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Energy Audits-Case
studies-Demo
Presentation at RENERGY 2013 at CTC-
Chennai on
11th May 2013
By S Kannan, Certified Energy Auditor
Director -AMSET Energy Systems and Solutions Private Limited,
Chennai/Bangalore/Pondy/Coimbatore/Trichy
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Presentation structure
• Energy laws-Basics
• Energy Audits-Definition, Areas
• Energy Audits- Scope & Approach
• Energy Audits-Case studies
• Benefits of Energy efficiency
• Future Energy
• Back to Basics
• Demo-Instruments & Products
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Energy Law/Basics
I Law- Law of Conservation
Energy can be neither created nor destroyed. It can be transformed from one form into another form. Total quantity of energy in the universe remains constant
II Law (Entropy)-Law of degradation
The quality of this energy is degraded irreversibly.
Entropy is a measure of disorder or uncertainty about a system
Sum total of Energy in the universe is constant, ever was, always will be, moving into form, through form and out of form.
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Basic definitions- as per EC act
2001
Energy conservation: Reduction of Energy consumption in physical terms
Energy efficiency: Reduction of Energy intensity in a specific product, process, area of production or consumption, without affecting output, consumption or comfort levels
Energy efficiency contributes to Energy conservation
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747326638808230710Total18
040.0000604.140145UI17
5882.900202910052.9003465NTPC-TNEB (IV)16
1553.000518773.000256MAPS (Addl.)15
2642.00013184272.0002135NLC-TS-II Expansion
14
5403.150171610223.1503245Kudankulam13
3302.33014152682.900925Simahadri12
3903.31011783643.0901178KAIGA11
3212.13015083212.1301508MAPS10
00.000000.0000Kayankulam9
11272.38247370510612.272183705NTPC -Talcher II8
52 52 340 3.21 52 897 NTPC ER 7
305 1.92 89 1125 311 1.98 88 1125 NTPC SR (III) 6
909 1.68 209 4164 932 1.89 147 4164 NTPC SR (I & II) 5
516 1.91 205 1624 494 1.94 179 1624 NLC-TS-I Expansion 4
NLC-TS-II (S age-II) 3 812 1.95 172 3272 708 1.84 105 3272
NLC-TS-II (S age-I) 2
658 1.73 129 3066 692 1.84 129 3066 NLC-TS-I 1
Rs.CroreRs./ kWh Rs. CroreMU Rs. CroreRs./ kWh Rs. CroreMU
Total Cost Energy Charges
Capacity Charges
Quantum Total Cost Energy Charges
Capacity Charges
Quantum
Commission Petition
Particulars S. No
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Energy Audits..
As per 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 action plan to reduce Energy consumption”.
DO NOT
1. Estimate when you can calculate
2. Calculate when you can Measure
3. Measure Non Value Adding processes-Eliminate those!!
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Energy use-Areas
Thermal Energy systems
Boilers, Steam systems, Furnaces, Heat Exchangers, Insulation and Refractory, Co-generation, Waste Heat Recovery
Electrical Energy systems
Motors, Pumps, Compressors, HVAC, Fans & Blowers, DG system, Lighting, Transformer, Cabling
In terms of Total Energy consumption the Electrical Energy share is 60% and Thermal share is 40%
1 kwh= 860 kcals
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Efficiency options
• Reduction of Specific Energy Consumption per unit of Production/Service
• Loss minimization
• Waste Minimization
• Low cost Energy substitution
• Renewable application
• Process savings- Raw Material & Wages reduction
Investment in Energy efficiency is estimated around Rs 1 cr/MW while for a Power producing plant in > Rs 4 Crores/MW + Generation cost!!
