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CHAPTER-1
INTRODUCTION:
With increase in demand in energy and deficient in power generation, the cost of
power is going to increase manifold. This will worsen the cost of lining if new technology
energy efficient fittings and machines are consuming more power. The energy savings can be
accomplished by efficient use of power and judiciously employing energy management
programmers. Energy Audit likes, a financial audit is a systematic and scientific process to
identify the potential for improvements in energy efficiency, to recommend the ways, with or
without financial investment, to achieve estimated savings in energy and energy cost. This
requires collection &analysis of existing energy usage data, careful study of existing
equipment and the process and then suggesting practical& economic ways for saving energy
&energy cost .The greatest malady that has plagued power supply utilities is the scourge of
transmission and distribution losses. Although the menace of transmission & distribution
losses in a power system in inevitable, yet these need to be continuously monitored and
mitigated to reasonable limits. Transmission & Distribution losses in power system account
for the energy lost in transit from the sending end to the receiving end. In the present era,
more generation of power is not sufficient; the prime concern is how we make power
available to the consumer that is reliable and at affordable cost.
Any changes in the power sector right from generation to transmission to distribution to the
consumer should focus on the customer.
CHAPTER -2
CHAPTER-2
2.0 COMPONENTS
2.1 Main Energy Consumptions:
Based on our data the main energy consumption in our college is
Fans
Tube lights
CFL lights
CRT monitors
Air conditioners
Printers
Projectors
Freezers
Xerox machines
Fig: 1
Combustion analyzer:
This instrument has in-built chemical
cells which measure various gases such
as CO2, CO, NOX, SOX etc
Fyrite:
A hand bellow pump draws the flue gas
sample into the solution inside the fyrite.
A chemical reaction changes the liquid
volume revealing the amount of gas.
Percentage Oxygen or CO2 can be read
from the scale.
Contact thermometer:
TABLE-1
Old equipment
Total wattage
New equipment
Total wattage
Fans
40.8kw
28.05kw
Fluorescent tubes
16.4kw
Led tubes
6.15kw
CFL lamps
1.279kw
Led lamps
0.425
CRT monitors
22.10kw
Led monitors
11.05
LCD monitors
6.4kw
Led monitors
4kw
AC s
40kw
30kw
TOTAL
126.97KW
TOTAL
79.625KW
TABLE-2
CHAPTER -3
CHAPTER - 3
3.1 Definition:
Energy is the capacity of a physical system to perform work. Energy exists in several
forms such as heat, kinetic or mechanical energy, light, potential energy, electrical or other
forms. According to the law of conservation of energy, the total energy of a system remains
constant, though energy may transform into another form.
To minimize costs for repairs and reconstruction increase quality of environment that
contributes to increased work productivity.
Energy audit is a systematic study or survey to identify how energy is being used in a
building or plant, and identifies energy savings opportunities. Using proper audit
methods and equipment, an energy audit provides the energy manager with essential
information on how much, where and how energy is used within an organization
(factory or building).
This will indicate the performance at the overall plant or process level. The
energy manager can compare these performances against past and future
levels for a proper energy management. The main part of the energy audit
report is energy savings proposals comprising of technical and economic
analysis of projects. Looking at the final output, an energy audit can also
Identify the most likely (and the easiest areas for attention.
flow situation within a declared system boundary, which may be a building, a factory, or a
product lane or an agricultural sector. This picture aids comprehension of the total overall
system activity, reveals inter-relations and allows priorities to be identified. It high lights
major areas where inefficiencies or waste occurs and allows economic estimates, leading to
fully reasoned investment decisions, to be considered. The energy audit enables analyzing the
data in meaningful manner to evolve measure to introduce checks and balances in the system.
3.5.1 Necessity:
Auditing of energy in electrical under taking has become increasingly important in
view of. Large energy shortages, mismatches in Demand and supply in all SEBs. Very low
sales & high T&D loss levels requiring identification of areas of rampant. Pilferage and
malpractices, due to organizational deficiencies. Deteriorating financial position, shortage of
funds for system improvement. Improving the efficiency of functioning of the power system
as also the personnel in the organization at each level. Analysis of expenditure/investment Vs
revenue. In any industry, the three top operating expenses are often found to be energy (both
electrical and thermal), labour and materials. If one were to relate to the manageability of the
cost or potential cost savings in each of the above components, energy would invariably
emerge as a top ranker, and thus energy management function constitutes a strategic area for
cost reduction. Energy Audit will help to understand more about the ways energy and fuel are
used in any industry, and help in identifying the areas where waste can occur and where
scope for improvement exists. The Energy Audit would give a positive orientation to the
energy cost reduction, preventive maintenance and quality control programmes which are
vital for production and utility activities. Such an audit programme will help to keep focus on
variations which occur in the energy costs, availability and reliability of supply of energy,
decide on appropriate energy mix, identify energy conservation technologies, retrofit for
energy conservation equipment etc. In general, Energy Audit is the translation of
conservation ideas into realities, by lending technically feasible solutions with economic and
other organizational considerations within a specified time frame. The primary objective of
Energy Audit is to determine ways to reduce energy consumption per unit of product output
or to lower operating costs. Energy Audit provides a bench-mark (Reference point) for
managing energy in the organization and also provides the basis for planning a more effective
use of energy throughout the organization.
segments and various categories of consumers and how it has been consumed out of total
available quantum over a specified time period.
