Case Studies Energy Audit Ir. Totok Sulistiyanto M.eng .Sc 1

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Energy Conservation(Free Encyclopedia): Efforts to reduce energy consumption through the result of several processes or developments, such as productivity increase or technological progress.

Energy Efficiencygy y(Free Encyclopedia): The goal of efforts to reduce the amount of energy required to provide products and services. It is achieved when energy intensity in a specific product, process or area of production or consumption is reduced without affecting output, consumption or comfort levels. Sometimes called efficient energy use.

Energy Management Energy Management is a technical and management function the remit of whichEnergy Management is a technical and management function the remit of which

is to monitor, record, analyze, critically examine, alter and control energy flows through system so that energy is utilized with maximum efficiency. (Paul O Callaghan, Energy Management)

The strategy of adjusting and optimizing energy, using systems and procedures so as to reduce energy requirements per unit of output while holding constant or reducing total costs of producing the output from these systems (Bureau of Energy Efficiency, India) 3

Energy Audit (Free Encyclopedia)An energy audit is an inspection, survey and analysis of energy flows for energy conservation in a building, an industry, process or system to reduce the amount of energy input into the system without negatively affecting the output(s).g y g p ( )

Energy Audit (US Agency for International Development)Energy audit is a tool to identify areas where energy can be conserved.

Energy Audit (Guide Book: Energy Audit)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 an action p g gy y yplan to reduce energy consumption.

Audit Energi (PP 70 tahun 2009 tentang Konservasi Energi)Adalah proses evaluasi pemanfaatan energi dan identifikasi peluang penghematan energi serta rekomendasi peningkatan efisiensi pada pengguna energi dan pengguna sumber energi dalam rangka konservasi energi.

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Preliminary Energy AuditPreliminary energy audit is a relatively quick exercise to: 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-cost/low-cost) improvements/savings Set a reference point Identify areas for more detailed study/measurement Preliminary energy audit uses existing, or easily obtained data

Detailed Energy AuditA comprehensive audit provides a detailed energy project implementation plan for a facility since it evaluates all major energy using systems This type of audita facility, since it evaluates all major energy using systems. This type of audit offers the most accurate estimate of energy savings and cost. It considers the interactive effects of all projects, accounts for the energy use of all major equipment, and includes detailed energy cost saving calculations and project cost.In a comprehensive audit, one of the key elements is the energy balance. This is based on an inventory of energy using systems, assumptions of current operating conditions and calculations of energy use. This estimated use is then compared to utility bill charges. 5

Pemanfaatan energi oleh pengguna sumber energi dan pengguna energi wajib dilakukan secara hemat dan efisien

(Pasal12)

energi wajib dilakukan secara hemat dan efisien. Pengguna sumber energi dan pengguna energi yang

menggunakan sumber energi dan/atau energi lebih besar atau sama dengan 6.000 (enam ribu) setara ton minyak per tahun wajib melakukan konservasi energi melalui manajemen energi.

Manajemen energi dilakukan dengan: menunjuk manajer energi; menyusun program konservasi energi;

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melaksanakan audit energi secara berkala; melaksanakan rekomendasi hasil audit energi; dan melaporkan pelaksanaan konservasi energi setiap tahun

kepada Menteri, gubernur, atau bupati/walikota sesuai dengan kewenangannya masing-masing.

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Industrial plantshigh energy intensity

Other sectors:Energy sector

Process IndustryEnergy Analysis

EnergyAudit

Programme

Power Plant Energy Analysis

Specific UtilityEnergy Audit

CH

EMEAir

Audit intensity

Industrialplants

Small Medium Enterprices

Small buildingsservice sector

Large buildingsi t

BuildingAudit

IndustrialEnergyAudit

EnergyInspection Post-

acceptanceEnergy

Audit

Follow-upEnergyAudit

IndustrialEnergy

Analysis

ProgrammeUpdating

withindustrialmodels

THE

VOLU

NTA

RY

AGR

EEM

ENT

SC

Infra-red Audit

HVACAudit

ElectricalAudit

IndustrialEnergyAudit

Building EnergyAudit

Model not subsidised / Commercial Audits Model subsidised / Partnership Program

service sector

Blocks / Apartment / flats / Neighbourhood

Small residential buildings

T

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Freelance energy auditors Energy Audit / Energy Management Consultants Mechanical & Electrical Consultants Equipment manufacturers / suppliers Energy committee in industries Energy audit training centers R h t Research centers Universities Related government officers Others

