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

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

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.

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

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

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!!

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

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!!

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

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

The man who waits for

conditions to improve may have

to wait for eternity

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

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.

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.

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

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

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

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

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.

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!!

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.

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

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

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)

Typical loading & unloading pattern

of a 100 CFM compressor

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 !!

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--

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

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

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

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

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

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!!

Future Energy

The “best” is the enemy of the

“good”

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.

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.

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.

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

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.

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

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

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

Knowledge is NOT free. Ignorance is

expensive

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

Change is certain, progress is not

Thanks for attention

S Kannan +91 96552 41599

AMSET Energy

www.amsetenergy.in