Providing cut-outs/MCBs after the meter as per sanctioned load & use of multi-core
PVC.
Providing adequate meter testing facilities. A time bound program should be chalkedout. For checking the meters with tested meters.
Pilot studies for introduction of modern technologies such as pre paid meters, remote
metering, automatic billing etc.
Difference of energy input measured at feeder end & the recorded consumption, is
total loss.
Input and output feeder wise power supply points to be identified for the state grid
and for all the circles (also divisions, sub divisions, sections/towns) for all lines
crossing the boundaries of respective jurisdictions at all voltage levels.
Sending ends are taken as metering points and readings taken on every 25th at
24.00hrs every month and net input is arrived at .Sending and measurement enables
inclusion of losses in the line segments as also cross checking with inputs arrived by
measurement done at generating station end.
The circle wise totaled net input of the state is cross checked net energy pumped into
grid i.e., generation less auxiliary consumption plus imports/ purchases and also with
the total billed units to AP TRANSCO by AP GENCO and others.
3.9 SCALES:
3.9.1 Metered sales:
HT (recorded units but not billed units) & LT (billed units) metered scales are taken
from ERO.
3.9.3 Losses:
The total losses at any level are the net input minus the metered plus un metered sales
put together in that area of network. The difference of total loss obtained from simulation
studies (Technical loss) is a indication of non technical loss i.e., commercial loss and together
are called T&D losses. The typical/optimum level of losses in various segments of the system
Areas are as under-the losses depend on pattern and nature of demand, load density and the
capability and configuration of system, equipment used and vary for various system elements.
However, system where total percentage loss lie beyond aforementioned values, should
become a matter of serious concern.
Important assessment of consumption in respect of stuck up, burnt meter cases and
door lock cases.
Non apportionment assessed energy in respect of pilferage, back billing cases and
revision of bills on subsequent dates etc to the corresponding monthly sales.
Obtaining Energy Audit reports & data from field officers and registers and
maintaining data bank.
State wide overall system losses and circle wise system losses and state wide EHT
losses are to be evaluated monthly.
Evaluating sub transmission (33kv) prim and secondary (11kv& LT) distribution
losses.
Arrive circle wise, division wise, sub division wise, section wise system losses.
The field reports received are to be registered analyzed, review and remarks
communicated to the field officers for taking remedial actions.
Watching the Indices prescribed and evaluates field officers performance from the
section to the circle level.
Preparation of monthly circle wise and state wise losses analysis reports for review
indicating the comparative performance during the current month & cumulative with
reference to corresponding period in the previous year etc.
Circle wise discrepancies are set right and uniform billing, accounting procedures are
ensured throughout the state.
Responsibilities are to be & norms are formulated for officers at different levels for
maintenance & reviewing various registers , conducting intensive raids, review of
Meter.
All revenue matters all reviewed and various instructions issued from time to time and
brought out in a book let and made available the lowest level officer concerned to set
right various discrepancies noticed during the review & of revenue officer and section
officers.
energy efficiency a plant or process can achieve is inversely proportionate to the energy loss that
occurs; the higher the loss, the lower the efficiency. Overall energy losses in a plant can result from
losses due to designs that do not incorporate energy efficient specifications such as heat recovery
option; operations that run on inefficient methods; and poor or
Non-energy efficiency-conscious maintenance programme. Reducing these losses will
substantially increase the plant's efficiency, but we need data to identify and quantify the losses and
subsequently suggest suitable techno-economic solutions to minimize the losses. This data can be
acquired through energy audits.
=760 watts
1 kilowatt
=1000 watts
1 watt
=1 joule/second
1 watt
=3.412 btu/hr
1000 Watts
= 1 kilowatt (kW)
Stages of
Energy Audit
Fig: 2
PLAN OF ACTION
PURPOSE / RESULTS
Step 1
Step 2
Step 3
Step 4
Step 5
Resource planning,
Establish/organize a Energy
audit team
Organize Instruments & time
frame
Macro Data collection (suitable
to type of industry.)