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Seeking for where the greatest energy Seeking for where the greatest energy consumed goes to

Measuring the energy losses started from the greatest energy consumer

Analyzing the problem bli hi i Establishing a saving strategy

Calculating the saving and payback period

Implementing the strategy 12

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1. Energy Consumption (kWh, Joule)

2 Energy Intensity / Specific Energy Consumption2. Energy Intensity / Specific Energy Consumption

(kWh/Ton Prod), (Ton Steam/Ton Prod), (kWh/m2/bl) (kW/TR), (liter of Oil/Ton Steam), (lumen/watt)

3. Lighting Intensity (lux) for specific activity

4. Power Intensity (watt/m2, pk/m2)

5. Energy Distribution (Energy used and losses). 5. Energy Distribution (Energy used and losses).

6. Efficiency and effectively of equipment

7. Aspects of human comfort and lighting comfort

8. Energy saving potentials (kWh/thn, Rp/thn.)

9. Energy Management Planning13

Inefficient design of utility systemsConfigurations, settings, and/or operation of utility system are inefficientLack of knowledge and lack of discipline of the operators, energy managers to the effect of energy wastageScheduling and maintenance of equipment are not optimalUtilities and its components in industrial processes are working at low efficiencyat low efficiencyDo not follow the basic procedures, control system is not functioning, and/or setting the system does not comply the requirementSensors or control systems are not functioning properly

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IMP 1

TransducersIntegrated Measuring Pods

Light IntensityLight Intensity

Electrical CurrentElectrical Current

IMP 2

IMP n

Electrical LoadElectrical Load

COCO22, O, O22 & CO& CO

HumidityHumidity

TemperatureTemperature

PressurePressure

FlowFlow

Measure Existing ParametersMeasure Existing Parameters Analyze Existing EquipmentAnalyze Existing Equipment

E l t E i ti I t ll tiE l t E i ti I t ll ti Evaluate Existing InstallationEvaluate Existing Installation Study Current Consumption BehaviorStudy Current Consumption Behavior

and Patternand Pattern

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$avingsAchievement:

C t Eff ti Cost Effective Efficiency Optimal Reliability

Searching New TechnologySearching New TechnologyConsideration:

Energy Efficient Reliability Low Investment Cost

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ReducingThe OperationalCosts

ImprovementOf Performance

The Performance of Units

Energy Consumption

Load Characteristic

Energy Consumption

The Performance of Systems

Operating Costs

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Executive Summary Energy Balance Profile of Energy Consumption Specific Energy Consumption Specific Energy ConsumptionIntroductory Background Aims and Goals Scope of Activities MethodologyEvaluation of Thermal Systems Thermal Energy Balance Thermal Energy Consumption

C b i S & Th l A l i Combustion System & Thermal Analysis Heat Integration and Process AnalysisElectrical System Evaluation Electrical Energy Balance Electrical Energy Consumption Demand Factor AnalysisEvaluation of Energy Management Asessemen of Energy Management 21

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Lift = 6.89%121.51 MWh/mo

Lighting = 10.63%187.43 MWh/mo

Others = 18.34%323.5 MWh/mo

Air Cond. System = 64.14%1,131.20 MWh/mo

PLN Supply = 100%1,763.64 MWh/Mo

Essential: 45.51%1,094.48 kW

Essential: 22 64%

Non-Essenttial: 2.46%59.17 kW

Essential: 22.64%416.96 kW

Non-Essential: 24.08%443.60 kW

Essential: 1.24%38.33 kW

Non-Essential: 4.06%124.62 kW

Garden Wing: 5.31% = 162.95 kW

PLN Supply = 100%2,177.16 kW

Tech Bld: 47.97%1,153.65 kW

Main Bld: 47.97%1,153.65 kW

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1 Building Type Office2 Year Built 20054 Gross Floor Area M2 3,0403 Conditioned Floor Area M2 2,736

