CONCEPT OF ENERGY AUDIT OPPORTUNITY OF ENERGY...
Transcript of CONCEPT OF ENERGY AUDIT OPPORTUNITY OF ENERGY...
© Confederation of Indian Industry
CONCEPT OF ENERGY AUDIT OPPORTUNITY OF ENERGY
EFFICIENCY IN INDUSTRIESat
TPDDL 5 March 2018
© Confederation of Indian Industry
from Creativity to Innovation –
Holistic Approach to Energy Management
Manpreet Singh
Counsellor – EnergyAccredited Energy Auditor
Confederation of Indian [email protected]
09876724003
© Confederation of Indian Industry
At the outset..
Thank you for
– Opportunity
© Confederation of Indian Industry
CII Energy Audit & Management
Energy Services
Detailed Energy Audit Mandatory Energy Audit Training Programs on Energy Developing road map/benchmarking on
Energy Consumption Missions/workshops/seminars on energy Audited more than 1500 units
© Confederation of Indian Industry
CII Energy Audit & Management
Major Initiatives & Projects
World Class Energy Efficiency in Power Plant World Class Energy Efficiency in Sugar, Paper &
Cement Sectors IREDA Project for Energy Efficiency in Textile
sector Energy Audit of major DCs sector under PAT
Scheme BEE – SME program for Energy Efficiency in SME
sectors BEE – GEF – WB Faridabad Cluster Developed Manual on Energy Efficiency at Design
Stage
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FMCGs PepsiCo
HLL
P & G
MDLZ
R M Chemicals
ACCL
Haldiram Snacks Pvt Ltd
Anmol Bakers Pvt Ltd
Tasty Dairy Specialities
Marico Ltd
Jubilant Group Plant
Mawana Sugar group Plants
Olam Sugar
KM Sugar Mills
Alwar Oil Mill Cluster
Hafed Oil Mill Plants
Reckitt Benckiser India Ltd
Colgate Palmolive Sri City
Nestle
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Pharmaceuticals
Baxter India Pvt Ltd
Glenmark Pharmaceuticals Ltd
USV Limited
Nectar Life Science
Sun pharmaceuticals Ltd
DSM Sinochem Pharmaceuticals
Cipla Ltd
Panacea Biotec Industries Ltd
Quad Life Sciences
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Textile Sector
Arisht Spinning Mills
Ganga Acrowool Ltd
Vardhman Textile
Abhishek Industries
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Process Plant
Bilt Graphics & Paper Products Ltd,
Khanna Paper Mill
Sainson Paper industry
Hindustan Zinc Ltd
PT Jindal, Indonesia
Chandigarh Distillers & Bottlers Ltd
Somany Ceramics Ltd
Orient Bell Ltd
Roca Bathroom Products Pvt. Ltd.
Piramal Glass Ltd
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Auto Sector OEMs Bajaj Auto
Escorts Group Plants
International Tractors Ltd
Hero Cycles Ltd
Hero Moto Corp
Escorts Faridabad ( 5 Plants)
Honda Cars India Ltd, Tapukara & G. Noida
Mahindra & Mahindra
Tata Motors (Pantnagar, Lucknow and Sanand)
Yamaha Motors G. Noida
SML ISUZU.. Many more
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Auto Sector (Auto ancillaries) JBM Group
Minda Group
Lumax Group
National Engineering Industries Ltd
Rockman Industries Ltd
Federal Mogul Goetz India Ltd ( 3Plants)
Shriram Pistons & Rings Ltd
RICO Auto Industries Ltd
Sona Koyo Steering Ltd ( 3 Plants)
Continental Engines
Omax Group
Shivam Autotech
Sun steering wheels… many more
© Confederation of Indian Industry
Energy Audit
An energy audit –
is an inspection, measurement
survey and analysis of energy flows for
energy conservation in an industry,
building, process or system
to reduce the amount of energy
input into the system without
negatively affecting the output
© Confederation of Indian Industry
Methodology
Data collection
Measurement
Knowledge Sharing & Training
Discussions & Presentation…….
