“Energy Audit of Generation and Distribution Systems- Nepal

Experience”Bhishma Pandit

National Energy Efficiency ExpertINTEGRATION GmbH for Nepal Energy Efficiency

Programme(GIZ)Nepal

Cut Costs?How?

Energy Efficiency?

Energy Audits- Technical –Economical Think little-Rs.2800/year?

Contents

• Programme Introduction- Saving potential

• Nepalese power generation and distribution scenario

• Transmission and distribution

• System load curve

• Load forecast

• Electricity consumption by sector

• Industrial/Commercial tariff

• System loss

Saving opportunities in Nepalese Industries

As Identified under ESPS /DANIDA programme:

Number of industries participated: 360

– Large:13%

– Medium and small: 87%

– Identified Energy saving potential: – Electrical ~ 15%

– Thermal ~30%

GTZ Program NEEP

Nepalese Energy Efficiency Programme

(NEEP)Govt. of Nepal and Govt. of Germany

Joint Collaboration Programme

Components

1. Component 1: Policy development,

implementation & awareness raisisng

2. Component 2: Energy Efficiency in Households

3. Component 3: Energy Efficiency in Industry

Energy Efficiency Centre (EEC)FNCCI

Establishment of EEC- 2010

Overall objective of EEC

– to provide quality Energy Efficiency

services to industrial community

9

Activities

• Awareness programme /trainings from District Chambers of Industries

• Training of Energy Auditors- NPC India/ BEE course.• Accreditation of EA• Investment Grade Energy Audits- 22 industries• Knowledge management centre – Website- www.eec-

fncci.org• Networking with regional organizations• Quality control of report & Capacity development of

DCCI & stakeholders• Financial Institutions trainings.

Kathmandu,13.93%

Bhaktapur,3.84%

Lalitpur,5.47%

Kanchanpur,2.89%

Morang,8.46%

Jhapa,3.98%Parsa,6.36%

Rupandehi,6.33%

Sunsari,6.28%

Bara,5.41%

Kaski,4.12%

Kailali,3.31%

Chitwan,2.89%

Banke,2.72%

Nawalparasi,2.13%

Dang,1.51%

Kapilbastu,1.49%Makwanpur,1.60%

Saptari,1.74%

Dhanusha,1.93%

Main Manufacturing Industry Distribution in the Country

100 % = 3446 Industry Establishments

Source: Census of Manufacturing Establishments Nepal 2006-2007

Electricity Consumption by Sectors:

Sou

rce

: WEC

S En

erg

y Sy

no

psi

s R

ep

ort

20

10

Time of Day (TOD) Meter/ Tariff

Consumer Category and

Supply Level

Monthly

Demand

Charge

(Rs/KVA)

Energy Charge (NRs/unit)

Peak

Time

Off

Peak Normal

17:00 -

23:00

23:00-

5:00

5:00-

17:00

High Voltage (66KV and Above)

Industrial 220 7.75 3.3 6.25

Medium Voltage (33 KV)

Industrial 230 8.5 4.2 7

Commercial 285 10.25 5.4 9

Medium Voltage (11 KV)

Industrial 230 8.75 4.3 7.1

Commercial 285 10.5 5.5 9.25

Non Commercial 220 11.25 5.7 10.2

No low power factor penalty

Total energy available and peak demand

What are the important point for NEA to carry out energy efficiency:

➢ Peak demand and energy crisis

➢ Supply and demand gap

➢ Need for optimization of generation and network utilization

➢ Regulator led energy efficiency mandates

➢ Strong lobbying from environmental groups

➢ Resource constraints and customer demands for cheaper rates

➢ Increased operational flexibility needs

➢ Competition, thanks to reform process and open access

Loss reduction Activities- NEA

• Technical and Non technical- Regular monitoring of feeder which has more than 40% losses

• Use of Areal bundle cable(ABC)

• Upgrading of overloaded transformers and conductors

• Energy efficiency in lighting-CFL programme

NEA- Demand side Management

• With the grant assistance from the ADB

• CFL

• Installations of capacitor banks to different sub stations.

Energy Access and Efficiency Improvement project- Project for

Energy Efficiency through loss

reduction

DSM LINKAGES-INDUSTRY SECTOR

Utility Load Shape

Objectives

DSM Implementation Methods

Industry sector potential End

Uses

DSM Technology Options

Peak Clipping

Load profile

Valley Filling

Load Shifting MW

Examples:

Water Pumping stationsIce Bank tanksProduction shuffling

generic DSM measures in load management, process/plant Utilities in industry sector…

➢ Power factor improvement

➢ Conventional ballast's on FTL’s replaced by low loss ballasts

➢ Adoption of energy efficient CFL’s/LEDs ,Magnetic induction lamps, LPSV, HPSV lamps…

➢ Adoption of Lighting voltage controllers

➢ Motor Soft starters/Energy savers adoption

➢ Replacement of old pumps by high efficiency pumps

➢ Replacement of old fans by high efficiency fans

➢ Application of VSD’s, cogeneration etc, for EE

➢ Replacement of old compressors, chillers, by energy efficient compressors, chillers.