Reference

5 Average Electricity Bill per Month Rp. 41,026,097Power Capacity Contract / Type kVA 414 / B3

6 Electrical Consumption per Month kWh/Mo 57,907

7 Electrical Energy Intensity of Conditioned Area kWh/y m2 253.98200

0 - 100ASEAN Energy AwardNZEB / EE Showcases

8 Type of LampsVarious capacity

TL, PL-C, HALOGEN, HALOPAR, HCI-T, DOWNLIGHT, T-5

9 Average Light Power Density Level Watt/m2 14.3110.76

4.80 - 12.00ASHRAE 90.1-2007

NZEB / EE Showcases

10 Average Office Plug Load Level Watt/m2 12.67 < 5.00 NZEB / EE Showcases10 P k L d/Off P k L d C t E % 13 23%10 Peak-Load/Off-Peak-Load Cost Expences % 13.23%11 Air Conditioning System (DX System):5 Units

Indoor Unit ( total number: 25) COP 2.56 2.802.96

3.50 - 6.50ASHRAE 90.1-2007

VRV/VRF System

12 Air Conditioning Type : Split Unit EER 08 0913.0017.75

ASHRAE 90.1-2007VRV/VRF System

13 Typical Zone Temperature oC 24 27 25 + 2 SNI14 Typical Zone Relative Humidity % 35 65 60 + 10 SNI

15 Total Cooling Capacity of Central Air Conditioning Ton.Ref 112,49 25

NO TYPE OF LOADS kW %

1 Air Conditioning System 125.43 40.23%

2 Lift 66 21.17%

3 Lighting System 43.5 13.95%

4 Plug Loads 34.67 11.12%

5 Ground Water Pump 24 7.70%

6 Computer 12.55 4.02%

7 Others 5.67 1.82%

Total 311.82 100 % 26

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Measurement of Chipper Motor:6 000 V 203 A cos=0 6356.000 V, 203 A, cos=0,635

Improvement of cos 0.9:kVARc 648,56 kVARc

Energy Saving: Operating Time 2400 hours / year

{(1.629,69) x 2400 - (0,65 x 1.339,6 x 2400)} x Rp. 114,-

= Rp.238,23 Mill,-/yrp , , y Transformer losses 5%, operating time 2400

hours / yr{1-(0,635/0,9)2} x 5% x 1339,6 x 2400 x Rp. 109,-

= Rp. 8,84 Mill,-/yru PLN tariff 1994

1.629,69 kVAR

Daya Resistif (Watt)

1.339,6 kW

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Other plant 1800 kW

G3

G2

G1 2700 kVA472A; 3.3 kV 1000 kVA; 3150 kVA/380 V; 183/1519 A

UTILITY 1- 405 kW/ 0.84

UTILITY 2 - 394 kW/ 0.83

SPINNING - 620 kW/ 0.82

POLYMER 248 kW/ 0 59

460OC

438OC

430OC

G4 Capacitors2 x 500 kVAR

STRETCHING - 415 kW/ 0.81

SOURCE WTR - 26 kW/ 0.80

TURBO REFRIG. - 220 kW

POLYMER - 248 kW/ 0.59

403OC

430 C

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Other plant 1800 kW

Recovering of Waste Heat Energy Cost saving Rp.297,230,000,-/y - Pay back period 1.6 years

WHRB

430OCG3

G2

G1 2700 kVA472A; 3.3 kV 1000 kVA; 3150 kVA/380 V; 183/1519 A

UTILITY 1- 405 kW/ 0.84

UTILITY 2 - 394 kW/ 0.83

SPINNING - 620 kW/ 0.82

POLYMER 248 kW/ 0 59

438OC

460OC9 bar1.25 T/h

9 bar1 25 T/h

WHRB

WHRB

430 C

G4 Capacitors2 x 500 kVAR

STRETCHING - 415 kW/ 0.81

SOURCE WTR - 26 kW/ 0.80

TURBO REFRIG. - 220 kW

POLYMER - 248 kW/ 0.59

403OC

Steam line to process

1.25 T/h

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flue gas

steam

Ms (kg/s)P (b )

Mu (kg/s)T (oC)CO2 (%)O2 (%)CO (ppm)

Mu (kg/s)T (oC)CO2 (%)O2 (%)CO (ppm)