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List of Instruments used during Audit
Ultrasonic Flow Meter
Power Analysers 3 Phase & 1 Phase
Digital Pressure Gauges
Thermal Imager
Vane type anemometer
IR Temperature Gun
Lux meter
Hygrometer
© Confederation of Indian Industry
Installation of Power Meter
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Equipment load pattern
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Installation of Flow Meter
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Installation of Flue gas analyser
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Process Flow Diagram
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Energy Audit - Benefits
Tangible Benefits
Intangible Benefits
Plant expansion – designing of
parameters
Energy Efficient equipment purchase
Alternate fuel/energy sources options
Identification & feasible
recommendation for critical issues
Reduction in energy consumption
Better control over quality
Savings in raw material consumption
Better equipment life
Reduced GHG emissions
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Measure of encon activities
Reduction in specific energy and Water consumption
Energy Conservation at Macro Level
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Energy Conservation at Macro Level …
Three-pronged approach
Capacity utilisation
Fine-tuning
Technology upgradation
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Macro Level - Methodology
Any process/unit operation
Unavoidable losses
(c)
(d)Avoidable losses
a = b + c + d
Energy input (a)
TheoreticalRequirement
(b)
© Confederation of Indian Industry
Losses – Avoidable Vs Unavoidable
• Pumps - Valve throttling control or Re-circulation
• Air Compressor leakage
• Compressed air generation pressure
• Furnace – Radiation losses
• Boiler – Flue gas losses
• Over designed equipments – Air Compressors, Fans & Blowers etc
• Condenser cooling water losses in Chillers etc
© Confederation of Indian Industry
Focus
should be
• To concentrate on avoidable losses
• Quantify the losses
• Identify ways and means for reduction
• Implementation
Macro Level - Methodology …
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Macro Level - Methodology
Losses – Two ways of representing
There is compressed air leakage from 6 mm pipe in the plant
Pump is operating at 40% valve throttling
ID/FD fan being controlled by closing the damper
Motor is under loaded
Boiler flue gas temperature is 40 deg higher thanrecommended
Specific Energy Consumption of Chiller is 0.15 kW/TR higher
SEC of Aluminium Tower Furnace is 60 Kg/ Ton of LPG for 1Ton per hour capacity
© Confederation of Indian Industry
Macro Level - MethodologyLosses – Two ways of representing
There is compressed air leakage from 6 mm pipe in the plant whichis costing Rs. 6.0 Lakhs/annum
Pump is operating at 40% valve throttling – Consuming 40% extrapower
Blower flow is being controlled by closing the damper – consuming5 kW more than requirement
Boiler flue gas temperature is 40 deg higher than recommended -Costing around 2% extra fuel
Specific Energy Consumption of Chiller is 0.70 kW /TR which is 0.15kW/TR higher than the rated and costs Rs. 30 Lakhs/Annum for 300TR Chiller
SEC of Aluminium Tower Furnace is 60 kG/ Ton of LPG for 1 Ton perhour capacity as compared to 45 kG/Ton as per OEM havingopportunity of 57 Lakhs annually in LPG Bill
© Confederation of Indian Industry
Macro Level - Methodology
Identify ways and means for reduction -
There can be 3 – 4 means of reduction
Over designed pump -
Replacing with correct size
Impeller trimming
Speed control
Two pump system
Decision depends on many factor – like cost, reliability, process etc
© Confederation of Indian Industry
Coverage
Thermal/Mechanical/Electrical
Furnace (Melting / Holding)
Boiler and Steam System
Ovens
HVAC System
Air compressors System
Leakage and Capacity Test
Cooling Towers
Major Motors
Thermal Imaging
Washing Machines
Process Equipments
Electrical distribution System
Bill Analysis
Harmonics Study
Power Factor Improvement
Capacitors Health Checkup
Electrical Safety & Cables
Lighting
Fans & Blowers (AWU & AHU)
All Major Pumps
Dust Collectors
© Confederation of Indian Industry
Three Pronged Approach
Detailed Energy Audit
Simple Projects(< 6 months payback)
Medium term(6-18 months payback)
Long term(18-30 months payback)
© Confederation of Indian Industry
Why energy saving?
