r

.....

~.---iCOST Electronic &comll1unicmion

proceedings

1315 ja~O II

Energy Audit in Industry -A case study of Centrifugal Pumps

R.M.Hohnukhe

K.D.Deshpande

Electrical Engineering Department

Bharati Vidyapeeth Deemed University
College of Enggineering, Pune, India
E-mail: rajeslunholmukhe@hotmaiLcom

Electrical Engineering Department

Bharati Vidyapeeth Deemed University
College of Enggineering, Pune, India
E-mail: rajeslunholmukhe@rediffmail.com

Abstract-s-, Energy conservation litis 1l0W become a necessity. Considerable energy saving is possible through
proper choice of equiprnents, and their effective use. The-only feasible way to handle energy crisis, apart from
capacity addition, is the efficient use of available energy. For this there is a need of optimizing energy, using
standard systems and procedures so as to reduce energy requirements per unit of output.In this paper a case study
of centrifugal

pump in industry

for energy

audit is presented.

Keywords-energy

audit,centrifuga!

pumps

Modeling and Simulation of Buck boost Controller of Solar Wind

Hybrid Energy System
IPatif S. N.

't. R.

2S.S. Patif

C Prasad

Asst. Prof. in Electrical Engg. Dept., P. V.P.lT Bavdhan, Pune

lAsst. Prof. in Electrical Engg. Dept., Sinhagad Academy of Engineering, Pune,
Jprof in Electrical Engg. Dept., College of Military Engineering, Pune
I

Ipatil sn@rediffmaiLcom
2prasadrcp@rediffmail.com

Abstractprices
There

Because of combustion
of fossil fuels global warming
caused by environmental
problems,
the raising
of crude oils and natural gases. They promote continuous
effort to improve energy system and its efficiency.
is a need to search for abundant and clean energy sources due to the depleted and increasing prices of oil.

Solar and wind energy acts as an alternative

energy source.
The objective
is to design and simulate a controller
for the unlimited
a higher
voltage output through the de-to-de
converters (Buck-Boost

solar power drawn

Converter).
The

from the sun and produce

Photovoltaic
cells have a

non-linear
V-I characteristics
and adapts the Maximum
Power Point Tracker (MPPT)
to achieve the maximum
permissible
power obtained.
A controller circuit is design to track the maximum
power of the photovoltaic
at the
peak voltage
and current level. De-to-De
converters (Buck-Boost
Converter)
are necessary
to produce
a higher
voltage due to the low input voltage drawn from the photovoltaic
cells. The voltage
is maintained
at a constant
voltage

at the output

and boost converter

track the maximum

Keywords:

S.S.V.P.S.'s

Modeling,

load by the switching

circuit
power

control

circuit.

Wind

controller

circuitry

comprises

a non-inverting

The result shows that the model can simulate the photovoltaic
models, wind
which helps to design and improve the power of solar wind energy system.

Photovoltaic

B.S.Deore college

System,

of

Maximum

Power

Point Tracker,

Engineering & Polytechnic.Dhule.

Buck-Boost

system

buck
and

Converter.

Page 28

Energy Audit in Industry -A case study of Centrifugal Pumps

RMHolmukhe

K.D.Deshpande

Electrical Engineering Department

Bharati Vidyapeeth Deemed University
College ofEnggineering, Pune, India
E-mail: rajeshmholmukhe@hotmail.com

Electrical Engineering Department

Bharati Vidyapeeth Deemed University
College ofEnggineering, Pune, India
E-mail: rajeshmholmukhe@rediffinail.com

Abstract-.
Energy conservation has now become a
necessity. Considerable energy saving is possible through
prtIfIt!T duIia of ~
tBUl tJuir eff~
I!SL 1h
0III;y ftWSible ....., ID IuuuIk nID1:.F am.s. 1IJIIIIt.frotrt
aqJIIdI:y IMI4iIimI. is tIu! ejJiL.inrt IISe of ~
I!III!I'VF", tIIis tlIen! is .ed of opti-kirtg DIDV, IISiIrK
sIIBIIItmI

sy.sIDIB

11IIIIprot:a/IIrt!s

:so

lIS

ID rrtIIu%

DfDV

~
per IIIIiI of twtpwt I. litis JIIIIN!' ccse sIIuIy
of centrifugal pump in industry for energy audit is
presented.
Keywords-energy

audit.centrifugal

pumps

lNrRoDUCl10N

An Energy Audit is the preliminary activity towards

instituting energy efficient programs in the eslablishmentlt
consists of activities that seek to identify conservation.
Factors to be considered during energy audit are energy
accounting,
better control of energy
use, process
optimization for efficient energy use, creating awarness and
foUowing standard rules and reguJations.Gener.dIy an
Energy Audit includes survey of work place ,analysis of
energy usagt;.SlUdyof energy use procedures,finding energy
improvement opportunities ,recommendations with cost
benefit analysis..
II.

