ELECTRICAL ENERGY AUDIT

Electrical Energy
2
Audit

Abstract

There are three major working expenses in the industrial plant which are mostly found out to be

on electrical energy. In this electrical energy audit of mogharbel plant we will discuss the

possibility of cost savings in each of the plants components, then electrical energy would

definitely come out on the top, and as a result electrical energy management would help in a

planned area for reducing the cost. This project for mogharbel plant will help in determining the

common features of electrical energy management. This document contains the complete result

which is required to do the electrical energy audit for the mogharbel plant industrial unit. The

electrical energy audit is carried out in by through following heads:

(i) Energy audit lights

(ii) Audit Power (machines, electric motorsetc.)

(iii) Harmonic research

We have done the complete energy analysis which is a two stage energy process for the

mogharbel plant. For this kind of work a mapping would be done for energy conservation

potential in the manufacture process.

This energy audit is for the foundry processes done at mogharbel plant. The main purpose is to

set up the major energy flows of the whole project which will help in utilizing the other

alternatives of energy conservation. As we all know production plays a very vital role in energy

audit which helps in performing the necessary analysis

 Electrical Energy
3
Audit

Executive Summary

In this energy audit for mogharbel plant, the production procedure will be described in sub-

procedure/procedural tools and based on that electrical energy balance sheet should be prepared.

With more demand and supply in energy objects balance sheets will be based on equipment

basis. The basic purpose of mapping of all the procedure will describe if there is any defects or

faults disclosed which might affect the consumption of energy from the system. This project

explains all the technical information about the electrical energy audit, also, this project will state

whether or not energy conservation prospects exist in this procedure, for the system inspected.

Furthermore, in this energy audit project of mogharbel foundry plant at Tamworth will help in

utilizing other renewable energy sources. (Foundry bench, 2013)

Acknowledgement
I would like to acknowledge my family and friends with the help of which I am able to complete

this energy audit.

Also, I want to thanks my lecturers and the entire class for their timely guidance for this

electrical energy audit which has helped me in understanding the concept in a much better way.
 Electrical Energy
4
Audit

List of Tables

S. No. Table Name

Table 1 Transformer A electrical Trends

Table 2 Transformer B electrical Trends

Table 3 Transformer C electrical Trends

Table 4 Transformer D electrical Trends

Table 5

Table 6

List of Figures

S. No. Figure Name

Figure 1 Graph: Efficiency Vs Loading

Figure 2 Harmonic Distortion

Figure 3 Harmonic trends

Figure 4 Harmonic Disturbances

Figure 5 Harmonic Distortion

Figure 6 Harmonic Alteration

Figure 7 Harmonic distortion

Figure 8 Harmonic trend

Figure 9 Harmonic Disturbance

 Electrical Energy
5
Audit

Figure 10 Reduced Current flow

Figure 11 Pyro Process

Figure 12 Distribution Network

Figure 13 Load files screenshot 1

Figure 14 Load files screenshot 2

 Electrical Energy
6
Audit

Table of Contents

1. Introduction .................................................................................................................................. 7
2. Objective of this energy audit ....................................................................................................... 7
3. Scope ............................................................................................................................................. 8
4. Auditing Process............................................................................................................................ 8
5. Mogarbel Plant electrical energy consumption ............................................................................ 9
Lighting survey...................................................................................................................................... 10
6. Electric Motor survey .................................................................................................................. 10
7. Harmonic Analysis....................................................................................................................... 12
8. Recommendations ...................................................................................................................... 24
9. Conclusion................................................................................................................................... 26
References ............................................................................................................................................ 27
 Electrical Energy
7
Audit

1. Introduction

Electrical energy is considered the most costly energy source for any industrial plant. As it is

used for efficient and balanced financial operation because of its litheness, electricity gives

benefits over another energy sources such as fossil fuels. A foundry industry uses electrical

energy in a very big amount, and because of that reason it is very important to conserve the extra

energy. This electrical energy audit will translate the ideas into certainty with the mix of

technical practical solutions with financial and other governmental considerations within

specified time. An electrical energy audit of a mogharbel plant will determine how and where

energy will be used and to determine the methods for saving energy and cost for the plant.

The extent of an electrical energy audit, the complications of calculations, and the level of

financial assessment are all problems that might be handled in a different way by every

individual energy auditor and this will be defined in the beginning of the auditing procedure.

Now if we are able to decrease the energy usage which will help in increasing the efficiency at

the plant, energy than can be conserved like ozone diminution and greenhouse effect that can be

improved. The energy audit of a mogharbel plant has been explained in this document.

By proper maintenance and operation energy conservation can be achieved. These actions

include using energy efficient equipment, which will improve electricity demand supervision,

thus by reducing summer temperature settings, for example turning off the light, fans etc.

(Application of energy audit in buildings and a case study, 1993).

2. Objective of this energy audit

 Electrical Energy
8
Audit

To check the Mogharbel plant electrical energy consumption

To do the light survey of the Mogharbel plant

To do the harmonic analysis Mogharbel plant

3. Scope

Energy consumption and energy expenses saving possibilities will be known

Energy consumption's center area will be measured

The essential information for optimizing electricity purchases will be compared with

energy purchase fees.