There have always been good reasons forenergy saving
• CO2 reductions• Environmental pollution• Reduced operation costs
Two reasons force the market to act
• Legislation – worldwide and local• Increasing energy costs
© Confederation of Indian Industry
Energy Saving Opportunities
Industrial sector consumes about
half of the total energy generation
Energy can be saved up to 5 – 30 %
5 – 10 % of energy saving by following
best operating practices
10 – 30 % of energy saving achieved by
using energy efficient systems
© Confederation of Indian Industry
3 Major Factors
© Confederation of Indian Industry
Cost of Chiller Operation
Total chiller power = 120 kW
Initial cost - Rs. 20.0 Lakhs
Life of Compressor - 10 yrs
Maintenance cost - Rs. 0.4 Lakh/yr
Energy Cost in 1 yr - Rs. 20.0 Lakhs
Energy Cost in 10 yr - Rs. 200.0 Lakhs
Equipment & Cost of Operation
© Confederation of Indian Industry
90 kW & 45 kW compressors in operation
Present power consumption – 87 kW & 54 kW on
loading
Total power = 141 kW
Running hrs = 24 hrs, 320 days/yr = 7680
hrs/yr, power cost Rs. 7.7/unit
Equipment & Cost of Operation
Air Compressor
© Confederation of Indian Industry
Cost of operation
Energy Cost in 1 yr - Rs. 83.38 Lakhs
Energy Cost in 10 yrs - Rs. 833.8 Lakhs
Initial cost - Rs. 15.0 + 5.0 Lakhs
Life of Comp - 10 yrs
Maintenance cost - Rs. 1.0 Lakh/yr
Equipment & Cost of Operation
Cost Air Compressor Operation
© Confederation of Indian Industry
Life cycle cost of Dust collector blower
Total blower power - 40 kW
Initial cost - Rs. 3.5 Lakhs
Life of Blower - 10 yrs
Maintenance cost - Rs. 0.5 Lakh/yr
Energy Cost in 1 yr - Rs. 23.0 Lakhs
Energy Cost in 10 yr - Rs. 230.0 Lakhs
Equipment & Cost of Operation
© Confederation of Indian Industry
Life cycle cost of Induction Furnace 1 T
Total power - @ 600 units/T
Initial cost - 70 - 80 Lakhs
Life of Furnace - 10 yrs
Maintenance cost - Rs. 10.0 Lakhs/yr
Energy Cost in 1 yr - Rs. 280.0 Lakhs
Energy Cost in 10 yr - Rs. 2800.0 Lakhs
Equipment & Cost of Operation
© Confederation of Indian Industry
I. Energy & Life cycle cost of an
equipment
Initial Cost
3.4%
Maintenance
Cost 2%
Energy Cost 94.6%
Energy Cost in 10
yrs- Rs. 833.8
Lakhs
Initial cost -
Rs. 30.0 Lakhs
Life of Comp
10 yrs
Maintenance cost
- Rs. 10 Lakh/yr
© Confederation of Indian Industry
Energy efficiency at design stage may reduce initial investment !
© Confederation of Indian Industry
Intial cost vs Energy Efficiency in new projects
best example excel CT pumps
recommended pumps - 120 kW
existing pumps - 200 kW
cost of 120 kW pump & motor set must be atleast 25% less than present cost
© Confederation of Indian Industry
Example from Industry - Excel Plant Cooling Tower
© Confederation of Indian Industry
Avoid Valve Control in Excel Plant Cooling Tower Pumps and Replace with correct size Energy
Efficient Pumps
Present System
Excel Plant Cooling Tower pump studied
Presently 4 Pumps are installed
Pump 1, 3 & 4 were in operation, 2 was on standby
Rated specification Head , Flow & power are noted
Actual Running parameters head , flow & power are
measured.