THE ROLE OF AN ENERGY AUDIT

Identify areas in the establishment consuming

unnecessarily too much energy.
Assess energy saving opportunities so as to save
money where it counts the most.
In the factory, an energy audit increases awareness
among plant personnel of energy issues.
An energy audit gauges the energy efficiency of the
plant against "best practices", when used as a
"baseline" for tracking yearly programs against
targets.
h is the f"lTSt step towards saving money in the
production pIanL

llI.

CONTENTS

OF AN AUDIT

An energy audit seeks to document things like energy being

used on site per year which includes use of energy and

opporturuties for savings.In the process it assesses the

effectiveness of management structure for controlling energy
use and impIement:iI1g cbaoges.The energy audit report
estabIisbes the need for plant metering and monitoring. The
plant Manager then instititutionaIize the practices thus saving
money fur the years to come:nM! energy audit action plan
IisIs the steps and sets the preliminaIy budget fur-the energy
managanent progranL

IV.

ANALYSIS

OF ENERGY

USE

Identifying areas where energy used is most useful.This

enables to focus OIl areas where the andit should be focused
and raises awareness of energy use and cost.The results
could be used in the review of management stroctures and
procedures fur controlling energy use.
V.

IMPORTANT POINTS TO CONSIDER WHEN COLLECTING

SITE LOAD DATA

Operating hours: It is collected from plant

personnel..This data sbouJd be accurate so as to
estimate energy savings correctly.
Duty Cycle: Machines, such as large induction
motors have varying loads with different power
requirements.Hence duty cycle is very important
Actual Power Consumed: For electric power users,
this is based on either 3-phase current/voltage
readings or power analyzer measurements(e.g.
direct
KW
which
incorporates
power
factor).
For fuel users, tank readings of monthly
consumption
estimates
and flow meters with totalization can be source of
measurement.
VI.

!DENTIFICA TlON OF ENERGY PROJECTS

In identifying energy ~
it is impor1ant to focus on
major eIiergy users and areas.Always apply 80120 rule, focus
OIl opportunities that provide XO'"/e of the savings but require
2()O/e inpuLSpeod more time on those projects which have
shorter payback period.

YH COST BENEFITANALySIS

The identififxJ energy conservation opportunities should be

anaiyzl:d in tenns of the costs of iq)IemeoIing the ~
versus the benefits that can be ~
makes a sense to go
011 with the project if there is a net positive benefit from the
project.

VIII ACTION PLAN TO SET IMPLEMENTATION PRIORITY

After passing the cost benefit analysis test, an action plan

should be developed to ensure that the opportunities
identified are implemented.The action plan should include all
the major steps for implementing the opportunity as well as
the people responsible. Furthermore, there should be a plan to
monitor the results.
IX

TYPES OF ENERGY AUDTr

TypesofE.ergy AIlCIits
The term Energy Audit tries to identify the alternative energy
efficient measures that would also satisfY the financial
criteria of the investors A demiled specification of the scope
of work: is necessary to speU out the requirement of the audit.
There are three common audit programs which are
described in next pages.
Prdimilary A.dit
The preliminary audit also called as a simple audit, screening
audit 01" walk: through audit, is the simplest and quicker type
of auditsJt involves minimal interviews with the site
operating personneI.a brief review of the fuciJity utility bills
and other operating data, and a walk-through of the facility
to become familiar with the plant operation and identify
areas of energy waste or inefficiency .Major problem areas
will be uncovered during this type of audit..Corrective
measures
are briefly
described
and estimates
of
implementation costs, potential operating cost savings, and
simple pay back periods are provided.This helps to priotize
energy efficient project and detennine the need for a more
detailed audit.

Geaentl Alldit
GeoeraJ audit or a mini audit/site energy at~it expands on
the preliminary audit.More detailed information about
facility operation is collected so as to perform a more
detailed evaluation of energy conservation
measures
identified. Utility bills for a period of 12 to 36 months are
coUected to evaluate the fucility's energy/demand rate
sIructures and energy wage profiIesAdditiooal metering of
specific energy- consuming systems is often performed to
supplement utility data..ln-depth interviews with facility
operating personnel are conducted to understand major
energy consuming systems as well as insight into variations
in daily and annual energy consumption and demand. A
detailed financial analysis is performed for each measures to
justify project implementation.

lnvestment-

Grade Audit

Facility's energy infiasbucture must compete with nonenergy related investment fur fur capital fimding Both energy
and DOD-eIIeIgy investnlents are rated on a single set of
financial criteria that generally stress the expected Return on
Jnveslmen1(ROI)..Retm:n 011 Investment =Net Profit after
taxesITotaJ InvestmentIhe projected operating savings fium
the ~Jemetdation
of energy savings should provide
confidence to the investors.The investment-grade audit also
known as a comprehensive audit,detailed audit, maxi audit or
technical analysis audit expands on general audit providing a
dynamic model of energy use of existing facility and all
energy conservation measures identified.
X

