Energy auditing, monitoring& targeting, and management

It contains a typical energy auditing ppt which was presented as a case study

1. By
KiranR Patil
Under the guidance of
Sri B. AprameyaSwarup
Asst. Professor
S.J.C.E, Mysore

2. Introduction
y
Energy the prime mover
y
For the progress of any country
y
Any industry
y
Any sector
y
Rising costs of new generating plants has led to
y
Financial constraints
y
Difficulty in production of electrical energy
y
Higher energy bills

3. Cont…….
y
Generated Energy has to be used
y
Efficiently
y
Reduce the energy consumption
y
Reduce the losses by end users
y
For many companies energy is the significant
operating cost
y
Bills of 1.5crores through 2crores are not uncommon
y
Flour milling is one of the largest energy intensive
industry after raw material costs
y
But, energy is the most controllable production costs.

4. Cont…….
y
We cannot reduce man power by fractions but we can
achieve significant savings by reduction in energy
consumptions
y
Consider the flour mill
y
The energy billing is high and penalty is also high
y
Energy is the direct charge on companies operating
budget
y
“Every 1 unit saved is equal to 2 units generated
y
Reducing energy bills accrues an increase in bottom line
profit
y
Improved electrical efficiency is the key to saving energy
in any industry or flour mills

5. Concept of Energy Audit
y
Why Energy Audit?
y
To reduce the cost of production
y
To identify areas of excess energy consumption
y
To suggest ways for minimizing energy consumption
y
Indicative Saving Potential
y
Good house keeping -5 -10%
y
Minor investment-10 –15%
y
Reasonable investment -20 –25%

6. Methodology Adopted
y
Understanding the process of the mill
y
Inspection and Data collection of machineries
y
Observation on general conditions
y
Facility
y
Equipment
y
Quantification
y
Month wise energy consumption and production data from
financial year April 2006 through March 2010
y
Identifying and verifying the major energy consumption
areas
y
Discussions with electrical and production personnel to
make necessary arrangements to take measurements

7. Cont……. y
Measurement of electrical parameters like
voltage, current, power factor, kW, kVA, kVAr, Hz and
Harmonics on all identified motors
y
Detailed calculations, analysis and assumptions
y
Validation from the electrical personnel and energy
auditor
y
Identify the potential energy saving area and analyzing
the saving proposals with plant personnel

8. A
Abc
def
ghij
klm
nop
qrst
uvw
xyz

9. A

10. Main processes
y
Wheat reception and storage
y
Cleaning and conditioning
y
Milling and sieving
y
Blending, flour storage and packaging

11. y
Annual energy consumption in C-mill
y
19,11,222.41 units out of 46,58,530 units
y
Annual demand charges
y
Rs. 16,47,900/-
y
Energy cost @ Rs. 4.65 per unit
y
Energy cost this year
y
Rs.1,98,24,457+ Rs.10,73,617.875 tax
y
Energy bill (app.) Rs. 16,52,038.1/month
y
SEC in a month( app.) 58.145kWh/ton
y
EC kWh/Ton per day - 2.32kWh/ton
y
Average power factor maintained 0.97
Energy scenario

13. Energy consumption in kWh from April
2006 –March 2010
0
50
100
150
200
250
300
350
400
450
500
2006 2007 2008 2009
Financial year
Total kWh C-mill kWh Lighting kWh other electronic goods kWh
million units

14. Energy bill and demand charges from
April 2006 -2010
0
20
40
60
80
100
120
140
160
180
200
Energy Cost C mill Energy
cost
Tax Demand
charge
2006 2007 2008 2009
Rupees in Crores
Cost of
Sections

15. Monthly peak demand from April 2009-
March 2010
0
100
200
300
400
500
600
700
800
900
MD Reached in kVA

16. Break up of energy use
Milling and grinding 44% Pneumatic conveying 32% mechanical conveying 9% Compressed air7% Particle separation 5% Services 3%