Pump NameRated Parameter Measured/Calculated Parameter
Flow
(m3/hr) Head (m) Power( kW) Flow (m3/hr) Head (m) Power( kW)
CT Pump (Excel) 1 1250 42.5 200 1000 31 179
CT Pump (Excel) 2 1250 42.5 200 1000 31 179
CT Pump (Excel) 4 1250 42.5 200 950 31 170
© Confederation of Indian Industry
Excel Plant Cooling Tower Pump
© Confederation of Indian Industry
Excel Plant Cooling Tower Pump 4
Valve Controlling at suction
© Confederation of Indian Industry
Excel Plant
Valve Controlling
© Confederation of Indian Industry
Avoid Valve Control in Excel Plant Cooling Tower Pumps and Replace with correct size Energy
Efficient Pumps
Observations
Mismatch of measured head & flow with rated
Valve controlling of Approx. 40-50% observed at suction
Required Head is much low than the rated
Results in decrease in efficiency and increase in power
consumption
Inefficient way of flow controlling
© Confederation of Indian Industry
Action Plan – Option 1
Replace present pumps with correct size impeller possible in same casing
Operation efficiency will be low
Investment will be minimal
Present Impeller size 450 mm
Proposed impeller size 405 mm
Power Consumption will be 130 kW/Pump
Saving Potential = 140 kW
Avoid Valve Control in Excel Plant Cooling Tower Pumps and Replace with correct size Energy
Efficient Pumps
© Confederation of Indian Industry
Avoid Valve Control in Excel Plant Cooling Tower Pumps and Replace with correct size Energy
Efficient Pumps
© Confederation of Indian Industry
Annual Saving - Rs 62.33 Lakhs
Investment - Rs 8.0 Lakhs*
Simple Payback - 2 Months
Option No 1
Saving = 140 kW x 24 hrs/day x 350 Days/Annum x 5.3 Rs/kWh
* For 4 nos. of impeller
Avoid Valve Control in Excel Plant Cooling Tower Pumps and Replace with correct size Energy
Efficient Pumps
© Confederation of Indian Industry
Action Plan – Option 2
Replace present pumps with correct size pumps
Install 4 nos. of pumps, 3 for operation & 1 standby
At least 175 kW will be saved
Recommended Pump
Avoid Valve Control in Excel Plant Cooling Tower Pumps and Replace with correct size Energy
Efficient Pumps
Flow(m3/hr) Head (m) Power(kW)
1200 27 118
© Confederation of Indian Industry
Air Compressor Running Pattern
010203040506070
2:4
7:2
7 P
M
2:4
7:5
4 P
M
2:4
8:2
1 P
M
2:4
8:4
8 P
M
2:4
9:1
5 P
M
2:4
9:4
2 P
M
2:5
0:0
9 P
M
2:5
0:3
6 P
M
2:5
1:0
3 P
M
2:5
1:3
0 P
M
2:5
1:5
7 P
M
2:5
2:2
4 P
M
2:5
2:5
1 P
M
2:5
3:1
8 P
M
2:5
3:4
5 P
M
2:5
4:1
2 P
M
2:5
4:3
9 P
M
2:5
5:0
6 P
M
2:5
5:3
3 P
M
2:5
6:0
0 P
M
2:5
6:2
7 P
M
2:5
6:5
4 P
M
2:5
7:2
1 P
M
2:5
7:4
8 P
M
2:5
8:1
5 P
M
2:5
8:4
2 P
M
2:5
9:0
9 P
M
2:5
9:3
6 P
M
3:0
0:0
3 P
M
3:0
0:3
0 P
M
3:0
0:5
7 P
M
3:0
1:2
4 P
M
3:0
1:5
1 P
M
3:0
2:1
8 P
M
3:0
2:4
5 P
M
3:0
3:1
2 P
M
3:0
3:3
9 P
M
3:0
4:0
6 P
M
3:0
4:3
3 P
M
3:0
5:0
0 P
M
3:0
5:2
7 P
M
3:0
5:5
4 P
M
3:0
6:2
1 P
M
3:0
6:4
8 P
M
3:0
7:1
5 P
M
3:0
7:4
2 P
M
3:0
8:0
9 P
M
3:0
8:3
6 P
M
3:0
9:0
3 P
M
3:0
9:3
0 P
M
3:0
9:5
7 P
M
3:1
0:2
4 P
M
Power 55 kW energy efficient air compressor
Power kW
© Confederation of Indian Industry
Air Compressor Running Pattern
0
5
10
15
20
25
30
35
40
5:3
6:2
0 P
M
5:5
8:2
0 P
M
6:2
0:2
0 P
M
6:4
2:2
0 P
M
7:0
4:2
0 P
M
7:2
6:2
0 P
M
7:4
8:2
0 P
M
8:1
0:2
0 P
M
8:3
2:2
0 P
M
8:5
4:2
0 P
M
9:1
6:2
0 P
M
9:3
8:2
0 P
M
10:0
0:2
0 P
M
10:2
2:2
0 P
M
10:4
4:2
0 P
M
11:0
6:2
0 P
M
11:2
8:2
0 P
M
11:5
0:2
0 P
M
12:1
2:2
0 A
M
12:3
4:2
0 A
M
12:5
6:2
0 A
M
1:1
8:2
0 A
M
1:4
0:2
0 A
M
2:0
2:2
0 A
M
2:2
4:2
0 A
M
2:4
6:2
0 A
M
3:0
8:2
0 A
M
3:3
0:2
0 A
M
3:5
2:2
0 A
M
4:1
4:2
0 A
M
4:3
6:2
0 A
M
4:5
8:2
0 A
M
5:2
0:2
0 A
M
5:4
2:2
0 A
M
6:0
4:2
0 A
M
6:2
6:2
0 A
M
6:4
8:2
0 A
M
7:1
0:2
0 A