Familiarization of
process/plant activities
First hand observation &
Assessment of current level
operation and practices
Building up cooperation
Issue questionnaire for each
department
Orientation, awareness creation
Historic data analysis, Baseline
data collection
Prepare process flow charts
All service utilities system
diagram (Example: Single line
power distribution diagram,
water, compressed air & steam
distribution.
Design, operating data and
schedule of operation
Annual Energy Bill and energy
consumption pattern (Refer
manual, log sheet, name plate,
interview)
Measurements :
Motor survey, Insulation, and
Lighting survey with portable
instruments for collection of
more and accurate data. Confirm
and compare operating data with
design data.
Trials/Experiments:
- 24 hours power monitoring
(MD, PF, kWh etc.).
- Load variations trends in
pumps, fan
TABLE: 3
CHAPTER -4
CHAPTER-4
Due to various constraints the losses can be given as a range only and not exactly to a
decimal.
The EHT, Sub transmission, HT< losses are higher than assessed.
Pilferage is one item long neglected and often not taken seriously by the organizations
and this is the major cause of financial erosion of the Electrical utilities. Firm and
concerted and action will correct the existing situations.
CFL lamp
LED
Lumens
40
8-12
6-9
400-500
60
13-18
8-12.5
650-900
75-100
18-22
13+
1100-1750
100
23-30
16-20
1800+
150
30-55
25-28
2780
TABLE: 4
1. Investment
3. Annual savings
Cost of capital
Thermal Energy
Equipments
Maintenance
Electrical Energy
Civil works
Manpower
Raw material
Instrumentation
Energy
Waste disposal
Auxiliaries
Depreciation
Understanding energy cost is vital factor for awareness creation and saving
calculation. In many industries sufficient meters may not be available to measure all the
energy used. In such cases, invoices for fuels and electricity will be useful. The annual
company balance sheet is the other sources where fuel cost and power are given with
production related information.
They provide a record of energy purchased in a given year, which gives a base-line for
future reference
Energy invoices may indicate the potential for savings when related to production
Understanding fuel cost is fairly simple and it is purchased in Tons or Kiloliters. Availability,
cost and quality are the main three factors that should be considered while purchasing. The
following factors should be taken into account during procurement of fuels for energy
efficiency and economics.
Price at source, transport charge, type of transport
Quality of fuel (contaminations, moisture etc)
Energy content (calorific value)
4.11 Power Costs:
Electricity price in India not only varies from State to State, but also city to city and
consumer to consumer though it does the same work everywhere. Many factors are involved
in deciding final cost of purchased electricity such as:
Maximum demand charges, kVA
(i.e. How fast the electricity is used? )
Energy Charges, kWh (i.e., How much electricity is consumed? )
TOD Charges, Peak/Non-peak period
(i.e. When electricity is utilized ?)
Power factor Charge, P.F
(i.e., Real power use versus Apparent power use factor )
Other incentives and penalties applied from time to time
High tension tariff and low tension tariff rate changes
Slab rate cost and its variation
Type of tariff clause and rate for various categories such as commercial, residential,
industrial, Government, agricultural, etc.
Tariff rate for developed and underdeveloped area/States
Tax holiday for new projects
logical evolution of avenues for improvement. Historical data well documented helps to bring
out energy consumption and cost trends month-wise / day-wise. Trend analysis of energy
consumption, cost, relevant production features, specific energy consumption, help to
understand effects of capacity utilization on energy use efficiency and costs on a broader
scale. External benchmarking relates to inter-unit comparison across a group of
similar units. However, it would be important to ascertain similarities, as
otherwise findings can be grossly misleading. Few comparative factors, which
need to be looked into while benchmarking externally are:
Scale of operation
Vintage of technology
Raw material specifications and quality
Product specifications and quality
Benchmarking energy performance permits
Quantification of fixed and variable energy consumption trends vis--vis
production levels
Comparison of the industry energy performance with respect to various
production levels (capacity utilization)
Identification of best practices (based on the external benchmarking
data)
Scope and margin available for energy consumption and cost reduction
Basis for monitoring and target setting exercises.
The benchmark parameters can be:
Gross production related
e.g. kWh/MT clinker or cement produced (cement plant)
e.g. kWh/kg yarn produced (Textile unit)
e.g. kWh/MT, KCal/kg, paper produced (Paper plant)
e.g. KCal/kWh Power produced (Heat rate of a power plant)
e.g. Million kilocals/MT Urea or Ammonia (Fertilizer plant)
e.g. kWh/MT of liquid metal output (in a foundry)
While such benchmarks are referred to, related crucial process parameters need mentioning
for meaningful comparison among peers. For instance, in the above case:
For a cement plant type of cement, blaine number (fineness) i.e. Portland and process
used (wet/dry) are to be reported alongside kWh/MT figure.
For a textile unit average count, type of yarn i.e. polyester/cotton, is to be reported
along side kWh/square meter.
