ENERGY AuditENERGY Audit

ByBy

Ravindra M DatarRavindra M Datar

Senergy Consultants (P) LtdSenergy Consultants (P) Ltd

91-982127163091-9821271630senergy@vsnl.com senergy@vsnl.com

www.senergy-india.comwww.senergy-india.com

Senergy Senergy

Synergy Synergy

between between

Our expertise on conservation of energy Our expertise on conservation of energy

&&

Your experience & knowledge ofYour experience & knowledge of

process, operations, plant engineering, etc. process, operations, plant engineering, etc.

To To

Save EnergySave Energy

Senergy Senergy • Leading Energy Conservation Consultants in Leading Energy Conservation Consultants in

IndiaIndia

• Conducting Studies for past 20 years.Conducting Studies for past 20 years.

• One of the first auditor to receive ISO 9001-One of the first auditor to receive ISO 9001-2000 certification. 2000 certification.

• Team of experts headed by a technocrat from Team of experts headed by a technocrat from IITIIT

• Customer driven company with many repeat Customer driven company with many repeat orders & orders form group companiesorders & orders form group companies

Senergy Senergy

• Empanelled with Maharashtra & Gujarat Empanelled with Maharashtra & Gujarat Governments (MEDA & GEDA)Governments (MEDA & GEDA)

• BEE certified auditorsBEE certified auditors

• Customer base of over 450 industriesCustomer base of over 450 industries

• Contributing Rs 50 crores/year, towards Contributing Rs 50 crores/year, towards conservation of energyconservation of energy

Senergy Senergy • Interactive studies.Interactive studies.

• Practical & Realistic Suggestions.Practical & Realistic Suggestions.

• Turnkey Consultancy during Implementation.Turnkey Consultancy during Implementation.

• Long term services for Sustainable Savings Long term services for Sustainable Savings & Continuous Improvements.& Continuous Improvements.

• Basic & Advanced Training Programs. Basic & Advanced Training Programs.

Few of our clientsFew of our clients• Sterlite Industries LtdSterlite Industries Ltd

• South Seas DistillerySouth Seas Distillery

• Excel Industries Ltd Excel Industries Ltd

• Century Enka Ltd Century Enka Ltd

• Century RayonCentury Rayon

• Asian Heart Hospital Asian Heart Hospital

• Essel World Essel World

• EBG India Pvt LtdEBG India Pvt Ltd

• Aarti Drugs LtdAarti Drugs Ltd

• EEmco Ltdmco Ltd

• PPepsiCo India LtdepsiCo India Ltd

• ICI LtdICI Ltd

• USV LtdUSV Ltd

• Allana Industries LtdAllana Industries Ltd

• Tata Chemicals LtdTata Chemicals Ltd

• Schenectady Herdillia ltdSchenectady Herdillia ltd

• Hindustan Lever Ltd Hindustan Lever Ltd

• Nicolas Piramal India LtdNicolas Piramal India Ltd

• Wyeth Lederle Ltd Wyeth Lederle Ltd

• DGP Hinoday Ltd DGP Hinoday Ltd

• GTC Industries LtdGTC Industries Ltd

• M S E B M S E B

• WhirlWhirlpool of India Ltdpool of India Ltd

• PPidilite Industries Ltdidilite Industries Ltd

• Sachivalay – Gujarat Sachivalay – Gujarat

• Wochkhardt Ltd Wochkhardt Ltd

Instruments Instruments

• Ultrasonic non-contact type flow meters for liquids Ultrasonic non-contact type flow meters for liquids

• Harmonic analyzer Harmonic analyzer

• Clamp-on type power / energy meters Clamp-on type power / energy meters

• Anemometers – to measure velocity of gases Anemometers – to measure velocity of gases

• Digital ManometerDigital Manometer

• Tachometers – Contact / Non-contact typeTachometers – Contact / Non-contact type

• Digital thermometers for liquid / surface temperatureDigital thermometers for liquid / surface temperature

• Lux meterLux meter

• Combustion Gas AnalyzerCombustion Gas Analyzer

• Pressure Gauges Pressure Gauges

• Digital Hygro-temp Meter (for Temp & RH measurement)Digital Hygro-temp Meter (for Temp & RH measurement)

Energy AuditEnergy Audit

1.1. Specific Energy ConsumptionSpecific Energy Consumption

2.2. Targets & Benchmarks Targets & Benchmarks

3.3. Unaccounted ConsumptionUnaccounted Consumption

4.4. Equipments PerformanceEquipments Performance

5.5. Distribution System Distribution System

6.6. UtilizationUtilization

7.7. Recovery from Waste Energy Recovery from Waste Energy

8.8. Cost of Energy Cost of Energy

9.9. Renewable Energy Renewable Energy

10.10.Energy Monitoring Energy Monitoring

Specific Energy Specific Energy ConsumptionConsumption

Specific Energy: Energy consumed per unit Specific Energy: Energy consumed per unit output.output.