M
7:3
2:2
0 A
M
7:5
4:2
0 A
M
8:1
6:2
0 A
M
8:3
8:2
0 A
M
9:0
0:2
0 A
M
9:2
2:2
0 A
M
9:4
4:2
0 A
M
10:0
6:2
0 A
M
Power Consumption Trend at comp 6 section VFD 45 kW
power
© Confederation of Indian Industry
Compressor for process air –
running @ 35% loading & 65%
unloading
Compressor No 5 & 6 with VFD –
both running at part load @ 55 –
60%
Air Compressor Running Pattern
© Confederation of Indian Industry
Energy efficient system is the combination of best and most efficient components –
• system efficiency can be defined at different system levels
II. Equipment Efficiency & System Efficiency
© Confederation of Indian Industry
System efficiency -Motor efficiency is a key for best system efficiency, but not the only one:
ƞ system = ƞ drive x ƞmotor x ƞcoupling x ƞfan
• Drive is increasing with power size.Typical 96…98%Motor depends on power size and motor type 92%
Coupling describes efficiency of powertransmission motor shaft to fan. Direct drivenfan = 100%, belt driven • 85-95%.Fan is related to fan construction. Huge rotorh can limit fan efficiency.System Drive Motor Coupling Fan
© Confederation of Indian Industry
Energy Efficiency of Compressed Air System:
ƞair compressor system =
ƞgeneration x ƞdistribution x ƞuser
Ƞinduction furnace =ƞfurnace type x ƞcontrol x ƞelectrical x ƞAutomation
© Confederation of Indian Industry
Energy Efficiency of Pumping System
Ƞpumping system =
ƞgeneration x ƞdistribution x ƞuser
Ƞgeneration side =ƞsuction/discharge line x ƞpump x ƞmotor x ƞdrive
© Confederation of Indian Industry
System efficiency – energy efficient equipment
may not work efficiently in a system !!!!
Example –FurnacePumpCompressorblower
© Confederation of Indian Industry
III. Energy Monitoring & Targeting
© Confederation of Indian Industry
Energy Monitoring and Targeting
© Confederation of Indian Industry
Areas Covered
Electrical Distribution System
Compressed Air System
Utility Section 1,2 & Bournvita
Chilled Water System (5.5 oC)
Brine System (-26 oC)
Boiler and Steam System
WTP, ETP, RO
Lighting Facility
Ovens
Process
HVAC, AHU, Exhaust
Warehouse
Thermal Imaging of Electrical Panels & Thermal system
© Confederation of Indian Industry
Good Practices Implemented at XYZ India
Foods Pvt Ltd
Application of VFD at many places for energy savings
Many fine tune projects for energy savings
Installation of APH at Boiler, auto blow down system &
Installation of flash vessel for heat recovery
Very good insulation practices for both hot and cold
Energy efficient chiller
Energy efficient pumps
Energy Efficient VFD Compressors & Aluminium piping
Utility Section
© Confederation of Indian Industry
Committed technical team
Good electrical distribution system
Excellent power factor
Capacitor Banks working in good condition
No voltage drop in system
Appropriate electrical safety measures
Electrical Section
Good Practices Implemented at XYZ India
Foods Pvt Ltd
© Confederation of Indian Industry
Concerned Points, Opportunities available at
XYZ India Foods Pvt Ltd
Pressure setting of Compressed air system is very high 6.9
kg/cm2
VFD Compressor running at full RPM, not able to reach to
set pressure
Separate AHU installed for Compressor no 7 & 8,
compressors required only natural cool atmosphere
Leakage level is very high approx. 40 %
Utility Section (Compressed Air System)
© Confederation of Indian Industry
Concerned Points, Opportunities available at
XYZ India Foods Pvt Ltd
VFDs installed on many secondary Pumps running on fixed
low/full RPM, opportunity to run on modulation as per
system requirement
VFDs installed on many Air Handling Units (AHU) running