17. Factors governing Energy use
y
Wheat quality
y
Impurities, moisture content and quality of wheat
y
Product quality
y
Need for blending and wheat products
y
Mill loading
y
Atmospheric conditions
y
Humidity, temperature and pressures

18. Operation schedule of machines
Section Wise HP
Wheat Cutting to A-Mill Silos 44 A-Mill Silo to C-Mill 22.5 Washing 103.75 Tempering 13.5 B1 Petty 26.5 General Exhaust for Dust 17.6 Refraction Grinding 69.5 Grinding section 421 Redressor section 34
•Washing section: 17 hours per day
•Other Sections: 21 hours per day

19. Need of determining motor load and
efficiency
y
Motor accounts for more than 80% load in a plant
y
Motors are mismatched or oversized for particular load
y
Motors might have rewound multiple times
y
So y
To compare the operating costs of an existing standard motor
y
And replace with appropriate sized Energy Efficient motor
y
Motor load and efficiency is to be determined.

20. Constraints of energy Auditing
y
No proper information
y
No real time data
y
Energy Auditing is based on the principle of
y
“We cannot manage, what we don’t measure”
y
One time energy auditing is not sufficient
y
No continuous monitoring

21. Monitoring & Targeting
y
It is a management technique which helps to
y
Control energy consumption
y
Control any resource
y
Continuous monitoring
y
Gather continuous information
y
Indicate the continuous varying pattern
y
“Without Compass and Map we are dead men in the Desert”.

22. Installation of Monitoring System
800kVA

23. Smart server or Data concentrator
y
It is used to
y
Control
y
Monitor
y
Manage any electronic device
y
Remotely access data
y
Manage the entire control system

24. Energy Nodes and Sensor gateway
y
Energy meter which helps in collecting
around 10 electrical parameters for
R, Y, B phases
y
Voltage, current, power
y
Active power, Reactive power
y
Frequency, power factor
y
Plots the load variations for the
connected machines
y
Sensor gateway gives the physical
parameters
y
Pressure, Temperature, Flow

25. How the monitoring system works y
Considering the Smart Server
y
Two types of internet protocols y
Static internet protocol
y
Dynamic internet protocol
y
Static internet protocol is used to access local works
either for LON or the LAN
y
Dynamic Internet protocol is used to access globally
y
Example Broad Band

26. Cont…….
Motor (Blower
Fan)
Compressor
Electrical
Panel
Sensor Gateway
Energy Node
Smart Server
Personal Computer

27. Cont…….
y
A particular machine
y
Motor or Compressor connected to energy meter or sensor
gateway respectively through electrical panel.
y
Panel is connected to Smart Server
y
Smart Server is connected to PC to access data
y
Connections are done through communication cable
y
Communication cables are used to inter connect server and
machines as well.

28. Cont…….
y
PC should be installed an application called as OPIUM
energy
y
This helps in accessing data
y
Plotting the graphs automatically
y
Smart Servers can be used as occupancy sensors
y
The application can be used y
To Control lighting system
y
To Control Fans and other electronic goods which saves energy

29. Advantages of Monitoring and Targeting
y
Expected Benefits
y
Guidance to reduce excess energy consumption
y
Identify the default equipments
y
Power factor improvement
y
Current reduction and reduction in line losses
y
Load balancing and minimizing of neutral current
y
Maintaining SEC and creating bench marks
y
Determining the future energy use when planning changes
y
Diagnose specific areas of wasted energy

30. Energy saving proposal 1
y
Investment = Rs. 3,50,000/-
y
Annual energy consumption = 19,11,222.41 kWh
y
Expected savings through EMS @ 5 –15% but assuming
y
= 95,561.12 kWh
y
Annual cost savings @ 4.7/unit = Rs. 4,49,137.264/-
y
Pay back period= Investment/ annual savings
y
Rs. 4,00,000/4,49,137
y
Approximately 10 months 18days
y
It is worth to invest in this monitoring system Investment on energy monitoring system

