAL POWER RATING (W) TOTAL POWER (W)

1 Fluorescent tube T8 4ft 5 36 1802 Fluorescent tube T8 4ft 5 36 1803 Fluorescent tube T8 4ft 5 36 1804 Fluorescent tube T8 4ft 5 36 1805 Fluorescent tube T8 4ft 5 36 1806 Fluorescent tube T8 4ft 6 36 216

8 Fluorescent tube T8 4ft 7 36 2529 Fluorescent tube T8 4ft 9 36 324

10 Fluorescent tube T8 4ft 7 36 252BALCONY GROUND FLOOR Fluorescent tube T8 4ft 4 36 144

BALCONY 1ST FLOOR Fluorescent tube T8 4ft 5 36 180

WATER CLOSETS Fluorescent tube T8 4ft 2 36 72

INDUSTRIAL TRAINING COORDINATOR

Desktop computers 3 170 510CRT Monitors 3 80 240Fluorescent tube T8 4ft 1 36 36Printer 1 50 45

COMPUTER LABORATORY

LCD Monitors 31 22 682Desktop Computers 31 120 3,720Printer 1 100 100Projector 1 288 288Fluorescent tube T8 4ft 2 36 72

ENVIRONMENTAL ENGINEERING PROGRAM COORDINATOR

Desktop computer 1 170 170

CRT Monitor 1 80 80

Fluorescent tube T8 4ft 1 36 36FORMER STAFFROOM Fluorescent tube T8 4ft 2 36 72

TOTAL CONSUMPTION (kWh) 8,391

• Energy Consumption of The Mechanical Classroom Block based on Application

Lighting Desktop Computers Printers CRT Monitors LCD Monitors Projector0

250

500

750

1000

1250

1500

1750

2000

2250

2500

2750

3000

3250

3500

3750

4000

4250

4500

Power Consumption (W) Vs. Application

Application

Cons

umpti

on (W

atts)

• Electricity Costs due to Consumption of Classroom Block

ApplicationPower Consumption

(kWh)Unit

(Ugx/kWh)Average Daily

Usage (hrs)

Average Daily Costs (Ugx)

Lighting 2.556 461.6 8 9,438

Computing 4.400 461.6 6 12,186

Printing 0.145 461.6 1 67CRT Monitors 0.320 461.6 6 886LCD Monitors 0. 682 461.6 6 1,889Projector 0.288 461.6 0.25 33TOTAL WATTAGE (kW) 8.391 TOTAL DAILY COST (UGX) 24,500

• Daily Electric Cost: The total daily cost of the electricity consumed by the Mechanical classroom block is 24,500 Ugx.

• Costs per Semester: Since there are four months in a semester, and each month has 26 working days, the total cost for a semester is; 4 x 26 x 24500 = 2,548,000 Ugx.

• Annual Electricity Costs:Therefore the total annual cost of the electric power consumption of the Mechanical Classroom Block is 2 x 2,548,000 = 5,096,000 Ugx

• Electricity Consumption of Machine Shop Block

ROOM EQUIPMENT/LOAD NO.INDIVIDUAL

CONSUMPTION (W)TOTAL

CONSUMPTION (Wh)

Machine Shop Fluorescent tube T8 4ft 27 36 972

Machine Shop 2 Wheel Grinder - Motor 1 1500 1500

Machine Shop 3 Chuck Colchester Centre Lathe 1 2200 2200

Machine Shop Vertical Milling Machine 1 1200 1200

Machine Shop Horizontal Milling Machine 1 1200 1200

Machine Shop Centre Lathe Harrison M250 1 1300 1300

Machine Shop Vertical Drilling Machine 1 750 750

Machine Shop 4 Chuck Centre Lathe 1 2200 2200

Tool Store Fluorescent tube T8 4ft 2 36 72

Staff Room Fluorescent tube T8 4ft 3 36 108

Machine Shop Photocopiers 3 553 1659

TOTAL WATTAGE 13,161

• The components that consume energy in the machine shop are; Machine Tools, Lights, and Photocopiers.

• Their total consumption per hour is 13,161 watt-hours.

• Average Daily Costs of Machine Shop Block based on Application

Lighting43%

Machine Tools26%

Photocopiers31%

Average Daily Costs (Ugx)

• Daily Electric Cost: The total daily cost of the electricity consumed by the Machine Shop Block is 22,063 Ugx.

• Costs per Semester: Since there are four months in a semester, and each month has 26 working days, the total cost for a semester is; 4 x 26 x 22063 = 2,294,552 Ugx.

