presentation energy audit 281105

8/14/2019 Presentation Energy Audit 281105

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ENERGY ConservationENERGY Conservation

ConsultancyConsultancy

ByBy

Ravindra M DatarRavindra M Datar

Senergy Consultants (P) LtdSenergy Consultants (P) Ltd

www.senergy.co.inwww.senergy.co.in

[email protected]@vsnl.com

91-22-5599308691-22-55993086
http://www.senergy.co.in/http://www.senergy.co.in/mailto:[email protected]:[email protected]:[email protected]://www.senergy.co.in/


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Why Conserve?Why Conserve?

Product need to be internationally competitive.Product need to be internationally competitive.

Cost raises but selling price stagnates.Cost raises but selling price stagnates.

Savings is surest way to increase profits.Savings is surest way to increase profits.

10-25% saving can be realized in many industries;10-25% saving can be realized in many industries;half of which with small investment.half of which with small investment.

The nation gains asThe nation gains as

A new captive power plant take 4 years to construct; whileA new captive power plant take 4 years to construct; while

benefits of savings can be enjoyed in 6 months.benefits of savings can be enjoyed in 6 months. The power plant costs Rs 50,000/- per kW, while savingsThe power plant costs Rs 50,000/- per kW, while savings

costs are not even Rs 10,000/- per kW.costs are not even Rs 10,000/- per kW.


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SenergySenergy

SynergySynergy

betweenbetween

Our expertise on conservation of energyOur expertise on conservation of energy

&&

Your experience & knowledge ofYour experience & knowledge ofprocess, operations, plant engineering, etc.process, operations, plant engineering, etc.

ToTo

Save EnergySave Energy


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Senergy isSenergy is

An ISO 9001-2000 company.An ISO 9001-2000 company. In this field for more than 14 years.In this field for more than 14 years.Team of experts headed by a technocratTeam of experts headed by a technocrat

from IIT - Mumbai.from IIT - Mumbai.

A company with customer Base of 300A company with customer Base of 300industries.industries.

Customer driven company with many repeatCustomer driven company with many repeatorders & orders form group companies.orders & orders form group companies.

Approved by MEDA & GEDA.Approved by MEDA & GEDA. Contributing Rs 50 crores/year, towardsContributing Rs 50 crores/year, towards

conservation of energy.conservation of energy.


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SenergySenergy

Provides Personalised services.Provides Personalised services.

Conducts comprehensive & interactiveConducts comprehensive & interactivestudies.studies.

Gives practical & realisticGives practical & realisticrecommendations.recommendations.

Provides services till actual realization ofProvides services till actual realization ofsaving.saving. Can organize subsidies and soft loans.Can organize subsidies and soft loans.Take responsibility for turnkeyTake responsibility for turnkey

implementation, on specific requests.implementation, on specific requests.


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Few of our clients

Century Enka Ltd

Century Rayon

Nanavati Hospital Essel World

EBG India Pvt Ltd

JBF Industries Ltd

Emco Ltd PepsiCo India Ltd

ICI Ltd

Essel Propack Ltd

M S E B

Hindustan Lever Ltd

Nicolas Piramal India Ltd

Wyeth Lederle Ltd

Nirlon Ltd

GTC Industries Ltd

Advani Oerlikon Ltd

Frigerio Conserva Allana Ltd

Whirlpool of India Ltd Pidilite Industries Ltd

Sumaira Group (Tanzania)

Ceylon Glass Company Ltd


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Senergy: ActivitiesSenergy: Activities

Energy Conservation Consultancy.Energy Conservation Consultancy.

Promotion of Renewable Energy Sources.Promotion of Renewable Energy Sources.

Turnkey consultancy for non-standard suggestions.Turnkey consultancy for non-standard suggestions.

Consultancy for Process Audit & Yield Improvement.Consultancy for Process Audit & Yield Improvement.

Consultancy for Proficient Plant Operations.Consultancy for Proficient Plant Operations.