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Process or Unit
Operation
Gaseous Emission
Product
By Product
Wastewater
Liquid waste for storage and disposal
Solid waste for storage and disposal
Raw
materials
Chemicals
Water/Air
Energy/power
Recycle
Reusable waste in other
operation
Components of material balance Components of Mass Balance
Raw
Materials
Chemicals
Water/Air
Energy/Power
Recycle
Reusable
Waste in
Other operation
Gaseous
Emission
Product
By product
Liquid waste
For storage
And disposal
Solid waste
For storage and
disposal
Waste water
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Process or Unit
Operation
Energy in Vapours
Radiation loss
Energy in hot poducts
Energy in hot Residues
Energy in condensate
Energy in cooling water
Electricity
Steam
Cooling Water
Chilled Water
Compressed Air
Energy in Raw Material
Components of Energy Balance Components of Energy Balance
Electricity
Steam
Cooling
Water
Chilled water
Compressed
Air
Energy in Raw
material
Energy in
vapours
Radiation loss
Energy in hot
Products
Energy in hot
residue
Energy in
Condensate
Energy in
Cooling water
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The man who waits for
conditions to improve may have
to wait for eternity
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Energy Audit-Approach & Scope
• Energy Data questionnaire-
ElectricalEnergy_Audit-Data sheet.doc
• Energy Audit scope-typicalEnergy Audit-
Scope.doc
• Baseline estimation-SEC-Specific
Energy Consumption
• Target Energy-SEC reduction
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Instrument List for Energy Audit-Typical
THERMAL
No
. Instrument Intended Use
1 Flue Gas
Analysers
Used for optimizing the combustion efficiency by measuring/monitoring
the oxygen and CO levels in flue gas of boilers, furnaces etc. and
calculation of CO2 percentage in excess air level and efficiency.
2 Temperature
Indicators
Used for measuring temperatures of gases/air, iquids, slurries, semi
solids, powders etc. Using different types of probes.
3 Infrared
Thermometers
Used for measuring temperatures from a distance using infrared
technology.
4 Thermal
Insulation scanner
Used for measuring loss of energy in Kcal per unit area from hot/cold
insulated surfaces. The total loss can be obtained by multiplying the
total surface under study.
5 Steam Trap
Monitor Used for performance evaluation of steam Traps.
6 Conductivity
Meter
Used for on the spot water analysis of the amount of dissolved solids in
water.
7 pH meter Used for on the spot analysis of effective acidity or alkalinity of a
solution/water. Acidity /alkalinity water.
8 Thermo-
hygrometer
Used for measurement of air velocity & humidification, ventilation, Air-
conditioning and refrigeration systems etc.
9 Ultrasonic Flow
Meter
Used for measurement of flow of liquids through pipelines of various sizes
through ultrasonic sensors mounted on the pipelines.
10 U-Tube
Manometer Used for measurement of differential pressure.
11 Digital Manometer Used for measurement of differential pressure.
12 Visguage Used for measurement of differential viscosity.
13 Used Lube Oil
Test Kit Used for testing lube oil.
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ELECTRICAL
1 Non-Contact
Tachometer Used for measurement of speed of rotation equipment.
2 Demand Analyser Used for measurement and analysis of electrical load and demand control.
3 Power Analyser Used for measurement and analysis of electrical Power.
4 Harmonic Analyser Used for analysis of harmonics in power System.
5 Luxmeter Used for measurement of illumination level.
6 Clip on Dig. Watt
Meter Used for measurement of power without interrupting the connections.
7 Clip on Dig. PF Meter Used for measurement of power factor without interrupting the connection.
8 Clamp on amp. Meter Used for measurement of current without Interrupting the connections.
9 Digital Multimeter Used for measurement of voltage. Current and resistance.
10 Frequency Meter Used for measurement of power supply frequency.
11 Earth Leakage Tester Used for the leakage current in the earthing.
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Typically 9-14 opportunities are identified under 3
categories
1. Without Investment-Instant payback-Low hanging
fruits
2. Minor Investment-3-12 months payback
3. Major Investment-Paid back in 3 years
Direct Savings-Energy, Material
Indirect savings-Machine Life, Time..