31. Energy saving proposal 2
Conversion of Delta to Star
y
For lightly loaded motors (Below 50% Load)
y
In Delta:10 hp Motor, 7.26kW, operating hours 16
y
In Star:6.55kW, operating hours 16
y
Difference in kW 0.71kW, 0.71*4800 h = 3408 kWh
y
Similarly, 7.5 hp, saved energy= 4416 kWh
y
For, 5hp, saved energy = 1344 kWh
y
Annual savings: 3408+4416+1344+1836 = 11004 kWh
y
Annual cost savings @4.7/unit=Rs.51,718.8/-
y
Investment nil
y
Payback period immediate

32. y
Load variations are common in flour milling industries
y
Considering the 10 hp motor
y
Rated speed = 1440 rpm
y
This motor is operated at less speed due to requirement
y
Reducing speed up to 1100 rpm
y
Cannot be achieved by reducing the pulley size
y
Therefore the VSD is used in order to quantify
y
Energy savings and reduce the losses
Energy saving proposal 3
Installation of Variable Speed Drive

33. Cont…….
y
Energy consumed without VSD = 6.323 units/hour
y
Energy consumed with VSD = 3.670 units/hour
y
Difference in Energy consumption = 2.653 units/hour
y
Total annual Energy savings by VSD
y
= 2.653 * 16 * 300
y
=12,734.4 units/year
y
Annual cost savings@ Rs.4.7/unit = Rs. 59,851.68/-
y
Approximate investment required = Rs. 65,200/-
y
Payback period= 13 months

34. Replacement of existing Less efficient motors
by Energy Efficient motors
y
Replacement model is concerned with replacement
y
Machines and Equipments
y
Replacement is done due
y
To their decreasing efficiency
y
Failures
y
Breakdown of equipment parts
y
Low performance
y
This model helps us to find
y
Optimum replacement period
y
Optimum cost

35. Cont…….
y
There are two types of failures
y
Gradual failure
y
Sudden failure
y
We are concerned with gradual failure which includes
y
Gradual decrease in the efficiency of equipments
y
Increased maintenance(operating and running costs)
y
Decreased productivity
y
Decrease in resale value which represents the depreciation

36. Calculation of optimal replacement period y
Optimal replacement period
y
Average cost incurred from the time of the implantation
of the machines
y
Money value has been taken into account
y
Present Value Factor (PvF) = 1/(1+r)
(N-1)
y
Where ‘r’ is the discount rate (the rupee value depreciates at a
constant rate i.e. 9%(standard))
y
‘N’ is the number of years

37. Replacement of 50 hp motor

38. Energy saving proposal 4
Replacement of less efficient to EEM

39. Cont…….
y
Total Annual Energy Savings
y
18 hours motor operation for 300 days per annum
y
= 10 kWh * 18 * 300
y
= 54000 kWh
y
Annual cost savings @4.7 = Rs. 2,53,800/-
y
Price of Energy Efficient motors obtained from M/s
Siemens Ltd. Is given below
y
10 hp, 6 poles = Rs. 32,640/-
y
15 hp, 6 poles = Rs. 40,570/-
y
15 hp, 4 poles = Rs. 31,640/-
y
20 hp, 6 poles = Rs. 58,270/-
y
30 hp, 2 poles = Rs. 87,990/-

40. Cont…….
y
Investment required for 10 number of EE motors
y
=Rs. 32,640 * 4
y
=Rs. 40,570 * 3
y
=Rs. 31,640 * 1
y
= Rs. 58,270 * 1
y
= Rs. 87,990 * 1
y
Total cost = Rs. 4,30,170/-
y
Payback Period= 20 months

41. Advantages of Energy Efficient Motor
y
Saves Energy and Money
y
Covers up to uniform Efficiency from 50% -100% of
full load
y
Ensuring savings at part load conditions also
y
Short Payback period
y
Substantial savings after Payback Period