Simple cost benefit ratio after implementing ADDMF technology :Boiler capacity 1.6 Ton/hour

BURNER

BOILER

ECONOMIZER

CHIMNEY

fuel in

Mf (kg/s)

Me (kg/s)

P (bar)T (oC)

CO (ppm) CO (ppm)

Boiler performance status 65% (total efficiency)Operating hour 12 - 20 hours/day

Fuel consumption 180,000 litres ADO /year = Rp. 99,000,000,-/yearMaintenance cost (cleaning, overhauling, etc.) Rp. 4,500,000,-/yearChemical component costs(softener, resin, salt, chemical injection compound, etc.) Rp. 2,000,000,-/yearF l t (ADO) i ft d i 1 i l t ti

ADDMF

combustion air

blowdown water feed water feed water

Ma (kg/s)Tdb (oC)Twb (oC)

Mb (kg/s)Tdb (oC)Twb (oC)

( g )T(oC)

Me (kg/s)T(oC)

Fuel cost (ADO) saving after during 1 year implementation,10% x 180.000 litres x Rp. 550,- /litre =Rp. 9,900,000,- /year

Reduction cost for maintenance Rp. 4,000,000,- /yearReduction cost for chemical compounds Rp. 2,000,000,- /year

Total cost saving = Rp. 15,900,000,- /yearThe cost of ADDMF equipment Rp. 18,000,000,- the pay back period of theimplementation of the equipment is about 1.1 year.

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jacket

coolingtower

waterHE

[-44%]40

UNITSWHRB[-83%]

38UNITS

18UNITS

100UNITS

generator[ -90%]

31UNITS

35UNITS

engine[ 35-45%]

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menara pendingin

unit pengolah udara (AHU)

Tic(oC) Tdu(oC)Twu(oC)Mu(kg/s)

Toc(oC)Tds(oC)T ( C) M (k / )

Tdf(oC)Twf(oC)

/

pompa

evaporator

kondensor

motor-kompresorkatup expansi

Wc(kW)Mc(kg/s )

Pc(bar)TC(oC)

Pe(bar)Te(oC)

Pk(bar)Tk(oC)

Two(oC)

Twi(oC)

Tws(oC), Ms(kg/s)

Tdr(oC)Twr(oC)Mr(kg/s)

Mf(kg/s)

Tdm(oC)Twm(oC)RH(%)

Wm(kW)

pompa

evaporator

unit koil kipas(FCU)

Mw(kg/s)Ww(kW)

toto/konser.hfx3232

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Measure , Record & Calculate

179oC

FuelBoiler400kg/hr

APH

5200kg/hr,120oC

Flue gas320oC

stack

Steamprocess

179 C

Condensatereturn

uetank 30oC

30oC

Feed water Tank520 kg.hr

4680kg/hr

10% makeup water

Air

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Perbandingan Konsumsi daya dan masa kembalinya investasiJumlah titik lampu tetap Jumlah titik lampu berubah

No deskripsi Kondisi awal konvensional Electronics konvensional Electronicsballast ballast ballast ballastballast ballast ballast ballast

1 Jumlah titik lampu 9 9 9 6 62 Jumlah lampu/armatur 4 3 3 4 43 Tipe lampu TLD18W/54 TLD18W/84 TLD18W/84 TLD18W/84 TLD18W/844 Tipe ballast konvensional konvensional elektronik konvensional elektronik5 Jumlah ballast 2 2 1 2 16 Total daya (watt) 828 666 504 552 4327 Kuat penerangan (lux) 338 538 538 512 5128 Penghematan daya/thn (kWh) - 801 1562,4 1331,3 1910,19 Penghematan biaya/thn(Rp) - 160.200,00 312.480,00 226.260,00 382.020,00

10 Investasi (Rp)a. Ballast 13.500,00 13.500,00 75.000,00 13.500,00 75.000,00b. Starter + holder 4.500,00 3.500,00 - 4.500,00 -c. Capasitor 7.500,00 7.500,00 - 7.500,00 -d. TLD 12.000,00 18.000,00 18.000,00 24.000,00 24.000,00e. Armatur kosong 110.000,00 100.000,00 100.000,00 120.000,00 120.000,00

11 Investasi per unit (Rp) 147.500,00 142.500,00 193.000,00 169.000,00 219.000,0012 Total investasi (Rp) 1.327.500,00 1.282.500,00 1.737.000,00 1.017.000,00 1.314.000,0013 Tambahan investasi (Rp) - -45.000,00 409.500,00 -310.500,00 -13.500,0013 Masa pengembalian (thn) - murah&hemat 1,3 murah&hemat murah&hemat14 Prioritas pilihan 2 4 1 3

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Sebelum Retrofit Sesudah RetrofitItem Rata2 Maks. Min. Dev.

