Case Study of Energy Audit

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Energy Audit and Case Study on Milk Plant

Energy Audit and Case Study on Milk Plant

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  • 1. 1 of 26 ENERGY AUDITDarshan Vithani ,Pranav Pathak ME-CSE
  • 2. 2 of 26 Energy Audit ENERGY AUDIT (EA)  pool of activities (systematic procedure) focused on analysis of current energy need and consumption going out of valid technical standards,  analysis of problems (weaknesses and deficiencies),  EA identifies and in detail quantifies effective possibilities of energy savings tailored to the object being analyzed,
  • 3. 3 of 26 Energy Audit AIM OF ENERGY AUDIT to minimize costs for energy to minimize operational costs to minimize costs for repairs and reconstruction increase quality of environment that contributes to increased work productivity
  • 4. 4 of 26 Energy Audit AIM OF ENERGY AUDIT to minimize costs for energy to minimize operational costs to minimize costs for repairs and reconstruction increase quality of environment that contributes to increased work productivity
  • 5. 5 of 26 Energy Audit TYPE OF ENERGY AUDIT  The type of Energy Audit to be performed depends on: - Function and type of industry - Depth to which final audit is needed, and - Potential and magnitude of cost reduction desired  Thus Energy Audit can be classified into the following two types. i) Preliminary Audit ii) Detailed Audit
  • 6. 6 of 26 Energy Audit PRELIMINARY ENERGY AUDIT METHODOLOGY  Establish energy consumption in the organization  Estimate the scope for saving  Identify the most likely (and the easiest areas for attention  Identify immediate (especially no-/low-cost) improvements/ savings  Set a ‘reference point’  Identify areas for more detailed study/measurement  Preliminary energy audit uses existing, or easily obtained data
  • 7. 7 of 26 Energy Audit DETAILED ENERGY AUDIT METHODOLOGY  It is offers most accurate estimate of energy savings and cost  This is based on an inventory of energy using systems, assumptions of current operating conditions and calculations of energy use.  Detailed energy auditing is carried out in three phases: Phase I, II and III. Phase I - Pre Audit Phase Phase II - Audit Phase Phase III - Post Audit Phase
  • 8. 8 of 26 Energy Audit Steps For DETAILED ENERGY AUDIT METHODOLOGY
  • 9. 9 of 26 Energy Audit Steps For DETAILED ENERGY AUDIT METHODOLOGY
  • 10. 10 of 26 Energy Audit Steps For DETAILED ENERGY AUDIT METHODOLOGY
  • 11. 11 of 26 Energy Audit Steps For DETAILED ENERGY AUDIT METHODOLOGY
  • 12. 12 of 26 Energy Audit Steps For DETAILED ENERGY AUDIT METHODOLOGY
  • 13. 13 of 26 Energy Audit Steps For DETAILED ENERGY AUDIT METHODOLOGY
  • 14. 14 of 26 Energy Audit AREAS OF ENERGY AUDIT Subject of energy consumption analysis are energy resources consumed in the industrial area, i.e.  Electricity  Natural gas  Steam  Coal  Wood, wood chips/pellets  Fuels (petrol, oil, propane-butane).....
  • 15. 15 of 26 Energy Audit AREAS OF ENERGY AUDIT • thermal-technical protection of buildings, • heating systems • hot water preparation, • ventilation systems and air-conditioning (buildings and technology) • electric appliances (administrative and technological incl. electrical connection, transformation, distribution network, el. switchboards, el. compensation) • gas or other energy resources consuming appliances (furnaces, cleaning devices,..) • Indoor/outdoor lighting, • measurement and regulation.
  • 16. 16 of 26 Energy Audit ENERGY AUDIT METHODOLOGY  Pre-audit presentation.  Collection of data / information.  Measurements and monitoring with instruments.  Computation and in-depth analysis.  Post-audit presentation to discuss the Energy Conservation Opportunities identified by the audit team.
