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ENERGY Audit

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

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ENERGY Audit

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  1. ENERGY Audit By Ravindra M Datar Senergy Consultants (P) Ltd 91-9821271630 senergy@vsnl.com www.senergy-india.com

  2. Senergy Synergy between Our expertise on conservation of energy & Your experience & knowledge of process, operations, plant engineering, etc. To Save Energy

  3. 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

  4. 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

  5. Senergy • Interactive studies. • Practical & Realistic Suggestions. • Turnkey Consultancy during Implementation. • Long term services for Sustainable Savings & Continuous Improvements. • Basic & Advanced Training Programs.

  6. 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 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 M S E B Whirlpool of India Ltd Pidilite Industries Ltd Sachivalay – Gujarat Wochkhardt Ltd Few of our clients

  7. Instruments • 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)

  8. Specific Energy Consumption Targets & Benchmarks Unaccounted Consumption Equipments Performance Distribution System Utilization Recovery from Waste Energy Cost of Energy Renewable Energy Energy Monitoring Energy Audit

  9. 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

  10. Specific Energy Consumption

  11. Specific Energy Consumption

  12. Specific Energy Consumption

  13. 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.

  14. Specific Power Consumption for Office Premises Case Study : 343 kWh/M2/Year Wipro :190 kWh/M2/Year ITC :125 kWh/M2/Year CII :70 kWh/M2/Year

  15. 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

  16. Energy Accounting / Balancing

  17. 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

  18. Performance of the Machines

  19. Specific Power Consumption : AC

  20. Norms: Specific Output - Air Compressor

  21. 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

  22. 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

  23. 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

  24. 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

  25. Renewable Energy • Solar Heating Applications up to 80 oC • Wind Mills • Fuel From Organic / Agro Waste • Methane from Effluent • Fuel from Municipal Waste

  26. 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

  27. Case Study - ISpecific Energy Consumption

  28. Case Study - IIHeat Recovery from Waste Stream Waste Ice 8.5 TPD Ch Water 110C 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 Process

  29. Case Study - IIHeat Recovery from Waste Stream Waste Ice 8.5 TPDFresh Water 300C221m3/day Ch Water 110C 250C E T P Effluent 120C229.5 m3/day1250 TR / 221 M3/day 130C Reduction in refrigeration load: 82% Process Plate Type Heat Exchanger Chilled Water System (1400 TR)

  30. Case Study - IIICondensing 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

  31. Case Study - III Condensing Turbine

  32. Case Study - III Condensing Turbine

  33. Case Study - IVPumps, 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

  34. Variable Speed based Control

  35. Thank You!

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