It is the Key performance assessment tool for It is the Key performance assessment tool for every energy consumer.every energy consumer.

Collect the details onCollect the details on

– Total productionTotal production– Power consumption – SEB & CaptivePower consumption – SEB & Captive– Consumption of each type of fuelConsumption of each type of fuel– Cost of each type of fuel Cost of each type of fuel

Specific Energy Specific Energy ConsumptionConsumption

Specific Energy Specific Energy ConsumptionConsumption

Specific Energy ConsumptionSpecific Energy Consumption

Targets & Benchmarks Targets & Benchmarks Benchmark is the desired or targeted Benchmark is the desired or targeted

consumption of energy or specific energy consumption of energy or specific energy consumption.consumption.

The benchmark values are set based on The benchmark values are set based on

Theoretical Calculations Theoretical Calculations

Specifications by equipment / plant supplier Specifications by equipment / plant supplier

Best achieved in the same plant Best achieved in the same plant

Best achieved in the similar industry.Best achieved in the similar industry.

Specific Power Consumption Specific Power Consumption for for

Office PremisesOffice Premises

Case StudyCase Study : 343 kWh/M: 343 kWh/M22/Year/Year

Wipro Wipro :190 kWh/M:190 kWh/M22/Year/Year

ITC ITC :125 kWh/M:125 kWh/M22/Year /Year

CII CII :70 kWh/M:70 kWh/M22/Year/Year

Energy Accounting & Un-accounted Energy Accounting & Un-accounted ConsumptionConsumption

Prepare break up of consumption for each Prepare break up of consumption for each form of Resources energy byform of Resources energy by

– Computing consumption of the respective Computing consumption of the respective area / equipment.area / equipment.

– Noting down operating period.Noting down operating period.– Take data from various sub-metersTake data from various sub-meters

Compare total consumption as estimated Compare total consumption as estimated above with actual consumption to above with actual consumption to ascertain ascertain

– ““Unaccounted” or “Miscellaneous” portion of Unaccounted” or “Miscellaneous” portion of the consumptionthe consumption

Analyze consumption pattern Analyze consumption pattern

Energy Accounting / Balancing Energy Accounting / Balancing

Cooling Water System

10%

Illumination8%

Air Conditioners - Data Center

7%

Air Conditioners - Miscellaneous

6%

Computers & UPS28%

Air Conditioners - Package

27%

Miscellaneous14%

Equipment PerformanceEquipment Performance Compute performance of all the Compute performance of all the

equipments by measuring equipments by measuring

•Actual Output Actual Output – Flow, pressure, refrigeration effect, FAD, Flow, pressure, refrigeration effect, FAD,

etc. etc.

•Specific Energy Consumption Specific Energy Consumption – kWh/TR, CFM/kWh, Steam to fuel ratiokWh/TR, CFM/kWh, Steam to fuel ratio

•Efficiency Efficiency – Pump, boiler, thermopacPump, boiler, thermopac

Performance of the Machines Performance of the Machines

Air Conditioning Effect

-5.0

0.0

5.0

10.0

15.0

20.0

TAG No

AC E

ffec

t (T

R)

DropActual Output TR

Specific Power Consumption : ACSpecific Power Consumption : AC

Specific Power Consumption

0

0.5

1

1.5

2

2.5

3

3.5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

TAG No

Sp P

ower

(kW

h/TR

)

LossDesired Sp Power

Norms: Specific Output - Air Norms: Specific Output - Air Compressor Compressor

Distribution System Distribution System

• Heat Loss – Hot Insulation, Surface Evaporation Heat Loss – Hot Insulation, Surface Evaporation

• Heat Ingress – Cold Insulation, Openings in AC Heat Ingress – Cold Insulation, Openings in AC area area

• Leakages – Compressed Air, Thermic Fluid Leakages – Compressed Air, Thermic Fluid

• Pressure Drop – Pumping Systems, Compressed Pressure Drop – Pumping Systems, Compressed Air Air

• Power Loss – Electrical Systems & Cabling Power Loss – Electrical Systems & Cabling

Utilization Utilization

• Over / Under Sized EquipmentOver / Under Sized Equipment Pumps, boilers, air compressors Pumps, boilers, air compressors

• High Grade Energy for Low Grade Applications High Grade Energy for Low Grade Applications Compressed air for cleaning, brine in place of chilled Compressed air for cleaning, brine in place of chilled

water water

• Unwarranted & Rigid Specifications.Unwarranted & Rigid Specifications. Stringent Process Conditions Stringent Process Conditions

Recovery of Waste EnergyRecovery of Waste Energy

• Recovery from Flue Gas ExhaustRecovery from Flue Gas Exhaust Preheat water, combustion air, product Preheat water, combustion air, product

• Recovery form Hot EffluentRecovery form Hot Effluent Preheat water or process fluidPreheat water or process fluid