Energy use linking materials that are used in the systems and devices, a proper training

and education will be given to the technical staff of the Mogharbel plant

To improve propositions for the energy consumption by improving indoor air quality and

also improving the working conditions

4. Auditing Process

Electrical energy audit with consent of senior management without their approval audit cannot

be carried out so, in the starting we will convince them for implementing the energy audit and

management. For this energy audit many tasks will be carried out depending on the type of the

audit facility provided for energy auditing. As a result, an energy audit will not be linear

procedure that is why it has to be integrated. Following functional activities have been followed

for the energy audit (Application of energy audit in buildings and a case study, 1993):
 Electrical Energy
9
Audit

Lightning survey

Electric load survey which is used in various processes of industrial unit

Harmonics analysis of Mogharbel plant

MEASUREMENT WORK

Mogharbel plant is one of the cutthroat foundry industry in tamworth area which supplies around

50% production of foundry in Export. With proper marketing it has become very popular in the

domestic market of tamworth area. Because of which very extensive electrical energy audit is

carried out for proper analysis.

5. Mogharbel Plant electrical energy consumption

The energy consumption of the mogharbel plant was identified with area wise and electric

equipment. During the plant visits the results were acquired after dimensions. Power analyzers,

clamp meters, Data loggers will be used to determine the electrical energy consumption of the

mogharbel plant. The final load of the plant comes out to be 5383.178 KW. (Electrical energy

management in small and medium size industries, 1993)

Following points are observed after this survey:

There are four transformers of the rating11 kv/415 kV, 1000KVA and one transformer of the

rating 33 kV /11 kV, 5000 KVA.

The major load in the plant is that of motor, which constitutes approximately 80% of the total

load.

Total number of units consumed per month after taking averages of 12 months 16-17 million

(Electrical energy management in small and medium size industries, 1993).

 Electrical Energy
10
Audit

Lighting survey

This survey will be done to evaluate the lighting requirement of the mogharbel plant and extent

of improvement of lighting value and lighting level, with a purpose of cutting down the electrical

energy consumption and which will help cost of electricity.

After this survey, it is found out that numbers of luminous tubes are used with copper counter

balance. It was observed that currently reflectors are detached which results into depletion of

light towards upper limit. For this we will recommend the following things:

In place of copper ballast use electronics ballast.

In ring frame area use reflector as it will improve lighting level at work area.

Light fixtures will be consistently checked

Energy saving by electronics ballast after replacing copper ballast:-

With copper ballast energy consumed per year = No. of lights watts 12 365

= 1060 36 12 365/1000= 1, 70,800.32 kwh

With electronics ballast energy consumed per year =125568.92 KWh

Energy saved = 44, 332 KWh

By replacement of copper ballast energy saved = Energy saving Rate/KWh =44,332 10

= 4, 43320

Thus 39% energy is saved after replacing copper ballast with electronics ballast

(Electrical energy management in small and medium size industries, 1993 )

6. Electric Motor survey

 Electrical Energy
11
Audit

The electric motors used in mogharbel plant have artificial cooling fans. And few of the motors

are fixed with very heavy metal cooling fan. The metallic fans are heavy and due to corrosion

after pitting over the years have consumed more power.

For large electric motors we will use cooling fans which will replace all such metallic fans by

Fiberglass permanent Plastic fans. Because of which total energy cost will be saved @ 20% of

rated power of motor.

Quantity of energy saved per year = Energy saved rate of energy

Following graph depicts the efficiency for the motors used:

Figure no. 1 (Energy efficiency,2012)

 Electrical Energy
12
Audit

7. Harmonic Analysis

In the mogharbel plant with the increase in use of non-linear electrical load and also with

computerization in plant, due to harmonic distortion a poor quality issue related to power has

occurred. As harmonic distortion has increased in electricity distribution system, various

guidelines has been used for the voltage control at the plant and after evaluating present

harmonic contents at Plant premises keeping in mind the Point of Common Coupling (PCC),

which will take counteractive sorting result. Now for harmonic limits which are in excess as

according to the IEEE- 519-1992 guidelines. The main purpose of this harmonic analysis is to

enumerate the distortion in voltage and check the current waveforms occurring in the power

distribution system of this plant. The end result will be very helpful in assessing the remedial

procedures and troubleshooting harmonic distortions problems with ease (IEEE Recommended

Practice for Energy Management in Industrial and Commercial Facilities, 2008).

Following are the effects that will occur because of Harmonic Analysis

Neutral conductor will be overloaded

Electric motors efficiency will be reduced

Control equipment will malfunctioned

With the introduction harmonic distortion power factor of the whole system will be poor

Capacitors will be overloaded

Due to boost in rms current drawn demand for kVA for the plant will be increased

(IEEE Recommended Practice for Energy Management in Industrial and Commercial Facilities,

2008)
 Electrical Energy
13
Audit

Harmonic distortion measurements at the plant:-

With the harmonic spectrum of LT currents in 3-phase electricity distribution system of the

mogharbel plant has been stored with the use of Harmonic and Power Analyzer. And results are

shown in the following table no. 1 to 6 and figure 1 to 8. .