One never notices what has been done; one
can only see what remains to be done
Energy Audit -outcome
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C1
C3
C2
B
A
Energy efficiency Check-Evaluation
Portfolio
Profitability
Profitable
3 years ROI
Not Profitable
Difficult Easy Technical Feasibility
Thermal
Electricity
Coolants
Gases
Bubble size = saving potential
Portfolio Categories
A = feasible and profitable
B = likely feasible and profitable, needs further
evaluation
C1 = technically (currently) not feasible but
profitable
C2 = technically feasible but not profitable
C3 = technically (currently) not feasible & not
profitable
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S
P
E
C
I
F
I
C
O
U
T
P
U
T
BC- WASTAGE
EFFORT
ECO
ECO- ENERGY CONSERVATION OPPERTUNITY
A B C
AB- SPECIFIC CONSUMPTION OF
PRESENT SYSTEM
AC-ACTUAL ENERGY INPUT
D
AD- SPECIFIC CONSUMPTION
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Case Study-DG
DG operation at < 50Hz
Of late due to Restriction and Control measures, operation by DG is on the rise.
Instead of operating at 50Hz, if the DG is operated at 49Hz, Diesel saving of around 4% [theoritically-5.88%] is feasible
Approach: To reduce @0.2Hz in 5 steps, assessing the loads.
Pay back: Instant
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KWH from DG set is Rs.15 where EB kwh costs Rs.6 only.
With our DG set, are we paying Rs.12 or Rs.20 per KWH
unit ?
Concentrate on the loading in KVAH of the DG set.
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Case Study-Compressor
Compressed Air-Leakage quantification
• Shut-off compressed air operated equipments or conduct test when no equipment is using compressed air
• Run the compressor to charges the system to set pressure on operation
• Note the subsequent time taken for “load” [T] and “unload” [t] cycles [avg for 8-10 cycles]
• The system leakage is T X 100/(T+t)
In a typical manufacturing industry, the leakage observed is > 30%.
Air is free
Compressed air is costly!!
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Case study-Compr.
Compressed air savings by replacing ordinary
cleaning nozzles with energy efficient nozzles
• In automotive plants compressed air cleaning is
an important process to ensure the quality.
• The compressor air guns, of10 mm ID are used
for cleaning minute particles in machine and to
clean the floor.
• Replacing these nozzles with energy efficient
transvector nozzles reduces the compressed air
consumption.
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Principle transvector nozzles
Air Jets utilize the coanda effect (wall attachment of a high
velocity fluid) to produce air motion in their surroundings.
As illustrated, a small amount of compressed air (black
arrows) is throttled through an internal ring nozzle above
sonic velocity. A vacuum is produced, pulling large volumes
of surrounding, or “free” air, through the jet (blue
arrows). Both the outlet and inlet can be ducted for remote
positioning.
• Pay back is <20 months
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Case Study-Compressor
Compressor- Inlet Air temp.
In Industries audited by us, we have observed that
Air Inlet temperature is higher than ambient.
Every 4degC rise in Air inlet temp will increase the
Power consumption by 1%
Energy efficiency options
• Ventilate the compressor room well
• Explore cooling inlet Air. Cooling up to 15deg C
are feasible by simple methods
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Case study-Compressor
VFD for Air-compressors
• If over designed air-compressors are installed in
an industry the compressor will be in unloading
mode for a longer time. The unloading power
consumed is a wastage .i.e no useful work done.
• To eliminate this wastage, variable frequency
drives can be installed.
• About 15 to 20 % of the energy can be saved by
installing VFD in a air compressors
• Pay back <25 months (based on the unloading time)
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Typical loading & unloading pattern
of a 100 CFM compressor
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Energy Saving-AC Air conditioning systems are usually dimensioned to cope with the extreme cooling demands of the few hottest days of the year (plus a safety margin).