Std.Keterangan Rata2 Maks. Min. Dev

StdKinerja Chiller PengukuranKinerja Chiller Pengukuran

(08.45 -16.22)(07.29 -15.52)

1. Daya Kompresi (kW) 68.9874.16

77.2480.55

65.4467.94

4.283.07

60.0560.80

64.4664.50

55.4453.01

1.961.96

2. Beban Pendinginan(kW)

159.24176.89

179.58196.04

143.66152.34

11.616.70

243.45230.85

266.97247.82

217.89211.90

8.217.57

3. COP 2.302.39

2.572.75

2.242.17

0.120.19

4.063.80

4.744.39

3.753.46

0.140.15

4. Suhu Udara Ambient(oC)

28.8529.76

31.6133.93

26.3225.85

1.202.08

28.8429.85

31.8732.48

25.5125.85

1.261.43

5. Temp. Input ChilledWater (oC)

15.7916.21

22.4120.25

12.8712.73

1.741.17

17.3017.62

18.4723.49

13.3214.82

1.321.49Water ( C)

6. Temp. Output ChilledWater (oC)

10.4710.33

16.8514.42

7.867.32

1.611.14

9.179.91

10.3516.04

6.007.48

1.091.35

Kinerja Chiller diukurdari Beban AHU

Peng. sesaat10/03/1999

22/03/19991. Beban Pendinginan

(kW)150.30 164.74

2. COP 2.24 2.77

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No Item Unit Jan Feb Maret April

1 Total Kamar kamar 150 150 150 150

2 Kamar Terjual kamar 2410 2160 2805 2715

3 Tingkat Hunian % 77 70 93 96

4 Konsumsi Listrik Perbulan

kWh 381.000 288.000 348.000 306.000

5 Biaya Listrik Rp/Bl 242.328.744 195.679.632 268.366.400 158.652.000

6 Konsumsi/Kmr Terjual

kWh/Kmr 158 133 124 113j

7 Biaya Listrik/Kmr Terjual

Rp/ Kmr 100.551 90.592 95.674 58.435

8 Total Revenue Rp 1.268.000.000 1.165.000.000 1.489.000.000 1.454.000.000

9 % Listrik thd Revenue

% 19 17 18 1136

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No Measures Avg Savings (% of Total Electrical Consumption)

B ELECTRICAL SYSTEM1 Raise Power Factor 5.12 Lower excess transformer capacity 3.3

C LIGHTING1 Lower Lighting Wattage 1.62 Reduce lighting hours 2.8

D ENVELOPE MODIFICATIONS1 Lower window-wall ratio 12.72 Install double glazed windows 2.13 Installation, infiltration, roof absorbtion 0.8

E ELEVATORS1 Eliminate 1-floor elevator trips 0.2

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No Action Average Saving % of Energy Consumption

Boilers

1. Boiler Tune Up 2 3 %o e u e Up 3 %

2. Reduce Operating Pressure 1 5 %

3. Install Preheater 4 7 %

4. Install Economizer 4 7 %

5. Recover Heat from Condensate 3 15 %

6. Minimize Radiation Heat Loss 1 %

7. Select Optimum Steam Pressure 1 %

8. Control Heat Using Instrument 1 %

9. Clean Heating Surface 1 %

Diesel Generators

1. Waste Heat Recovery 5 25 %

2. Fuel Additive 1 3 %

3. Fuel Preheating 1 %

Electrical Power Systems

1. Raise Power Factor 5 6 %

2. Electrical Balance Loads 1 5 %

3. Lower Excess Transformer Capacity 3 3.5%

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No Measures Avg Savings (% of Total Electrical Consumption)

