case study of energy audit
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ENERGY AUDITDarshan Vithani ,Pranav Pathak
ME-CSE
2 of 26Energy Audit
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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Steps For DETAILED ENERGY AUDIT METHODOLOGY
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Steps For DETAILED ENERGY AUDIT METHODOLOGY
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Steps For DETAILED ENERGY AUDIT METHODOLOGY
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Steps For DETAILED ENERGY AUDIT METHODOLOGY
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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).....
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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.
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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.
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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
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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
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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%
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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%
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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
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Air Compressors
Observations:1. Air leakage are about 26%.
Recommendations:2. Plugging of air leakages
Savings Estimated / year Investment Payback Period
Rs 4.0 Lac Nominal Immediate
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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.
Savings Estimated / year Investment Payback Period
Rs 3.34 Lac Rs 4.0 Lac 16 Months
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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
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