How ever in most operational conditions, this maximum output is not required
and the system is over sized. So running the system continuously until the room thermostat switches it off that the system operates with the excess capacity most of the time
When the cycle starts, the compressor pushes cooling energy in to the heat exchanger which acts an energy storage. At this stage systems works with high efficiency because compressors operate most efficiently when fully loaded.
In normal weather conditions, the energy storage is soon fully “charged up” From this point onwards ,The compressor provides more cooling energy than the heat exchanger can take up [Thermodynamic saturation]
Running the compressor beyond this stage does not increase the cooling effect any more. It’s just a waste of Energy !!
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Energy Saving-AC –contd. Ideal for AC units operating more than 10 hrs/day 300 days/year.
Faster paybacks for higher capacity AC systems
German technology--
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Case Study- Lighting
Lighting-Voltage optimisation
Lighting requires 210V, while the normal voltage is
240V.
A voltage stabilizer can be installed, where
separate feeder for lighting is existing.
This is economically viable above 50kw lighting
load. The loss in illumination, if any, can be
compensated by increasing lamp/lux levels
Pay back: < 2 years
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Case Study- Lighting Retrofits
• A typical Tube light [T12-40w] consumes 52 watts with
Copper choke & 42 watts with Electronic choke
• New range of T5 [24/28w] lamps are energy efficient by
30% for same/better illumination levels
• Retrofit options are introduced [no change of Fitting],
with faster paybacks
Payback- less than 2 years
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Case Study-Solar pre heating
Solar (pre) Heating of Water-Canteen/Boiler
Heating water up to 70 deg C by Solar panels are
economically viable now. Many Hotels and
Hospitals have benefited by this. Now Industrial
canteens, where Hot water is required for
washing utensils, are opting for Solar heating.
Pay back: < 2 years
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Case Study - AC Stabilizer
• An AC stabilizer consumes 20watts.
• Typically AC is ON for 12 hrs/day (max)
• If Stabilizer is NOT switched OFF, when
AC is OFF [remote does NOT switch off
Stabilizer!!] 240 watts of Energy is
wasted/day
• For 300 days/year= 72 units @
Rs.7/unit=Rs.504/AC/year
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Case study - UPS-Efficiency
• Efficiency of UPS= Output kw.h/Input kw.h
• Efficiency is related to “loading” of UPS
• At typical “loading” of 20%, the Efficiencies are
lower.
• Energy Efficient UPS register around 90%
efficiency, even under low loading.
• Pay back = < 2 years
• Switch-off UPS, during “idle” time
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Constant flow water taps-
Canteen/Toilets • Usage of water is on the rise in any
establishment be it washing, cleaning etc
• Constant flow Water taps are available, in
which the flow is anywhere between 50
and 70% of normal flow
• Considering the cost of water and its
pumping cost, the pay backs are attractive
Payback- few days!!
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Future Energy
The “best” is the enemy of the
“good”
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Reserves Background-Oil/Gas
• Oil/Gas- With all “information pollution” from media about exhaustion, the fact remains that the exact amount of “oil/gas” reserves is not explored/published!!
• Opinion of world running out of oil range from year 2030 to 2083 to 2100. We may NOT be alive beyond Year 2100 to verify this !!
• Cost of oil drilling is around $ 15/barrel, while the price is quoting around $ 100+/barrel.
• Even at $ 100/barrel [=165 litres], adding the cost of refining, the cost of oil [petrol/diesel] works out to Rs 30/litre, while it is being sold at > Rs 50/litre average. Almost Govt. receives > Rs 20/litre of oil “sold”, by means of Taxes and Duties.
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Reserves Background-Coal
• Under current Reserve to Production ratio, India Coal reserves are estimated to last > 200 years.
• Many areas in the states of Chattisgarh/MP/Bihar/Jharkhand/Orissa which have Coal reserves, are in areas reserved as “forests”. Mining coal from forest will call for felling of trees, which will impact the “monsoon” rains, again a key factor affecting the livelihood of Indian population.