PUMP ENERGY REDUCTION

Pump system account for 13% of Electrical Energy

Consumption in India.When analyzing the life cycle of
pwnping equipment, the energy cost in operation is 85% for
large water utility pumps.Selecting a bigher efficiency pwnp
will reduce power consumpIion, but by improving the design
of the pwnp system and cootrolling the interaction between
the pwnp & the system would acbieve greater improvement,

I
'--

;~

DlI!l

-/
-,

~'\.,
,---..-

Figure NO.1. Pump system identification

If pwnp systems are initially designed on an energy efficient

basis and pmnps are correctly operated & sized, the energy
savings will often be in excess of 50%.lDe reasons for
energy inefficient pumping system are Poor System
Design,over sizing of pump,pump and system mismatching,
pipe work layouts.Significant savings can be made in
existing system by carrying out systematic audit & better
operation eontrol.A study indicates that greatest energy
consumption by pumps is in application in commercial &
public buildings(41%), water & sewerage facilities(14%)
and others (9010) as shown in fig.

EnergJ CcnsuqIIion bv ~or

OIaldGi15

IIII!ria;; aid

~"UhIaI

:11

inaccurate.However
the vananons
form the original
specified duty is so large that estimated actual performance
fiom data which is available is sufficieut to to guide actions
for energy reduction.. Trimming cost of an impeller inStead
of Ibrottling can be recovered in a few days..For large pmnps
where saving potentiaI are high. a specialists is employed
who insIaUs tempotaay insmurc:adalions
to accurately
measure perlOnnance.

Figure o2J~DagyCOIl5UIDp6on by sedor"

Xl

CARRYING 0

A SYSTEM AUDIT

Purpose of energy audit is to reduce 'operating costs by

reducing energy consumption. Energy audits carried out by
IPMA shows that savings in the range 30 to 50% are not
unusual.By reviewing utility bills one can get an indication
of the savings to be made and the estimate of investment to
be made into auditing process.In most industrial sites two
thirds of the energy is consumed by electric motors.The cost
of energy consumed by motor during its life time may be
100 times its purchase cost.Through
modem design
techniques, this loss can be reduced to 30%.Many pumps &
motors are operated at full power constantly, irrespective of
process needs, and in some sites this offers the potential of
large cost reductions.An energy audit is a significant
investment and many man-hours are needed to find out
where energy is consumed. A thorough log of consumption
on each spur is made because excess energy is sometimes
used in most unlikely place.An energy audit identifies
savings to be made by resizing or retrofitting pumps which
are
operating
away
from
their
best
efficiency
points.Variable speed motors in place of standard motors
can be used to control pump operations.By studying process
requirement, energy audit can identify requirement of
energy consumption
and compares
it with actual
consumption.lf every pump and motor is working at the
maxm.
efficiency,
great
savings
can
be
achieved. Performance data for the equipment as originally
supplied or manufacturers curves are required to carry out
the audit.From the name plates of the pump and motor data
can be recorded.Determination of actual flows and pressures
may be difficult at site due to non-availability of pressure
gauge and flow meters. Power readings on site may often be

Figure No3. Pump

XII.

A CASE STUDY OF CENTRIFUGAL PUMPS

Existing pump details:Kirioskar pump model DB

50/20,size (65x50)mm,Pump sr. no.9370757,58
Head: 46 mtrs
Discharge: 6 Ips
Pump efficiency: 47%
BKW: 5.75
Motor: 7.5KW/IOHP,TEFC induction motor
Observations: 1Pumps operating 6hrs per day
2Pumps operated at full capacity
Suggested pump
Kirloskar Pump Model DB 40/20,size (65x40)mm
Head: 46 mtrs
Discharge: 61ps
Pump efficiency: 54%
BKW:5KW
Motor recommended
5.5KW/7.5HP
TEFC
industion motor
Cost Benefit Analysis
C =(n2-nl) x PxZxSx 0.746/n]
C= (54-47)xlOx2J90x7.5xO.746/54 = Rs 14825 per
year
Cost of new pump type DB 40/20 with 5.5HP
motor = Rs 12030
Pay back period = 10 months.
Total saving during full life(15 yrs) = Rs 2,22,375
each pump.

'--------------~l..

RESULTS

II
~/

.II

'

.. t

ACKNOWLEDG lENT

Bharati
Vidyapeeth
Engineering, Pune.

Deemed

University

REFERENCES

[I]

Field Visitsin various industries

[2]

Manuals of Kirloskar motors and pumps.

[3]

Handbook of Energy Conservation.

[4]

Various IEEE papers on motors and pumps.

College

of