Case Study of Energy Audit

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ENERGY AUDITDarshan Vithani ,Pranav Pathak

ME-CSE

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ENERGY AUDIT (EA)

pool of activities (systematic procedure) focused on analysis of current energy need and consumption going out of valid technical standards,

analysis of problems (weaknesses and deficiencies), EA identifies and in detail quantifies effective

possibilities of energy savings tailored to the object being analyzed,

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AIM OF ENERGY AUDIT

to minimize costs for energyto minimize operational coststo minimize costs for repairs

and reconstructionincrease quality of environment that

contributes to increased work productivity

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AIM OF ENERGY AUDIT

to minimize costs for energyto minimize operational coststo minimize costs for repairs

and reconstructionincrease quality of environment that

contributes to increased work productivity

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TYPE OF ENERGY AUDIT

The type of Energy Audit to be performed depends on:

- Function and type of industry

- Depth to which final audit is needed, and - Potential and magnitude of cost reduction desired

Thus Energy Audit can be classified into the following two types.

i) Preliminary Audit ii) Detailed Audit

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PRELIMINARY ENERGY AUDIT METHODOLOGY

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’ Identify areas for more detailed study/measurement Preliminary energy audit uses existing, or easily obtained

data

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DETAILED ENERGY AUDIT METHODOLOGY

It is offers most accurate estimate of energy savings and cost This is based on an inventory of energy using systems,

assumptions of current operating conditions and calculations of energy use.

Detailed energy auditing is carried out in three phases: Phase I, II and III.

Phase I - Pre Audit Phase Phase II - Audit Phase Phase III - Post Audit Phase

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Steps For DETAILED ENERGY AUDIT METHODOLOGY

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AREAS OF ENERGY AUDIT

Subject of energy consumption analysis are energy resources consumed in the industrial area, i.e.

Electricity Natural gas Steam Coal Wood, wood chips/pellets Fuels (petrol, oil, propane-butane).....


AREAS OF ENERGY AUDIT

• thermal-technical protection of buildings,• heating systems• hot water preparation,• ventilation systems and air-conditioning (buildings and technology)• electric appliances (administrative and technological incl. electrical

connection, transformation, distribution network, el. switchboards, el. compensation)

• gas or other energy resources consuming appliances (furnaces, cleaning devices,..)

• Indoor/outdoor lighting,• measurement and regulation.


ENERGY AUDIT METHODOLOGY

Pre-audit presentation.

Collection of data / information.

Measurements and monitoring with instruments.

Computation and in-depth analysis.

Post-audit presentation to discuss the Energy Conservation Opportunities identified by the audit team.


INSTRUMENTS USED

Flue Gas Analyzer

Power Analyzer, Tachometer

Ultrasonic Flow Meter

Trap Man (For Steam Trap Survey)

Raytech Gun & Digital Thermometer (Non-contact and Contact type both)

Anemometer, pH/TDS/Conductivity meter

LUX Meter, Digital Manometer

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Energy Audit at Mother Dairy (Milk Plant)

Case Study


BASE LINE DATAProduct Bulk Processed Milk (Toned, Double Toned

& Full Cream)

Capacity of the plant 8 Lac liters of Milk per day

Annual Fuel / Energy Consumption PNG: 17,76,000 SCM Worth: Rs 3.7 CroresElectricity: 134.6 Lac kVAhWorth: Rs 6.68 Crores

Annual Energy Bill Rs 10.38 Crores

Compressed Air generation 180 cfm

Steam Consumption 65,000 kg/month for Milk Plant15,000 kg/month for Ice Cream Plant


Summary of Savings Identified & Realized (Year 2003 & 2004)

Major recommendations implemented:1. Boiler fuel switched over to PNG from LDO2. Steam supplied to ICP from this boiler3. Improvement of Power Factor from 0.9 to 0.9964. New air compressor installed lowering SEC5. Installation of Auto Blow Down system for Boiler

Total Savings projected by PCRA

Electricity: 21,43,360 kVAh Worth: Rs 78.24 LacLDO: 184.31 KL Worth: 85.8 Lac

Total Savings Realised till date

Electricity: 5,21,017 kVAh Worth: Rs 19.02 LacLDO: 130.06 KL Worth: Rs 60.55 Lac

% Savings Realised of total energy consumption

Electricity: 3.7%LDO: 20.3%


Summary of Savings Identified (Year 2005)

Total savings identified Electricity: 7,17,004 kVAhPNG: 1,36,042 SCMWorth: Rs 59.18 Lac

No cost savings with immediate payback

Electricity: 95,308 kVAhWorth: Rs 4.1 Lac

Low cost savings with payback < 1 year

Electricity: 5,41,796 kVAhWorth: Rs 23.3 Lac

High cost savings with payback between 1-2 years

Electricity: 79,900 kVAhWorth: Rs 3.44 LacGas: 1,36,042 SCMWorth: Rs 28.34 Lac

% savings identified of total energy consumption

Electricity: 5.32%Gas: 7.66%


BOILERS

Observations:1. Condensate recovery is not being done.2. Feed water temperature presently is 50C.

Recommendations:3. Recover condensate to raise feed water temperature to upto 85C4. Install de-aerator head on feed water tank and recover condensate.5. Install steam operated condensate recovery pump

Savings Estimated / year Investment Payback Period

Rs 28.34 Lac Rs 25 Lac 11 Months


Air Compressors

Observations:1. Air leakage are about 26%.

Recommendations:2. Plugging of air leakages


Rs 4.0 Lac Nominal Immediate


Illumination

Observations:1. HPMV lamps are used for street lighting.2. 36 Watt Tube lights with copper chokes are used.

Recommendations:3. Replace HPMV lamps by HPSV lamps4. Replace 36 Watt Tube lights with T-5 28 Watt with electronic choke in a

phased manner.


Rs 3.34 Lac Rs 4.0 Lac 16 Months


Conclusion

The gaps may exist in design & actual operations for large complexes due to integration of :

Steam thermal systems.Electrical systemsProcess systems (Motive/ Thermal loads) due to variation in efficiencies/ actual requirements

Continuous monitoring and analysis of integrated systems is essential for improvements.

Energy Audits will identify such gaps.Implementation of recommendations will result into considerable energy savings.

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Thank YouDarshan Vithani ,Pranav Pathak

ME-CSE

Technology

Case Study of Energy Audit