For a paper plant paper type, raw material (recycling extent), GSM quality is some
important factors to be reported along with kWh/MT, kCal/Kg figures.
For a power plant / cogeneration plant plant % loading, condenser vacuum, inlet
cooling water temperature, would be important factors to be mentioned alongside heat
rate (kCal/kWh).
For a fertilizer plant capacity utilization (%) and on-stream factor are two inputs worth
comparing while mentioning specific energy consumption.
For a foundry unit melt output, furnace type, composition (mild steel, high carbon
steel/cast iron etc.) raw material mix, number or power trips could be some useful
operating parameters to be reported while mentioning specific energy consumption data.
For an Air conditioning (A/c) plant Chilled water temperature level and refrigeration load
(TR) are crucial for comparing kW/TR.
For a boiler plant fuel quality, type, steam pressure, temperature, flow, are useful
comparators alongside thermal efficiency and more importantly, whether thermal
efficiency is on gross calorific value basis or net calorific value basis or whether the
computation is by direct method or indirect heat loss method, may mean a lot in
benchmarking exercise for meaningful comparison.
Cooling tower effectiveness ambient air wet/dry bulb temperature, relative humidity, air
and circulating water flows are required to be reported to make meaningful sense.
Compressed air specific power consumption is to be compared at similar inlet air
temperature and pressure of generation.
Diesel power plant performance is to be compared at similar loading %, steady run
condition etc.
4.13Plant Energy Performance:
Plant energy performance (PEP) is the measure of whether a plant is now using more
or less energy to manufacture its products than it did in the past: a measure of how well the
energy management programme is doing. It compares the change in energy consumption
from one year to the other considering production output. Plant energy performance
monitoring compares plant energy use at a reference year with the subsequent years to
determine the improvement that has been made.
However, a plant production output may vary from year to year and the output has a
significant bearing on plant energy use. For a meaningful comparison, it is necessary to
determine the energy that would have been required to produce this year production output, if
the plant had operated in the same way as it did during the reference year. This calculated
value can then be compared with the actual value to determine the improvement or
deterioration that has taken place since the reference year.
4.14 Production factor:
Production factor is used to determine the energy that would have been required to
produce this years production output if the plant had operated in the same way as it did in the
reference year. It is the ratio of production in the current year to that in the reference year.
4.15 Reference Year Equivalent Energy Use:
The reference years energy use that would have been used to produce the current years
production output may be called the reference year energy use equivalent or reference
year equivalent for short. The reference year equivalent is obtained by multiplying the
reference year energy use by the production factor (obtained above)
Reference year equivalent = Reference year energy use x Production factor
The improvement or deterioration from the reference year is called energy performance
and is a measure of the plants energy management progress. It is the reduction or increase in
the current years energy use over the reference, and is calculated by subtracting the current
years energy use from the reference years equivalent. The result is divided by the reference
year equivalent and multiplied by 100 to obtain a percentage.
CHAPTER -5
CHAPTER -5
5.2 By replacing fluorescent tubes with led tubes the savings are as follows:
1 fluorescent tube wattage =40watts and the cost is Rs.200/Extra amount invested
=Rs.800/-
Power saving
=20 watts
Total lamps
=240 lamps
Power saving
=240*20
=4800 watts
=5 hours (approx)
=20 days/month
=4800*5*20
=480000 WH
=480 KWH
Amount saving /month
=480*9
=Rs.4320/-
Amount saving/year
=4320*12
=Rs.51,840/-
=240*800
=Rs.1,92,000/-
=Rs.67,200/-
Fig: 3
CHAPTER -6
CHAPTER -6
ENERGY SAVINGS AND TECHNIQUES:
energy consumption.
Replacing of all these equipment involves a lot of money investment .but in due
course we can achieve in payback period. After that it is very economical.
Fig: 4
CHAPTER -7
CHAPTER-7
7.1 Conclusion:
The benefits of Energy Audit and Accounting are inter-related and outcome of a study
shall form the basis for detailed and complete evaluation of the system, which is need of the
hour. The adoption of proper energy accounting would ultimately facilitate increased revenue
realization for the energy supplied to the consumers, identification of areas and causes of high
energy losses and cutting down on its own expenses on account of the operational
inefficiencies.
7.1.1 The implementation of a structured energy audit offers numerous benefits to the
enterprises including:
CHAPTER-8
CHAPTER-8
Reference:
1. NPC energy audit manual and reports
2. Energy management handbook, John Wiley and Sons - Wayne C. Turner
3. Guide to Energy Management, Cape Hart, Turner and Kennedy
4. Cleaner Production Energy Efficiency Manual for GERIAP, UNEP, Bangkok
prepared by National Productivity Council
www.eeca.govt.nz
www.energyusernews.com/