(Electrical energy management for low-voltage clients , 2007)

 Electrical Energy
14
Audit

Figure no 2 Harmonic distortion (Electrical energy management for low-voltage clients ,

2007)

Figure no 3 Harmonic trends (Electrical energy management for low-voltage clients , 2007)
 Electrical Energy
15
Audit

(Electrical energy management for low-voltage clients , 2007)

Figure 4 Harmonic disturbances (Electrical energy management for low-voltage clients , 2007)
 Electrical Energy
16
Audit

Figure 5 Harmonic distortion (Electrical energy management for low-voltage clients , 2007)
 Electrical Energy
17
Audit

Figure 6 Harmonic Alteration (Electrical energy management for low-voltage clients , 2007)
 Electrical Energy
18
Audit

Figure 7 Harmonic distortion (Electrical energy management for low-voltage clients , 2007)

(Electrical energy management for low-voltage clients , 2007)

 Electrical Energy
19
Audit

(Electrical energy management for low-voltage clients, 2007)

Figure 8 Harmonic trend (Electrical energy management for low-voltage clients, 2007)
 Electrical Energy
20
Audit

Figure 9 Harmonic Disturbance (Electrical energy management for low-voltage clients, 2007)

Following table verifies the IEEE standards:

(IEEE Recommended Practice for Energy Management in Industrial and Commercial Facilities,
2008)
 Electrical Energy
21
Audit

(IEEE Recommended Practice for Energy Management in Industrial and Commercial Facilities,

2008)

With this type result as mentioned in the above table the manner in which plant consumer falls

under the type of short-circuit ratio which will lie in the range of 10<20, and the maximum

allowed THD value for this will be up to 11th harmonics (4 %). With this THD value at the

mogharbel plant is high in comparison to 4%, which is a allowable limit. Now as the measured

THD value is high as compared to permissible limit so, for that reason the mogharbel plant must

set up a harmonic filter which improve the power quality of the plant and that will save the cost

on harmonic discharge.

This will help in reducing the current flow. See the figure below to check out the exact result:
 Electrical Energy
22
Audit

Figure 10 (Energy efficiency, 2012)

 Electrical Energy
23
Audit

And after doing all the process the power optimization will look like this:

Figure 11 (Energy efficiency,2012)

Before and after Power Optimization depicts the similar Production level, rate of production and

for how much hours it is running.

 Electrical Energy
24
Audit

8. Recommendations

We will recommend that replace the Copper ballast with Electronic ballast. Replace 40Watt/36

Watt tube lights with the 35 Watt tri-phosphor. And 40W /36 watt tube rod has following

features:

The scale is quite similar to ordinary daylight

It has brilliant contrast vision

It has rendering properties i.e. Optimum color

Very good light quality

With electronic ballast it has service life that is when operated:13,000 hours

It is easy to clean these light fixtures periodically.

(IEEE Recommended Practice for Energy Management in Industrial and Commercial

Facilities, 2008)

Other Recommendations

By using false ceiling and twofold door system electric energy cost could be saved where

air conditioners are used,

Fiberglass unbreakable Plastic should be used instead of metallic fans to save energy.

Harmonic filter must be installed to improve the power quality of the plant as harmonic

components at PCC are larger than the allowed limits

Now the distribution network will look like this as shown below:
 Electrical Energy
25
Audit

Figure 12 (Energy efficiency,2012)

And when the load files are loaded in the software following result will comes out as shown

below:

Figure 13 (Energy efficiency, 2013)

 Electrical Energy
26
Audit

Figure 14 (Energy Efficiency, 2013)

9. Conclusion

By performing Energy Audit with above recommendations mogharbel plant can save up to 8

million dollars per year. As electrical energy audit is an efficient device for managing energy

utilization. It will help in reducing the depletion of energy and required conservation steps will

be taken with a cost effective methods. This audit is very vital for Power optimization which will

help in reducing energy consumption of the whole plant by about 10%. With the diminution of

energy wastage, the equipment life will increase and it will increase the power distribution

utilization. And with Power utilization improvement will improve equipment consistency which

will help in saving the cost for plant. (Energy efficiency, 2012)
 Electrical Energy
27
Audit

References

Foundry bench, 2013,

http://www.swerea.se/Global/Swerea_SWECAST/Foundrybench/Foundrybench%20D3

%20Common%20analysis%20method.pdf

Energy efficiency,2012,

http://www.msmementor.in/SIDBI_Publications/Energy%20Effiency%20in%20Foundry

%20Sector.pdf

Application of energy audit in buildings and a case study, 1993, H. K. Wong, and C. K.

Lee, IEEE International Conference on Advances in Power System Control, Operation

and Management.

Electrical energy management in small and medium size industries, 1993, P. Z. Yaacoh,

and A. A. Mohd. Zin, IEEE TENCON, Beijing

IEEE Recommended Practice for Energy Management in Industrial and Commercial

Facilities, 2008, www.ieee.org

Electrical energy management for low-voltage clients , 2007, Huyck and J. Capple