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Energy ConservationEnergy Conservation

ConsultancyConsultancy

1.1.Team formationTeam formation

2.2. Overview of Process & OperationsOverview of Process & Operations

3.3. Analysis of Specific Energy ConsumptionAnalysis of Specific Energy Consumption

4.4. Energy Accounting & BalancingEnergy Accounting & Balancing

5.5. Energy Consumers / ConvertersEnergy Consumers / Converters

6.6. Distribution SystemsDistribution Systems

7.7. Utilization systemsUtilization systems

8.8. Identification of potential saving areasIdentification of potential saving areas

9.9. ImplementationImplementation

10.10.MonitoringMonitoring


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TEAMTEAM

Participation of all concerned.Participation of all concerned.

Positive suggestions through various schemes.Positive suggestions through various schemes.

Immediate & correct evaluation of suggestions.Immediate & correct evaluation of suggestions.

Positive solutions for roadblocks / problem areas.Positive solutions for roadblocks / problem areas.

Wider acceptance for recommendation.Wider acceptance for recommendation.

Quick and effective implementation.Quick and effective implementation.

Development of knowledge bank.Development of knowledge bank.

Continual improvements.Continual improvements.

Savings on sustainable basis.Savings on sustainable basis.


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Overview of Process /Overview of Process /

OperationsOperations Brief description of activities, withBrief description of activities, withemphasis of major consumers.emphasis of major consumers.

Process / Material flow diagram.Process / Material flow diagram. Utilization pattern for major consumers.Utilization pattern for major consumers.

Co-relate the critical parameters at theCo-relate the critical parameters at thepoint of generation & utilizationpoint of generation & utilization

Air pressure at compressor outlet / point ofAir pressure at compressor outlet / point of

utilizationutilization

Suction pressure of refrigeration compressorSuction pressure of refrigeration compressor

/ process temperature/ process temperature


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Specific EnergySpecific Energy

ConsumptionConsumption

Specific energy is the energy consumedSpecific energy is the energy consumed

per unit output.per unit output.

Analyze variations with respect toAnalyze variations with respect to OutputOutput

Seasonal variationsSeasonal variations

YieldYield

Start the analysis at Macro-levelStart the analysis at Macro-level

thenthen

Proceed towards Micro-levelProceed towards Micro-level

E lE

l


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ExampleExample

Specific EnergySpecific Energy

ConsumptionConsumption

20

22

24

26

28

30

32

34

1000 1050 1100 1150 1200 1250 1300 1350 1400

Production (kg/day)

SpEnergy(Rs/kg)

InitialStage

Final

Ideal


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Energy Accounting /Energy Accounting /

BalanceBalancePrepare break up of consumption for eachPrepare break up of consumption for eachform of energy byform of energy by

Measuring energy consumption of individualMeasuring energy consumption of individualequipment.equipment.

Noting down operating period.Noting down operating period.

Take data from various sub-metersTake data from various sub-meters

Compare total consumption as estimatedCompare total consumption as estimatedabove with actual consumption to ascertainabove with actual consumption to ascertain

Unaccounted or Miscellaneous portion of theUnaccounted or Miscellaneous portion of theconsumptionconsumption

Analyze consumption pattern (wrt time)Analyze consumption pattern (wrt time)


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ExampleExample

Energy Accounting / BalancingEnergy Accounting / BalancingDescription % kWh/M

Illumination 30% 5,40,000

Air conditioning 20% 3,60,000

Computers 7.5% 1,35,000

Pumps 12.5% 2,25,000

Electrical Heating 2.5% 45,000

Residential & Commercial 15% 2,70,000

Miscellaneous 12.5% 2,25,000

Total 1


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Energy AccountingEnergy Accounting

Description Consumption

kWh %

Residential &Commercial

270000 15.0%

Hostels 420000 23.3%

Pumping 225000 12.5%Common Lighting 120000 6.7%

Departments 765000 42.5%

Total 180000 100.0%


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Average Power (kW)Average Power (kW)

Month Overall 22 to 6 6 to 9 &12 to 18

9 to 12 18 to 22

Aug-04 2525 2096 2658 2979 2746

Sep-04 2545 2111 2687 2930 2807

Oct-04 2591 2177 2690 2962 2918

Nov-04 2390 2016 2472 2732 2700

Dec-04 2092 1706 2194 2500 2329

Jan-05 2204 1825 2287 2519 2539

Feb-05 2152 1772 2265 2479 2414

Mar-05 2693 2144 2851 3116 2950

Apr-05 2855 2416 3001 3308 3061

May-05 2704 2308 2843 3190 2821


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Energy Consumers /Energy Consumers /

ConvertersConvertersEvaluate performance of major consumers toEvaluate performance of major consumers to

Carry out energy balance for the entire system.Carry out energy balance for the entire system.