on fixed low/full RPM, opportunity to run on modulation as
per system requirement
Many Chillers of same temperature ranges are running on
Part loading, causing high power consumption in present
season
Some Chillers having low condenser / evaporator flow
causing high power consumption
Condenser water pipe size is less as per requirement in 1 –
2 Chillers
Utility Section (Chilled Water System)
© Confederation of Indian Industry
Concerned Points, Opportunities available at
XYZ India Foods Pvt Ltd
Utility 2 , 5.5 Deg C Chiller’s condenser water pump circuit
having 2 running parallel pumps, one on VFD, one fixed,
should be Fixed with correct parameters
Chilled water is being used to cool down 85 Deg C / 55 Deg
C water for process application, first we are giving energy
to heat the water and to cool the same
RH level is very low in some areas in range of 30 – 35 ,
requirement is 40
CO (carbon monoxide) level is very high (2000 – 6000 PPM)
in boiler no 3 & 4, Running efficiency is low
APFC panels are running in manual mode
Utility Section (Chilled Water System)
© Confederation of Indian Industry
Concerned Points, Opportunities available at
XYZ India Foods Pvt Ltd
False Ceiling can be provided in packing areas to reduce
cooling load
Utility Section (Chilled Water System)
Bore well utility 1 flow is controlled by valve throttling
Provision of Dissolved Oxygen sensor has made, not
installed, opportunity to control air blower by VFD
Utility Section (Water System)
© Confederation of Indian Industry
SUMMARY OF FINDINGS
Total annual savings - Rs. 340.18 Lakhs (32 Proposals)
Savings without Investment - Rs. 15.86 Lakhs(4 proposals)
Capital Project Saving - Rs. 252.31 Lakhs (6 proposals)Capital Project investment - Rs. 349.00 Lakhs (6 proposals)
Total Investment - Rs. 415.64 Lakhs (32 proposals)
Simple Payback - 15 Months
© Confederation of Indian Industry
S. No List of Energy Saving Proposal
Saving
Potential
Investm
ent
Payback
Period
Rs.
Lakh/AnnumRs. Lakh Months
1Minimize Compressed air Leakage by
Rigorous Maintenance 61.99 10 2
2Optimize Compressed Air Generation
Pressure 2.58 - -
3 Avoid Operation of VFD Compressor 5.53 - -
4Shut Operation of AHU Installed for Unit II
Compressors6.72 - -
5 Install Back Pressure Micro Turbine 10.84 20 22
6Avoid Damper Control & Use VFD to
Control ID Fan1.03 - -
© Confederation of Indian Industry
S. No List of Energy Saving Proposal
Saving
Potential
Investm
ent
Payback
Period
Rs.
Lakh/AnnumRs. Lakh Months
7Improve Surface Insulation to Reduce
Radiation Losses of Bourn vita Ovens22.42 12 6
8Stop Circulation of Chilled Water to
Maintain Hot Water Temperature25.76 20 9
9Improve Surface Insulation to Reduce
Radiation Losses8.71 3.4 5
10
Optimize Steam Consumption by
Condensate Recover and Waste
Minimization
3.25 4.0 15
11Performance Analysis of Chillers Installed
operating at 5.5 °C 43.78 3.0 1
12Optimize Power Consumption of
Secondary Pumps of Trane Chiller1.73 2.0 14
© Confederation of Indian Industry
S. No List of Energy Saving Proposal
Saving
Potential
Investm
ent
Payback
Period
Rs.
Lakh/AnnumRs. Lakh Months
13Optimize Power Consumption of
Condenser Pumps of Trane Chiller3.66 3 10
14Optimize Power Consumption of Primary
Pumps of Daikin Chiller at unit 24.45 5 13
15Optimize Power Consumption of
Secondary Pumps 1&2 of Frick Chiller6.6 2 4
16Optimize Power Consumption of
Secondary Pumps2.25 2 11
17Optimize Power Consumption of Primary
Pumps of Brine -25 Degree0.52 0.3 7
18Optimize Power Consumption of Hot Water
Generator2.23 0.5 3
© Confederation of Indian Industry
S. No List of Energy Saving Proposal
Saving
Potential
Investm
ent
Payback
Period
Rs.
