Unit 5
Unit 5
Unit 5
Ste
PLAN OF ACTION PURPOSE / RESULTS
p
No Phase I –Pre Audit Phase Resource planning, Establish/organize
a Energy audit team
Step 1 Plan and organise
Walk through Audit Organize Instruments & time frame
Informal Interview Macro Data collection (suitable to
with type of industry.)
Familiarization of process/plant
Energy Manager,
Production activities
/ Plant Manager First hand observation &
Assessment of current level
Conduct of brief operation and practices
Step 2 meeting / awareness
programme with all Building up cooperation
divisional heads and Issue questionnaire for each
persons concerned (2-3 department
hrs.) Orientation, awareness creation
Phase II –Audit Phase
Step 3 Primary data gathering, Historic data analysis, Baseline data
Process Flow Diagram, & collection
Energy Utility Diagram 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)
Step 4 Conduct survey and
Measurements :
monitoring Motor survey, Insulation, and Lighting
survey with portable instruments for
collection of more and accurate data.
Confirm and compare operating data with
design data.
Step 5 Conduct of detailed trials Trials/Experiments:
/experiments for selected energy - 24 hours power monitoring (MD, PF, kWh etc.).
guzzlers - Load variations trends in pumps, fan
compressors etc.
- Boiler/Efficiency trials for (4 – 8 hours)
- Furnace Efficiency trials
Equipments Performance
experiments etc
ANNEXURE
Al. List of instruments
A2. List of Vendors and Other Technical details
Energy Audit Instruments
POWER ANALYSERS
Electrical Measuring
Instruments:
These are instruments for measuring major
electrical parameters such as kVA, kW, PF,
Hertz, kvar, Amps and Volts. In addition some
of these instruments also measure
harmonics.
Fyrite:
Infrared Pyrometer:
Common Fuels
Power Costs
• Fuel oil,• Low Sulphur In India Electricity costs
Heavy Stock (LSHS),• Light
Diesel Oil (LDO),• Liquefied vary substantially not only
Petroleum Gas (LPG) from State to State, but
• Coal,• Lignite,• Wood also from city to city and
also within consumer
Fuels Cost Inputs & Factors to consumer – though
power does the same
• Price at source, transport
charge, type of transport, work everywhere.
• Quality of fuel
Reason:
• Contaminations, Moisture, •Tariff Structure
Energy content (GCV)
Energy conservation measures
Understanding energy costs
An industrial energy bill summary
• FACTORS INVOLVED:
– Scale of operation
– use of technology
– Raw material specifications and quality
– Product specifications and quality
Benchmarking for Energy
Performance
• Internal Benchmarking
Historical and trend analysis
• External Benchmarking
Across similar industries
Scale of operation, use of technology, raw
material specification and quality and
product specification and quality
Bench Marking Energy Performance
EXAMPLES:
procedures .
These techniques covers all plant and building
utilities such as fuel, steam, refrigeration,
compressed air, water, effluent, and electricity
are managed as controllable resources in the
same way that raw materials, finished product
inventory, building occupancy, personnel and
capital are managed.----It Becomes the
“Energy Cost Centers.”
Elements of Monitoring & Targeting System
• • Reporting -Reporting the results including any variances from the targets which have been set
• • Controlling - Implementing management measures to correct any variances, which may have been occurred.
• Recording energy use, so that projects intended to improve energy efficiency can bechecked
• Cumulative Sum (CUSUM) represents the difference between the base line and
the actual consumption points over the base line period of time.
• This useful technique not only provides a trend line, it also calculates
savings/losses to date and shows when the performance changes.
CUSUM Technique
CUSUM analysis
1 Plot the Energy - Production graph for the first 9 months 4-Analysis-TABLE
2. Draw the best fit straight line
3. Derive the equation of the line, y=mx+c
4. Calculate the expected energy consumption based on the
equation
5. Calculate the difference between actual and calculated
energy use
6. Compute CUSUM
7. Plot the CUSUM graph
8. Estimate the savings accumulated from use of the heat recovery
system
1-Given
2-plot graph
3-fit equation
Case Study
The CUSUM Technique
Therefore,
Energy consumed for the period=C+m*production for the same
period.
• Consider the sample points,
(X1,y1).(x2,y2)……(xn,yn)
Therefore,
Equation of straight lines are,
1. cn+m∑x=∑y
2. c∑x+m∑X2 = ∑xy….(on the basis of production
i.e independent variable)
n= no. of data points
These equations are known as normal equations
of the problems and they can be used to
establish the value of “c” and “m”.
Example
Answer