• Process Energy Optimization Process Energy Optimization Pinch Analysis to optimize heating & cooling load Pinch Analysis to optimize heating & cooling load

• Condensate Heat RecoveryCondensate Heat Recovery Low Pressure Flash Steam, condensateLow Pressure Flash Steam, condensate

Cost of Energy Cost of Energy

• Avail Maximum Tariff Concessions & Benefits Avail Maximum Tariff Concessions & Benefits Unity PF, Night Operation, Bulk Discount, Bulk Unity PF, Night Operation, Bulk Discount, Bulk

Purchases Purchases

• Switchover to cheaper FuelSwitchover to cheaper Fuel Electrical to fuel heating. FO to Coal for Boiler, Electrical to fuel heating. FO to Coal for Boiler,

thermopac. FO to Producer Gas for furnaces. thermopac. FO to Producer Gas for furnaces.

• Co-generation Co-generation Heat Recovery from engine exhaust / cooling. Heat Recovery from engine exhaust / cooling.

Steam based co-generation Steam based co-generation

Renewable Energy Sources

Solar

Wind

Bio

Geo

Tidal

Renewable Energy Renewable Energy

• Solar Heating Applications up to 80 Solar Heating Applications up to 80 ooCC

• Wind Mills Wind Mills

• Fuel From Organic / Agro Waste Fuel From Organic / Agro Waste

• Methane from Effluent Methane from Effluent

• Fuel from Municipal Waste Fuel from Municipal Waste

Energy Monitoring Energy Monitoring

• Overall Monitoring of Energy as well as Specific Overall Monitoring of Energy as well as Specific Energy ConsumptionEnergy Consumption

• Key parameters for all the major equipments Key parameters for all the major equipments

• Cost of Energy Cost of Energy

• Power Factor, Maximum DemandPower Factor, Maximum Demand

20

22

24

26

28

30

32

34

1000 1050 1100 1150 1200 1250 1300 1350 1400

Production (kg/day)

Sp

En

ergy

(R

s/k

g)

Initial

Stage

Final

Ideal

Case Study - ICase Study - ISpecific Energy ConsumptionSpecific Energy Consumption

Process

Waste Ice 8.5 Waste Ice 8.5 TPDTPD

Ch WaterCh Water

111100CC

Effluent Effluent

121200C C To E To E

T PT P 300 m3/DAY 300 m3/DAY

Fish, laced with ice is received in trucks from various places. Fish, laced with ice is received in trucks from various places. The ice is removed and thrown in common pit and fed to ETPThe ice is removed and thrown in common pit and fed to ETPChilled Water is used for washing the fish.Chilled Water is used for washing the fish.The Chilled Water is collected in a common pit and fed to ETP. The Chilled Water is collected in a common pit and fed to ETP. On an average 300 M3/hr of water is chilled from 30 to 10 Deg On an average 300 M3/hr of water is chilled from 30 to 10 Deg

C.C.

Original System: 1400 TR of Load per day Original System: 1400 TR of Load per day

Case Study - IICase Study - IIHeat Recovery from Waste Heat Recovery from Waste

StreamStream

Plate Type Heat

Exchanger

Waste Ice 8.5 TPDWaste Ice 8.5 TPD Fresh Water 30Fresh Water 3000CC 221m221m33/day/day

Ch WaterCh Water 111100CC

25 2500C E T P C E T P Effluent Effluent 121200CC 229.5 m229.5 m33/day/day

1250 TR / 221 M1250 TR / 221 M33/day/day

13 1300C C

Reduction in refrigeration load: 82% Reduction in refrigeration load: 82%

Process

Chilled Water System(1400 TR)

Case Study - IICase Study - IIHeat Recovery from Waste Heat Recovery from Waste

StreamStream

Case Study - IIICase Study - IIICondensing TurbineCondensing Turbine

Thermal Efficiency of the system depends on Thermal Efficiency of the system depends on

• Steam temperature & pressure at the inlet of Steam temperature & pressure at the inlet of turbine.turbine.

• Steam temperature & pressure at turbine Steam temperature & pressure at turbine outlet Controlled by Cooling Water outlet Controlled by Cooling Water Temperature.Temperature.

12% Addition Power through 12% Addition Power through rationalization of Cooling Water Systemrationalization of Cooling Water System

Case Study - III Case Study - III Condensing TurbineCondensing Turbine

Case Study - IIICase Study - III Condensing Turbine Condensing Turbine

Flow Rate / Efficiency is greatly influenced byFlow Rate / Efficiency is greatly influenced by

• Discharge Pressure.Discharge Pressure.

• Pump Conditions Pump Conditions

• Suction Pressure.Suction Pressure.

20 to 50% Energy Savings through 20 to 50% Energy Savings through rationalization of Suction & Discharge rationalization of Suction & Discharge Pressures Pressures

Case Study - IVCase Study - IVPumps, Fans & BlowersPumps, Fans & Blowers

Variable Speed based Variable Speed based Control Control

Thank Thank

You!You!