42. Recommendations
y
Reduce system load e.g. by using more efficient fan
y
Minimizing the amount of air used by pneumatic systems
y
Reducing leakages from compressed air systems
y
Reducing pressure drops in pneumatic and compressed air
systems
y
Improve maintenance schedule and procedures
y
Switch of when idling
y
Soft starters can be used
y
Ensure that motor is not oversized for the job
y
Reduce motor losses
y
Replace with energy efficient motors
y
If repaired or rewound, ensure efficiency losses are
minimized

43. Cont…….
y
Reduce motor running speed by using variable speed
drives
y
Advantages include y
Significant cost savings
y
Automatic or manual control
y
Versatility
y
Reliability
y
Use Multi speed Motors (MSMs)
y
Can be used when two or more speeds of
operation, particularly effective if speeds are carefully
matched to the characteristics of fan
y
Operate at full load for shorter periods
y
Operate with a high loading to maximize efficiency

44. Cont…….
y
Lighting systems connected to the Smart servers act as
occupancy sensors which controls the lighting circuits
y
Maximum demand charges can be reduced by managing
the load at peak times
y
The whole mill is inter connected to one another
y
if one machine shuts off complete mill should be shut down
y
separate connections to separate sections of the machine
y
reduces high amount of Maximum demand charges.
y
Refurbishments
y
Keep conveying and transfer routes as short as possible
y
Minimize transfer distances for wheat and flour y
so that each processing area is next to the previous one

45. y
Minimize the number of lifts of wheat and stock
y
Copper catalyst at the end of the exhaust of general dust
exhaust minimizes the effect of dust to the environment
y
Install the process control and monitoring equipment Cont…….

46. Summary

47. Future Scope

48. Cont…….
y
Bloom Energy is a solid oxide fuel cell server
y
Uses solid, liquid or gaseous fuel
y
It produces electricity which is cleaner form of energy
y
If used renewable fuel form of energy, y
It is more cheaper and more cleaner form of Energy

49. Cont…….
y
This solid fuel cells can generate 100kW through MW of
Electricity
y
Fuel cell converts Hydrogen, Natural gas any fuel to
electricity
y
This is an “ELECTRO-CHEMICAL PROCESS”
y
The bloom energy is 67% clean if used hydrocarbon fuels
y
If renewable fuel cells are used, 100% clean and cheaper
energy can be produced and used which is abundant

50. References
y
Energy Auditing concepts of M/s KovilpattiLakshmiroller
Flour Mills Ltd. Gangaikondan(Tirunelveli), Energy Audit
conducted by, Central Scientific Instruments
Organization, CSIR Madras complex, Govt. of INDIA.
y
Guide Books for the National Certificate Examination for
Energy managers and Energy Auditors (set of four books
available at
http://www.energymanagertraining.com/new_course.php)
y
J.C. Andreas, Energy Efficient Motors. Marcel Dekker publication, New York1992

51. Cont…….
y
Good practice guide 212 for improving Energy Efficiency
and reduce Energy costs in Flour Milling, Energy Efficiency
enquiries Bureau, Oxfordshire, UK.
y
Typical performance data of premium Energy Efficient
(EE) Motors and standard motors from BharathBijleeLtd.
Motors for general applications.
y
Official Website of the Bureau of Energy Efficiency, Govt.
of INDIA,www.bee-india.nic.in
y
Quick start guide to Energy Monitoring and Targeting (M&T), www.oursouthwest.com

52. y
Detailed information and case studies on energy
audits, www.energymanagertraining.com
y
Energy monitoring and targeting (M&T), www.mt.wikipedia.org/wiki/monitoring_targe ting
y
The energy conservation act, 2001, http://powermin.nic.in/acts_notification/en ergy_conservation_act/index.htm
Cont…….

53. y
www.en.wikipedia.org/wiki/energy_audit
y
Website of Ministry of Power, http://powermin.nic.in/energy_audit
y
“Bloom Energy” –What is it and how does it works?
http://peswiki.com/index.php/Directory:BloomBox_F
uel_Cell_by_Bloom_Energy
.
Cont…….