Lakh/AnnumRs. Lakh Months
19Optimize Power Consumption of
Secondary Pumps of E-2 plant6.07 8 16
20Optimize Power Consumption of
Secondary Pumps 1& 29.22 6 8
21Optimize Power Consumption of WRP
cooling tower pump0.78 0.5 8
22Optimize Power Consumption of
Condenser cooling tower pump1.04 1.5 17
23Optimize Power Consumption of CETP
Transfer Pump0.69 1 17
24Optimize Power Consumption of Anfil feed
pump of New ETP 0.94 1 13
© Confederation of Indian Industry
S. No List of Energy Saving Proposal
Saving
Potential
Investm
ent
Payback
Period
Rs.
Lakh/AnnumRs. Lakh Months
25Optimize Power Consumption of
Circulation pump of new ETP1.41 1 9
26Optimize Power Consumption of Transfer
RO water to plant1.92 1.5 9
27Optimize Power Consumption of Anfil feed
pump of old ETP0.94 1 13
28Optimize Power Consumption of Nano
Feed Pumps of unit 2 utility1.48 0.5 4
29Replace 250 Watt With 120 Watts Led
Lamp 0.52 1.44 33
30Replace 3x36 Watt Light With 80 Watts
LED Light 42.96 135 38
© Confederation of Indian Industry
S. No List of Energy Saving Proposal
Saving
Potential
Investm
ent
Payback
Period
Rs.
Lakh/AnnumRs. Lakh Months
31Optimize Power Consumption of AHU fans
installed for Comfort Cooling55.4 169 37
32 Install DO Analyzer 2.76 1.00 4
Total 337.42 414.64 15
© Confederation of Indian Industry
SUMMARY OF FINDINGS – Patiala Facility
Total annual savings - Rs. 423.78 Lakhs
(42 Proposals and 6 Observation)
Savings with 3 months payback - Rs. 106.74 Lakhs
(14 Proposals)
Total Investment - Rs. 238.78 Lakhs
(42 Proposals)
Simple Payback - 7 months
© Confederation of Indian Industry
SUMMARY OF FINDINGS – Bhiwadi Facility
Total annual savings - Rs. 117.48 Lakhs
( 12 Proposals)
Savings with Nil Investment - Rs. 14.97 Lakhs
( 3 Proposals)
Total Investment - Rs. 76 Lakhs
(9 Proposals)
Simple Payback - 8 months
© Confederation of Indian Industry
Energy Saving Achieved in Plantby Replacing Old Compressors
© Confederation of Indian Industry
Normal Compressor in Operation – 29 September 2014
S. No. Compressor
No.
Type Rated
Capacity
(CFM)
Actual Power
Consumption
(kW)
1 1 Reciprocating 535 78
2 4 Reciprocating 1000 145
3 7 Screw 1024 188
4 9 Reciprocating 353 62
5 10 Reciprocating 535 73
6 11 Screw 1024 183
7 12 Booster 500 15
8 13 Booster 500 15
Total Power 759
© Confederation of Indian Industry
Normal Compressor is Operation – 30 Sep 2014
S. No. Compressor
No.
Type Rated
Capacity
(CFM)
Actual Power
Consumption
(kW)
1 1 Reciprocating 535 78
2 4 Reciprocating 1000 145
3 6 Screw 892 119
4 7 Screw 1024 188
5 11 Screw 1024 183
6 12 Booster 500 15
7 14 Booster 500 15
8 15 Booster 500 15
Total Power 758
© Confederation of Indian Industry
Normal Compressor is Operation – 9 August 2016
S. No. Compressor
No.
