Transcript ENERGY Audit By Ravindra M Datar Senergy Consultants (P) Ltd 91-9821271630 [email protected] www.senergy-india.com Senergy Synergy between Our expertise on conservation of energy & Your experience & knowledge of process, operations, plant engineering, etc. To Save.

ENERGY Audit
By
Ravindra M Datar
Senergy Consultants (P) Ltd
91-9821271630
[email protected]
www.senergy-india.com
Senergy
Synergy
between
Our expertise on conservation of energy
&
Your experience & knowledge of
process, operations, plant engineering, etc.
To
Save Energy
Senergy
• Leading Energy Conservation Consultants in India
• Conducting Studies for past 20 years.
• One of the first auditor to receive ISO 9001-2000
certification.
• Team of experts headed by a technocrat from IIT
• Customer driven company with many repeat
orders & orders form group companies
Senergy
• Empanelled with Maharashtra & Gujarat
Governments (MEDA & GEDA)
• BEE certified auditors
• Customer base of over 450 industries
• Contributing Rs 50 crores/year, towards
conservation of energy
Senergy
• Interactive studies.
• Practical & Realistic Suggestions.
• Turnkey Consultancy during Implementation.
• Long term services for Sustainable Savings &
Continuous Improvements.
• Basic & Advanced Training Programs.
Few of our clients
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Sterlite Industries Ltd
South Seas Distillery
Excel Industries Ltd
Century Enka Ltd
Century Rayon
Asian Heart Hospital
Essel World
EBG India Pvt Ltd
Aarti Drugs Ltd
Emco Ltd
PepsiCo India Ltd
ICI Ltd
USV Ltd
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Allana Industries Ltd
Tata Chemicals Ltd
Schenectady Herdillia ltd
Hindustan Lever Ltd
Nicolas Piramal India Ltd
Wyeth Lederle Ltd
DGP Hinoday Ltd
GTC Industries Ltd
MSEB
Whirlpool of India Ltd
Pidilite Industries Ltd
Sachivalay – Gujarat
Wochkhardt Ltd
Instruments
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Ultrasonic non-contact type flow meters for liquids
Harmonic analyzer
Clamp-on type power / energy meters
Anemometers – to measure velocity of gases
Digital Manometer
Tachometers – Contact / Non-contact type
Digital thermometers for liquid / surface temperature
Lux meter
Combustion Gas Analyzer
Pressure Gauges
Digital Hygro-temp Meter (for Temp & RH measurement)
Energy Audit
1. Specific Energy Consumption
2. Targets & Benchmarks
3. Unaccounted Consumption
4. Equipments Performance
5. Distribution System
6. Utilization
7. Recovery from Waste Energy
8. Cost of Energy
9. Renewable Energy
10.Energy Monitoring
Specific Energy Consumption
Specific Energy: Energy consumed per unit output.
It is the Key performance assessment tool for every
energy consumer.
Collect the details on
– Total production
– Power consumption – SEB & Captive
– Consumption of each type of fuel
– Cost of each type of fuel
Specific Energy Consumption
Specific Power Consumption
1400.0
1200.0
Specific Power (kWh/T)
1000.0
800.0
600.0
400.0
200.0
0.0
5-May
12-May
19-May
26-May
2-Jun
9-Jun
16-Jun
Date
23-Jun
30-Jun
7-Jul
14-Jul
21-Jul
28-Jul
Specific Energy Consumption
1400.0
1200.0
Specific Power Consumption (kWh/T)
1000.0
800.0
600.0
400.0
200.0
0.0
Copper Production (TPD)
Specific Energy Consumption
Specific Energy Consumption
40.0
35.0
Specific Power (kWh/M2)
30.0
25.0
20.0
15.0
10.0
5.0
0.0
January
February
March
April
May
June
Month
Aug
Sep
Oct
Nov
Dec
Targets & Benchmarks
Benchmark is the desired or targeted consumption
of energy or specific energy consumption.
The benchmark values are set based on
 Theoretical Calculations
 Specifications by equipment / plant supplier
 Best achieved in the same plant
 Best achieved in the similar industry.
Specific Power Consumption
for
Office Premises
Case Study
: 343 kWh/M2/Year
Wipro
ITC
CII
:190 kWh/M2/Year
:125 kWh/M2/Year
:70 kWh/M2/Year
Energy Accounting & Un-accounted
Consumption
Prepare break up of consumption for each form
of Resources energy by
– Computing consumption of the respective area /
equipment.
– Noting down operating period.