• Also the quality of Indian Coal is poor compared to that of Australia/Indonesia, containing around 40% ash, which does not give energy and have disposal problems.
• Coal based power plants pollutes the environment and a recent study of IIM-A has estimated the “health” cost as Rs 3/kw.hr, which is more than “generation” cost!!
• Most polluted city of India is NOT Delhi or Mumbai or Bangalore or Chennai. It is Raipur in Chattisgarh, owing to large scale Coal mining!!. Ankleshwar/Vapi/Korba/Ludhiana/Vellore/Noida/Kanpur/Cuddalore are in “Top Ten’ list of pollution,due to Industrial activities, as per recent CPCB-IIT Delhi study.
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Energy –Future trends-Supply side
• Share of Renewable will increase in the Energy mix.
• Generation cost of Solar is expected to come down drastically by/before Circa 2015.
• More mini Hydel plants will get installed.
• Rural energy-Micro turbines/Biomass
• Share of Gas will increase, as many gas finds are reported-Reliance/Cairn..
• Reduction in AT & C losses. Many Electricity boards are mandated.
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Energy-Future trends-Demand side
• As happened in Telecom, consumers will
have the option to “chose” their Energy
supplier.
• Energy pricing will be aggressive like pre-
paid, post-paid, off-peak etc.
• Off-grid consumers-islanding Energy
• Off shore energy-wind/geothermal
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Future-Immediate
• 500+ Designated Consumers –DC [>3000 MTOE/annum] have been mandated by BEE to pursue Energy efficiency.
• Perform, Achieve, Trade [PAT] scheme had come into force from April 2011, by which Energy efficient DC’s [below Baseline] can trade the surplus to other DC’s who consume Energy above Baseline.
• Energy Management Standard-EnMS under ISO 50001 [BS 16000] series notified in June 2011.
• Buildings with connected load > 100kw [120kva] have to conduct Energy audits with 3 year frequency, as notified in Gazette during Sep 2010.
• Kerala has mandated Energy Audits for all HT consumers, with 3 year frequency. Karnataka is contemplating a GO.
• TN has notified Solar Purchase Obligation-SPO. Big consumers [HT/Buildings] are mandated to invest in Solar for meeting 6% of their Power needs from Jan 2014-3000MW investments envisaged.
• TN has also notified voluntary Energy audit for big consumers.
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Return to Energy Basics
Energy law-I
Energy can be neither created nor
destroyed. It can be transformed from one
form into another form.Total quantity of
energy in the universe remains constant
But….
Energy can be WASTED
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Law II
The quality of this energy is degraded irreversibly
Entropy is a measure of disorder or uncertainty
about a system
Organizations to evolve a robust Energy
Management system, with policies and Planning.
Energy can be planned and controlled..
Policy-Quality, HR….. Energy
Procedure-Quality, Recruitment….Energy
Planning-Quality, Material, Business….Energy
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Sum total of Energy in the universe is constant, ever was, always will be, moving into form, through form and out of form.
But… It comes with a COST
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Knowledge is NOT free. Ignorance is
expensive
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Input Raw
Materials
Intermediates PROCESS PROCESS PROCESS
Environmental
Aspects
Environmental
(Env Effects)
Stakeholders
Government
Hazards
Working
Conditions
Employees
ENERGY
Analysis For
Energy
Conservation
opportunities
PROFIT PLANET PEOPLE = ENERGY RHYTHM
OUTPUT
PRODUCTS
QUALITY
CHARACTERISTICS
PRODUCT QUALITY
CUSTOMER
CRITICAL ASPECTS OF QUALITY,ENVT,OHS &EC
INTEGRATED MANAGEMENT
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Change is certain, progress is not
Thanks for attention
S Kannan +91 96552 41599
AMSET Energy
www.amsetenergy.in