Check if the equipment operates at design capacity.Check if the equipment operates at design capacity.

Estimate efficiency at design / operating capacity.Estimate efficiency at design / operating capacity.

Compute specific energy consumption.Compute specific energy consumption.

List the major losses and estimate their contribution.List the major losses and estimate their contribution.

Discuss & finalize ways to eliminate / minimize the losses and optimizeDiscuss & finalize ways to eliminate / minimize the losses and optimizethe efficiency /output.the efficiency /output.

Evaluate possibility of enhancing useful output.Evaluate possibility of enhancing useful output.

Check feasibility of using cheaper source of energy do the same work.Check feasibility of using cheaper source of energy do the same work.


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Basic DefinitionsBasic Definitions

Efficiency:Efficiency:

Ratio of Energy utilized for useful work to theRatio of Energy utilized for useful work to thetotal energy supplied to the equipment.total energy supplied to the equipment.

Ratio of to energy supplied less sum of all lossesRatio of to energy supplied less sum of all lossesto the total energy supplied to the equipment.to the total energy supplied to the equipment.

Capacity utilization:Capacity utilization:

Ratio of the Actual output to the Rated output ofRatio of the Actual output to the Rated output of

the equipment.the equipment.Specific energy consumption:Specific energy consumption:

Ratio of the total energy supplied to theRatio of the total energy supplied to theequipment to the Actual output.equipment to the Actual output.


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Specific Power Consumption Specific Power Consumption

Shaft Power (kWh/TR)Shaft Power (kWh/TR)

EvaporatorTemp(0C)

Condenser Temperature (OC)

20 25 30 35 40 45

10 0.27 0.33 0.40 0.47 0.55 0.65

5 0.33 0.40 0.48 0.57 0.67 0.79

0 0.41 0.49 0.57 0.67 0.78 0.89

-5 0.50 0.59 0.69 0.80 0.91 1.04

-10 0.60 0.70 0.82 0.94 1.07 1.21

-15 0.73 0.84 0.97 1.10 1.25 1.42

-20 0.87 1.00 1.14 1.29 1.46 1.67

-25 1.04 1.18 1.33 1.51 1.72 1.96

-30 1.23 1.39 1.57 1.78 2.03 2.31


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Refrigeration Effect (TR)Refrigeration Effect (TR)

EvaporatorTemp(0C)

Condenser Temperature (OC)

20 25 30 35 40 45

10 100.0 96.8 93.7 90.5 87.3 83.9

5 83.1 80.4 77.7 74.8 71.9 68.9

0 68.4 66.1 63.6 61.1 58.4 55.7

-5 55.9 53.8 51.6 49.3 46.9 44.4

-10 45.0 43.1 41.1 39.1 36.9 34.9

-15 35.7 34.0 32.2 30.3 28.6 27.1

-20 27.8 26.2 24.6 23.1 21.8 20.7

-25 21.1 19.7 18.4 17.4 16.4 15.5

-30 15.5 14.4 13.5 12.7 12.0 11.4


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Air CompressorAir Compressor

Pr Sp Power Sp Output Power

Bar kW/M3 M3/kW kW

1 0.037 27.0 100

2 0.057 17.6 153.3

3 0.077 13.0 207.3

4 0.086 11.7 231.6

7 0.108 9.3 291.6

10 0.128 7.8 345.6

15 0.154 6.5 416.9


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Distribution SystemsDistribution Systems

Utilities like steam are generated at centralized place &Utilities like steam are generated at centralized place &distributed through out plant.distributed through out plant.