➢ Distribution system upgrades in water pumping, compressed air, chilled water systems for EE

➢ Material handling system upgrades for EE.

➢ Adoption of distributed control systems, process automation for EE

➢ Furnace, heater upgrades for EE.

➢ Replacement of old rewound motors by new high efficiency motors. motors………

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•

•

•

•

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Energy Efficiency Generation side

Transmission line planning and loading

Substation loading and energy management

Distribution line loading / Power factor improvement / Transformer efficiency Power quality issues Consumer energy

efficiency

•Power factor improvements•Transformers•Voltage Regulators•Load management•Energy efficient motors•A/C system•VFD•Compressed air system•Ventilation system•Lighting system

Plant efficiencyBoiler efficiency

• Institutionalizing energy audit expertise

• Policy with mandatory periodic energy audits and reporting

• Competition and award for improvement in EE by sector

• Focus on best practices and best available technology on energy

• Involve educational institutions for offer course on EE

Recommendations- Energy Efficiency within Nepal

• Energy audits must be carried out periodically in all the industries so that opportunities are known and understood

• Awareness & training about EE

• Financing for the implementation of energy saving options – mobilize financial institutes and banks

• Keeping the record of data and monitoring

•

– IEC 60076 series for liquid immersed or dry power transformers covering ratings, test

methods, measuring methods for losses.

– IEC 61803, Determination of power losses in HV direct current converter stations.

– IEC 60826, Design criteria of overhead transmission lines

• methods, measuring methods for losses,

•

•

•

•

Energy Audit Approach- Nepal

• Energy Auditors course- training – On the job training

• Accreditation of Energy Auditors-

• Pilot Energy Audits and Recommendations

• Implementation with Financial Institutions( Banks)

• Energy Efficiency policy- Mandatory Energy Audits for biggest consumers and target

• Awareness training on sector approach

• Plant operators trainings

• Capacity building of district industrial associations

Energy Audit -Methodology

• Historical data analysis• Bench marking• No cost- low cost options( Housekeeping options)• Measurements with Energy Audit tools• Data Analysis• Feasibility Analysis of the reports- Vendor information• Draft report submission with Management• Final Report • Implementation plan• Target setting• Banking - Financing

Post audit activities

Implemented cases

vi.Evaporative Condenser

Condenser with open panel

and fouled with scales.

After Cleaning

Savings:

By Reducing the condensing temperature from 58 oC to

35oC

Reduction in Work done by compressor = 44289

KCal/hr

Annual Electrical Savings = 257,495 kWh

Annual Cost Saving = NPR. 1,519,221

Labor Cost for De scaling = NPR 10,000

Pay Back Period = 3 days

Installation of capacitor bank for power factorimprovement.

Investment : NRs. 3.9 lakhs Pay back period : 12 months.

Particular Before After

Power factor 0.76 0.95

KW load 732 732

KVA load (demand) 963 770

Demand savings/month: 193 kVAAnnual cost savings on demand@ Rs. 190/kVA: Rs. 440000Reduction in cable and distribution losses: 29,410 kWhAnnual cost savings on energy@ Rs. 5.85/kwh: Rs. 172000Total cost savings/yr: Rs. 6,12,000Implementation cost: Rs. 700,000Simple payback period: 14- months

Case study-Installation of Silica Insulated Heater for Extruder Machines.

• Plastic industry saves up to 25 % on energy for heating extruder

After installation of the nicrome wire elements(Insulation on heaters)

Energy saving/year due to above: 38031kWh

Cost savings @ Rs.6.60/kWh NRs. 251,661

Cost of Implementation NRs. 500,000

Simple payback period 24-months

Parameter STD EE STD EERated kW 11 9.3 15 15

Measured kW 6.5 6.5 12 12

opearing efficiency 85 92 88 92

Operating losses kW 1.1 0.63 1.54 1.03Difference in losses kW 0.47 0.51Annual Operating hours 6000 6000

Saving in kWh 2820 3060

Unit cost Rs/kWh 5.5 5.5

Cost Saving 15510 16830

Payback 2 years 2 Years

Save Energy, Save environment, Save

Earth….save your livelihood

Energy efficiency is a tools for cost

reduction, productivity enhancement and profit increase.

Energy consumption is your profit consumption