• Annual Electricity Costs:Therefore the total annual cost of the electric power consumption of the Machine Shop Block is 2 x 2,294,552 = 4589104Ugx

3. To identify Energy Conservation Measures

a) For Lighting in both blocks; the currently used T8 Fluorescent Tubes should be replaced with T8 LED Tubes that fit exactly in the same fixtures as T8 Fluorescent but save more energy, have added durability and are more environmental friendly. The power consumption of a T8 LED is 16W compared to 40W of a T8 Fluorescent. These lamps provide more power compare to the conventional T8 Fluorescent tubes.

b) In the Machine Shop, installation of four switches to control the lighting of the different sections other than one switch which lights areas even where light is not needed.

c) Monitors; Replacement of the high energy consuming CRT Monitors with LCD monitors in the Environmental Engineering Coordinators office and Industrial Training Coordinator's Office. This will save the power consumption of these four monitors by about 60%.

d) For Desktop Computers; switching off of computers whenever they are not in use. This reduces power consumed during standby mode and sometimes also the environmental pollution due to radiation.

e) For Machine Tools, all the current machine tools use the standard conventional motors. These motors can be replaced by energy efficient motors. This is more profitable if these motors operate for more than 4000 hours a year which is not the case for the University machine shop.

f) For Machine Tools; the working criterion / behavioural criterion can be changed by putting up guides for energy efficient use of each of the machine. From observation, students use wrong machines for wrong work processes, so this can be a better solution.

3. To carry out a cost benefit analysis of the Identified Energy Conservation Measures• Replacement of T8 Fluorescent with T8 LEDs

Investment Required: No. of Loads x Cost= 103 x 30,000 = 3,090,000 Ugx

The Energy Consumption of 103 T8 Fluorescent tubes is 3.708kW for one hour and 25.956 kWh for a day taking average usage of 7hrs per day.

Replacing them with T8 LED saves energy by;

Total Energy Saving = No. of Loads x Average usage (Wattage of T8 Fluorescent – Wattage of T8 LED)/1000

=103 x 7 (36 – 16) / 1000= 14.42 kWh per day.Annual Energy savings = 14.42 x 2 x 4 x 26 = 2999.36 kWhAnnual Cost Savings = 2999.36 x 461.6 = 1,384,504.576 Ugx

Simple Payback Period = Investment / Annual Savings = 3,090,000 / 1,384,504 = 2.2 years.

Replacement of CRTs with LCDsInvestment Required: Cost of four LCD 18’’ = 1,000,000 Ugx

Daily Energy savings: (80 – 22) x 4 x 6 /1000 = 1.392 kWh

Annual Energy Savings: 1.392 x 4 x 2 x 26 = 289.536 kWh

Annual Cost Savings = 289.536 x 461.6 = 133,650 Ugx

Simple Payback Period: Investment/Annual Savings = 1000000/133650 = 7.4 years

Savings to Investment Ratio: Estimated Useful Life of LCD = 8 years

SIR = (133650 x 8) / 1000000 = 1.0692. This ratio justifies the project.

CONCLUSION

• There were a lot of irregularities in energy use of the workshop and poor record keeping as regards the operations of the workshop.

• The consumption pattern was based on mainly equipment power ratings and just a few measurements were taken. The consumption costs were based on energy consumption and not demand. However, UMEME assesses our tariff based on energy use, maximum demand and a constant monthly charge of 22,400 for Medium Industries. That’s why the costs were low.

• The identified Energy Conservation measures are both economical and behavioural. The economical ECMs need replacement of energy consumption components/appliances with economic impact on the University. The behavioural measures just need the bettering of the operations conduct of the students and staff.

• ECMs a), b) and c) are economically feasible and viable. ECMs d) and f) just need change in conduct but annual energy savings due to their implementation cannot be assessed.

RECOMMENDATIONS

• There should be proper book keeping as regards the use of machine tools in the workshop to better ascertain their energy consumption and usage. This further helps in planning a maintenance schedule and reducing breakdowns.

• The workshop should be restored to proper order by establishing maintenance schedules for machines and restoration of machine tools are currently down. This can be backed up by using energy saving techniques when carrying out machine operations to get better results.

• The university should implement the above energy conservation measures that are economically feasible to cut down on utility expenses.

REFEREENCES

• Lecture Notes; Power plant engineering by Mr. Kakebe Robert

• Lecture Notes; Project Management

• Energy Audit Guide book; Ali Hasanbeigi, Lynn Price; China Energy Group

• Electricity End-User Tariff and Charges, UMEME Uganda, 2014

• Energy Management and Utilisation; by Assoc. Prof. Dr.Ugur Atikol, CEA; Chapter 2 Energy Audit

• Applied Industrial Energy and Environmental Management; z.k. Morvay, D.D. Gvozdence

• www.Wikipedia.org/energy-audit

• Industrial Energy Audit Guide Book_EN; Ali Hasanbeigi, Lynn Price

• Energy Demand of Machine Tools and Performance Management; (Dyckhoff and Souren 2008;

Meadows et al. 2001).

• Energy Efficient Technologies; A publication of Enerdata, 2008

Thanks For Your Time