  • 17. 17 of 26 Energy Audit INSTRUMENTS USED  Flue Gas Analyzer  Power Analyzer, Tachometer  Ultrasonic Flow Meter  Trap Man (For Steam Trap Survey)  Raytech Gun & Digital Thermometer (Non-contact and Contact type both)  Anemometer, pH/TDS/Conductivity meter  LUX Meter, Digital Manometer
  • 18. 18 of 26 EnergyAuditatMotherDairy (MilkPlant) Case Study
  • 19. 19 of 26 Energy Audit BASE LINE DATA Product Bulk Processed Milk (Toned, Double Toned & Full Cream) Capacity of the plant 8 Lac liters of Milk per day Annual Fuel / Energy Consumption PNG: 17,76,000 SCM Worth: Rs 3.7 Crores Electricity: 134.6 Lac kVAh Worth: Rs 6.68 Crores Annual Energy Bill Rs 10.38 Crores Compressed Air generation 180 cfm Steam Consumption 65,000 kg/month for Milk Plant 15,000 kg/month for Ice Cream Plant
  • 20. 20 of 26 Energy Audit Summary of Savings Identified & Realized (Year 2003 & 2004)  Major recommendations implemented: 1. Boiler fuel switched over to PNG from LDO 2. Steam supplied to ICP from this boiler 3. Improvement of Power Factor from 0.9 to 0.996 4. New air compressor installed lowering SEC 5. Installation of Auto Blow Down system for Boiler Total Savings projected by PCRA Electricity: 21,43,360 kVAh Worth: Rs 78.24 Lac LDO: 184.31 KL Worth: 85.8 Lac Total Savings Realised till date Electricity: 5,21,017 kVAh Worth: Rs 19.02 Lac LDO: 130.06 KL Worth: Rs 60.55 Lac % Savings Realised of total energy consumption Electricity: 3.7% LDO: 20.3%
  • 21. 21 of 26 Energy Audit Summary of Savings Identified (Year 2005) Total savings identified Electricity: 7,17,004 kVAh PNG: 1,36,042 SCM Worth: Rs 59.18 Lac No cost savings with immediate payback Electricity: 95,308 kVAh Worth: Rs 4.1 Lac Low cost savings with payback < 1 year Electricity: 5,41,796 kVAh Worth: Rs 23.3 Lac High cost savings with payback between 1-2 years Electricity: 79,900 kVAh Worth: Rs 3.44 Lac Gas: 1,36,042 SCM Worth: Rs 28.34 Lac % savings identified of total energy consumption Electricity: 5.32% Gas: 7.66%
  • 22. 22 of 26 Energy Audit BOILERS Observations: 1. Condensate recovery is not being done. 2. Feed water temperature presently is 50C. Recommendations: 1. Recover condensate to raise feed water temperature to upto 85C 2. Install de-aerator head on feed water tank and recover condensate. 3. Install steam operated condensate recovery pump Savings Estimated / year Investment Payback Period Rs 28.34 Lac Rs 25 Lac 11 Months
  • 23. 23 of 26 Energy Audit Air Compressors Observations: 1. Air leakage are about 26%. Recommendations: 1. Plugging of air leakages Savings Estimated / year Investment Payback Period Rs 4.0 Lac Nominal Immediate
  • 24. 24 of 26 Energy Audit Illumination Observations: 1. HPMV lamps are used for street lighting. 2. 36 Watt Tube lights with copper chokes are used. Recommendations: 1. Replace HPMV lamps by HPSV lamps 2. Replace 36 Watt Tube lights with T-5 28 Watt with electronic choke in a phased manner. Savings Estimated / year Investment Payback Period Rs 3.34 Lac Rs 4.0 Lac 16 Months
  • 25. 25 of 26 Energy Audit Conclusion The gaps may exist in design & actual operations for large complexes due to integration of :  Steam thermal systems.  Electrical systems  Process systems (Motive/ Thermal loads) due to variation in efficiencies/ actual requirements  Continuous monitoring and analysis of integrated systems is essential for improvements.  Energy Audits will identify such gaps.  Implementation of recommendations will result into considerable energy savings.
  • 26. 26 of 26 Thank YouDarshan Vithani ,Pranav Pathak ME-CSE