A AIR CONDITIONING SYSTEM

1 Install VAV controls 12.6

2 Install Heat Exchanger for incoming air 12.0

3 Install high efficiency chillers 9.6

4 Maintain clean AHU filters, cooling coils 7.2

5 Minimize outdoor air intake 6.0

6 Optimize multiple chiller operation 4.9

7 Raise A/C condenser temperature 4.1

8 Replace Over-sized electrical motor 3.8

9 Raise set point to 25.5o C 3.6

10 Relocate offices to lower cooling load 3.0

11 Modify airflow to condenser 2.8

12 Reduce A/C equipment run time 2.3

13 Install variable speed pumps 1.6

14 Install small A/C for separate space 1.3

15 Install high efficiency pumps 1.339

Low cost/no cost investmentMedium cost investmentHigh cost investment

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Luas lantai (ft2)BTU/jam

Tembok tebal Tembok biasa

100125150175200250300

4.5505.1505.7006.2006.5007.5508 300

5.3006.1006.8007.5008.1009.300

10 400300400500

8.3009.70011.000

10.40012.40014.250

1 ft1 ft22 = 0,09290 m= 0,09290 m22 1 BTU = 3142 kWh1 BTU = 3142 kWh 1 BTU/j = 3142 kW1 BTU/j = 3142 kWKoreksi : Koreksi : dinding ke timur = 0,95 dinding ke timur = 0,95 LangitLangit--langit > 3 m = 1,1 Ruang teduh = 0,8langit > 3 m = 1,1 Ruang teduh = 0,8

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Basic Electrical Parameters in AC &DC systems Voltage (V) Current (I)

RPMAir VelocityN i d Vib tiVoltage (V), Current (I), Power factor (cos ), Active

power (kW), Maximum demand (kVA), Reactive power (kVAr), Energy consumption (kWh), Frequency (Hz), Harmonics, etc. Temperature & Heat Flow

Noise and VibrationDust ConcentrationTDSPHMoisture ContentRelative HumidityFlue Gas Analysis CO2, O CO SO NOTemperature & Heat Flow

RadiationAir and Gas FlowLiquid Flow

O2, CO, SOx, NOxCombustion EfficiencySteam trap analyzerInfra-Red Thermography

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C:\Document\Totok\PT. Narama Mandiri 2011

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1

IR - I0000000.035 189.6 C

1501

2

3

4

24/10/96 1:59:51 PM

-62.4-50

0

50

100

150

0.1

0.6 170.0

-50

0

50

100

150

0.6

0.5

1.6

3.4

9.6

13.2

43.3

21.5

4.8

1.4

0.0

155.0

140.0

125.0

110.0

95.0

80.0

65.0

50.0

35.0

20.0


59

IR - I0000000.018 89.4 C

70

80

70

80

IR - I0000000.029 40.0 C

0.0

0.0 40.0

23/10/96 2:23:29 PM

27.230

40

50

60

70

30

40

50

60

70

24/10/96 10:55:32 AM

15.015

20

25

30

35

400.0

0.0

0.1

4.8

6.2

8.7

10.0

16.2

50.7

3.4

0.0

37.5

35.0

32.5

30.0

27.5

25.0

22.5

20.0

17.5

15.0


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EnergyEnergylosses

Energy waste

Useful energy

gyinput

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Buildings Nation Globe

Reduced energy bills Increased

Competitiveness

Reduced energy imports Avoided costs can be used

for poverty reduction

Reduced GWP impacts Reduced GHG and

th i iCompetitiveness Increased productivity Improved quality Increased profits !

for poverty reduction Conservation of limited

resources Improved energy security

other emissions Maintains a sustainable

environment

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Thank YouS

TerimakasihMatur Nuwun

DankeDankeSpasiboSpasibo

XieXie xiexie

Salamat PoShukriya Aabhar

Arigatou Gozaimasu

Prepared by:Prepared by:Totok SulistiyantoTotok Sulistiyanto

XieXie--xiexie

64

Case Studies Energy Audit Ir. Totok Sulistiyanto M.eng .Sc 1

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Transcript of Case Studies Energy Audit Ir. Totok Sulistiyanto M.eng .Sc 1