Type Rated
Capacity
(CFM)
Actual Power
Consumption
(kW)
1 4 Screw 1000 165
2 8 Screw 1000 98-130
3 9 Screw 1000 189
4 10 Screw 1000 170
Total Average Power 630
© Confederation of Indian Industry
Comparison
Description
Average Power before in 2014 759 kW
Average Power before in 2016 630 kW
Difference in power 129 kW
No of operational Hours 23 Per day
No of Operational Days 320 Per Year
Power Cost Rs.7.5/Unit
Net savings Achieved 71.2 Lakhs/Annum
Investment 80 Lakhs
Major Savings Achieved
By replacing old inefficient Reciprocating Compressor
80kW
By reducing leakages 50 kW
© Confederation of Indian Industry
Installed Light Pipes to Stop Operation of Lights in Day Time
Day Time
Night Time
Day Time
© Confederation of Indian Industry
Thermal Imaging
© Confederation of Indian Industry
Thermal Imaging
Compressor II 110 kW PCC Panel
© Confederation of Indian Industry
List of Instruments used during Audit
Ultrasonic Flow Meter
Power Analysers 3 Phase & 1 Phase
Digital Pressure Gauges
Hot wire anemometer
Thermal Imager
Vane type anemometer
IR Temperature Gun
Lux meter
Hygrometer
© Confederation of Indian Industry
Notification for Industry/Buildings/Malls etc & Various Categories of Power Consumers
Haryana Government New and Renewable Energy Department
Directions for Mandatory Detailed
Energy Audit*
*as per notification issued on 9th November 2016
© Confederation of Indian Industry
Consumer Category Type 1: Designated Consumers (DC’s)
By Central Government vide notification no.S.O. 1378(E), according to latest addition ofdirections dated 9th November 2016, thedesignated consumers shall -
Get energy audit from accredited energy auditor, inaccordance with BEE (Bureau of Energy Efficiency)Regulations, 2010
Furnish information to concerned designated agency, onenergy consumed and actions taken fromrecommendations of energy audit report, in accordancewith Energy Conservation Rules, 2008
© Confederation of Indian Industry
Consumer Category Type 2: Category (a) with load of 1 MW or above
All consumers in Haryana with connected loadof 1 MW or above, including open accessconsumers -
Should mandatorily get 1st detailed energy audit from BEEaccredited energy auditor firms/Energy Service Companies(ESCOs) within 18 months of above notification
Within 2 years, recommended actions in energy auditreport should necessarily be taken
After a lapse period of 2 years, within 3 months the detailson actions taken on basis of energy audit report should befurnished to New and Renewable Energy Department,Haryana
© Confederation of Indian Industry
Consumer Category Type 2: Category(b) of demand 10 MVA or more
Consumers of power with contract demand of10 MVA or above -
Should mandatorily get energy audit from accreditedEnergy Auditor, in accordance with BEE Regulations 2010
Within 2 years implementation of recommendation ofenergy audit report should necessarily be taken
After a lapse period of 2 years, within 3 months the detailson actions taken, based on energy audit report should befurnished to New and Renewable Energy Department,Haryana
© Confederation of Indian Industry
Consumer Category Type 3
All Commercial Malls, Plazas, Hospitals, Institutional,Govt./Board/Corporation owned building includingMunicipal and Water supply department buildings,having connected load of 100 kW and above orcontract demand of 120 kVA :
Should mandatorily get 1st energy audit by BEE certified EnergyAuditor (with min. 5 year work experience)/Firm/ESCO within 18months from above notification.
Within 2 years recommended actions from energy audit shouldnecessarily be taken.
After a lapse period of 2 years, within 3 months the details onactions taken based on energy audit report should be furnished toNew and Renewable Energy Department, Haryana.
© Confederation of Indian Industry
All Consumers Obligation
Within 3 months from conducting energyaudit, above category consumers shallsubmit to New and Renewable EnergyDepartment, Haryana following:
A copy of energy audit report
The action plan, based on energy auditrecommendations, including details of investment
© Confederation of Indian Industry
Actions regarding act
As per pre defined schemes/guidelines, the Govt.of India/ State Govt. incentive/ subsidy, if any, willbe provided to the building/unit owners throughNew and Renewable Energy Department, Haryanasubject to availability of funds.
The penalty will be recovered in case of failure toconduct energy audit, periodically every 3 yearsand 6 months.
The penalty imposed will be according to BEEguidelines for category type 1 (DC’s) and accordingto State Govt. for categories type 2 and 3consumers.
© Confederation of Indian Industry
Steps for successful energy audit
Recognize your consumer category
• In next 3 months submit this report
Contact Energy Service Company (CII in this
case) and schedule audit
• The 1st audit needs to be done before 8th May 2018
Get Energy Audit conducted in your firm
• A report needs to be submitted within 3 months, based on planned actions
Discuss the Audit recommendation and
plan for actions
Implement the actions in 2 year period and prepare a detailed report
on actions taken
• Repeat these steps in every 3years and 6 months
© Confederation of Indian Industry
Manpreet SinghCounsellor – Energy
Confederation of Indian [email protected]
09876724003