Such distribution is always associated with drop inSuch distribution is always associated with drop in

energy level.energy level. Distribution losses are such losses expressed as fractionDistribution losses are such losses expressed as fraction

(or percent) of the initial energy.(or percent) of the initial energy.

Such losses can be in in more than one form likeSuch losses can be in in more than one form likepressure drop, heat gain, leakages, etc.pressure drop, heat gain, leakages, etc.

Minimizing such losses is one of the simplest & surestMinimizing such losses is one of the simplest & surestway of conservation of energy.way of conservation of energy.


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ExampleExample

Distribution SystemsDistribution Systems

SteamSteam

InsulationInsulation

LeakagesLeakages Pressure dropPressure drop

RoutingRouting

Line sizeLine size

TrappingTrapping LocationLocation

SizeSize

TypeType


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Utilization SystemsUtilization Systems

Efficient utilization of utilities / energy is of primeEfficient utilization of utilities / energy is of primeimportance.importance.

Conduct energy balance for each form of energy.Conduct energy balance for each form of energy.

Identify critical parameters for utilities.Identify critical parameters for utilities.

Validate criticality of process / plant parameters.Validate criticality of process / plant parameters.

Map process / plant requirement with generation forMap process / plant requirement with generation forcritical parameters.critical parameters.

Quantify waste streams and potential for energyQuantify waste streams and potential for energyrecovery through the same.recovery through the same.

Look for more economical source of energy.Look for more economical source of energy.


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Plate TypeHeat

Exchanger

Energy Recovery from Effluent ChilledEnergy Recovery from Effluent Chilled

WaterWater

Waste Ice 8.5 TPDWaste Ice 8.5 TPD Fresh Water 30Fresh Water 3000CC221m221m33/day/day

Ch WaterCh Water 111100CC

252500C E T PC E T PEffluentEffluent

121200CC

221m221m33/day/day

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

131300CC

Process

Chilled WaterSystem


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IdentificationIdentificationofof

Energy Saving AreasEnergy Saving Areas Analyze the deviations from norms /Analyze the deviations from norms /

normal values.normal values.

Identify reasons.Identify reasons. Work out corrective action.Work out corrective action. Discuss with TEAM to formulate ActionDiscuss with TEAM to formulate Action

PlanPlan

Make simple but complete fact sheet forMake simple but complete fact sheet foreach area.each area.

Categorize areas based on ease ofCategorize areas based on ease ofimplementation, investment, etc.implementation, investment, etc.


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ImplementationImplementation

Pick up low hanging fruits it goes in a great wayPick up low hanging fruits it goes in a great wayto boost up team moral and management support.to boost up team moral and management support.

Supervise actual implementationSupervise actual implementation

Provide assistance during commissioning &Provide assistance during commissioning &trouble-shooting.trouble-shooting.


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MonitoringMonitoring

Ensure that the Team is on the right pathEnsure that the Team is on the right pathand at correct pace.and at correct pace.

Measure the actual savings and ensureMeasure the actual savings and ensurerealization on sustainable basis.realization on sustainable basis.

Devise monitoring system for key energyDevise monitoring system for key energyconsumers & prepare log / data sheets.consumers & prepare log / data sheets.

Install mechanism for suggestion schemeInstall mechanism for suggestion schemewith effective implementation.with effective implementation.

Monitor specific energy consumption atMonitor specific energy consumption at

macro as well as micro level.macro as well as micro level.


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In NutshellIn Nutshell

1.1.Team formationTeam formation

2.2. Overview of Process & OperationsOverview of Process & Operations

3.3. Analysis of Specific Energy ConsumptionAnalysis of Specific Energy Consumption

4.4. Energy Accounting & BalancingEnergy Accounting & Balancing

5.5. Energy Consumers / ConvertersEnergy Consumers / Converters

6.6. Distribution SystemsDistribution Systems

7.7. Utilization systemsUtilization systems

8.8. Identification of potential saving areasIdentification of potential saving areas

9.9. ImplementationImplementation

10.10.MonitoringMonitoring


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ThankThank

You!You!

presentation energy audit 281105

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