– Take data from various sub-meters
Compare total consumption as estimated above
with actual consumption to ascertain
– “Unaccounted” or “Miscellaneous” portion of the
consumption
Analyze consumption pattern
Energy Accounting / Balancing
Air Conditioners Package
27%
Miscellaneous
14%
Air Conditioners Data Center
Computers & UPS
28%
Illumination
8%
7%
Cooling Water
System
10%
Air Conditioners Miscellaneous
6%
Equipment Performance
Compute performance of all the equipments
by measuring
• Actual Output
– Flow, pressure, refrigeration effect, FAD, etc.
• Specific Energy Consumption
– kWh/TR, CFM/kWh, Steam to fuel ratio
• Efficiency
– Pump, boiler, thermopac
Performance of the Machines
Air Conditioning Effect
Drop
Actual Output TR
20.0
10.0
5.0
-5.0
TAG No
45
42
39
36
33
30
27
24
21
18
15
12
9
5
0.0
1
AC Effect (TR)
15.0
Specific Power Consumption : AC
Specific Power Consumption
Loss
Desired Sp Power
3.5
3
Sp Power (kWh/TR)
2.5
2
1.5
1
0.5
0
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
Norms: Specific Output - Air Compressor
30
Specific Output: Air Compressor
Specific Output (M3/kW)
25
20
15
10
5
0
1
2
3
4
Air Pressure (bar)
7
10
15
Distribution System
• Heat Loss – Hot Insulation, Surface Evaporation
• Heat Ingress – Cold Insulation, Openings in AC area
• Leakages – Compressed Air, Thermic Fluid
• Pressure Drop – Pumping Systems, Compressed Air
• Power Loss – Electrical Systems & Cabling
Utilization
• Over / Under Sized Equipment
 Pumps, boilers, air compressors
• High Grade Energy for Low Grade Applications
 Compressed air for cleaning, brine in place of chilled water
• Unwarranted & Rigid Specifications.
 Stringent Process Conditions
Recovery of Waste Energy
• Recovery from Flue Gas Exhaust
 Preheat water, combustion air, product
• Recovery form Hot Effluent
 Preheat water or process fluid
• Process Energy Optimization
 Pinch Analysis to optimize heating & cooling load
• Condensate Heat Recovery
 Low Pressure Flash Steam, condensate
Cost of Energy
• Avail Maximum Tariff Concessions & Benefits
 Unity PF, Night Operation, Bulk Discount, Bulk Purchases
• Switchover to cheaper Fuel
 Electrical to fuel heating. FO to Coal for Boiler, thermopac.
FO to Producer Gas for furnaces.
• Co-generation
 Heat Recovery from engine exhaust / cooling. Steam based
co-generation
Renewable Energy Sources
Tidal
Solar
Wind
Geo
Bio
Renewable Energy
• Solar Heating Applications up to 80 oC
• Wind Mills
• Fuel From Organic / Agro Waste
• Methane from Effluent
• Fuel from Municipal Waste
Energy Monitoring
• Overall Monitoring of Energy as well as Specific
Energy Consumption
• Key parameters for all the major equipments
• Cost of Energy
• Power Factor, Maximum Demand
Case Study - I
Specific Energy Consumption
Initial
34
Stage
Final
Sp Energy (Rs/kg)
32
Ideal
30
28
26
24
22
20
1000
1050
1100
1150
1200
1250
Production (kg/day)
1300
1350
1400
Case Study - II
Heat Recovery from Waste Stream
Waste Ice 8.5 TPD
Ch Water
110C
Process
Effluent
120C
To E T P 300 m3/DAY
Fish, laced with ice is received in trucks from various places.
The ice is removed and thrown in common pit and fed to ETP
Chilled Water is used for washing the fish.
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 C.
Original System: 1400 TR of Load per day
Case Study - II
Heat Recovery from Waste Stream
Waste Ice 8.5 TPD
Ch Water
110C
Fresh Water 300C
221m3/day
Process
Effluent
120C
Plate Type
Heat
Exchanger
1250 TR / 221 M3/day
Chilled Water
System
130C
(1400 TR)
Reduction in refrigeration load: 82%
250C E T P
229.5 m3/day
Case Study - III
Condensing Turbine
Thermal Efficiency of the system depends on
• Steam temperature & pressure at the inlet of
turbine.
• Steam temperature & pressure at turbine outlet
Controlled by Cooling Water Temperature.
12% Addition Power through rationalization
of Cooling Water System
Case Study - III
Condensing Turbine
Case Study - III
Condensing Turbine
0.125
Specific Power Generation (kWh/kg)
Effect of Condensing Temperature on Power Generation
0.120
0.115
0.110
0.105
0.100
30
35
40
45
50
55
Condensing Temperature (Deg C)
60
65
70
Case Study - IV
Pumps, Fans & Blowers
Flow Rate / Efficiency is greatly influenced by
• Discharge Pressure.
• Pump Conditions
• Suction Pressure.
20 to 50% Energy Savings through
rationalization of Suction & Discharge Pressures
Variable Speed based Control
Thank
You!