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& Audit
Definition of Energy Audit
“The judicious and effective use of energy to
maximize profits (minimize costs) and enhance
competitive positions”
“The strategy of adjusting and
optimizing energy, using systems and
procedures so as to reduce energy
requirements per unit of output while
holding constant or reducing total costs
of producing the output from these
systems”
Types of Energy Audit
• Walk Through or Preliminary energy
audit
• Detailed energy audit
4. Formulate plan
Formulate Immediate energy-saving
actions: Where? How ? How much?
– Areas to investigate further
– Resources required for more
detailed study
5. Action and Monitoring
6. Next steps (e.g Need for detailed
Audit)
Detail audit
Detail audit is carried out for the energy
savings proposal recommended in walk-
through or preliminary audit. It will provide
technical solution options and economic
analysis for the factory management to
decide project implementation or priority.
A feasibility study will be required to
determine the viability of each option.
Detailed Energy Survey
Step6 Analysis of energy use Energy and Material balance & energy
loss/waste analysis
Areas covered under Electrical audit
are
1. Electrical System :
• Electrical Distribution system
(substation & feeders study)
• PF Improvement study
• Capacitor performance
• Transformer optimization
• Cable sizing & loss reduction
• Motor loading survey
• Lighting system
• Electrical heating & melting
furnaces
• Electric ovens
2. Mechanical System :
• Fans & Blowers
• Exhaust & ventilation
System
• Pumps and pumping
System
• Compressed air
System
• Air Conditioning &
Refrigeration System
• Cooling Tower System
THERMAL ENERGY AUDIT
Conclusion
Focus on Processes
Energy intensive processes and equipment
1200
1000
800
kW
600
400
200
0
744 1464 2208 2928 3672 4416 5136 5880 6552 7296 8016
Hrs / Year
A complete analysis of the energy bills for a facility
requires a detailed knowledge of the rate structures in
effect for the facility.
To accurately determine the costs of operating individual
pieces of equipment, break down energy bills into their
components (e.g. demand charge and energy charges for the electric bill).
This breakdown also allows more accurate savings
calculations for Energy Management Opportunities
(EMOs) such as high-efficiency equipment, rescheduling
of some on-peak electrical uses, etc.
Lighting Boiler
130,560 kWh 329,863 GJ
Facility
Motors Electric
1,516,619 kWh Heaters
100,100 kWh
HVAC Miscellaneous
Compressors 34,286 kWh 260,000 kWh
116,379 kWh Chillers
274,560 kWh
Total: 2,432,501 kWh/yr
Lighting
18 kW
Facility
Motors Electric
197.1 kW Heaters 13 kW
HVAC Miscellaneous
Compressors 17.1 kW 35 kW
14.9 kW Chillers
34.3 kW
Total: 329.4 kW
– Facility size
– Floor plan
– Construction features
(wall and roof material, insulation levels, door
and window sizes and construction)
• Executive Summary
Brief summary of recommendations and cost
savings
• Introduction
Purpose of the energy audit
Need for a continuing energy cost control program
• Facility Description
Size, construction, facility layout, and hours of
Operation, equipment list, with specifications
• Internal Benchmarking
Historical and trend analysis
• External Benchmarking
Across similar industries
Scale of operation, vintage of technology, raw material
specification and quality and product specification and quality
Bench Marking Energy
Performance
• Quantification of fixed and variable energy
consumption trends vis-à-vis production levels
• Comparison of the industry energy performance
w.r.t. 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
Benchmarking parameters
•Gross production related
e.g. kWh/MT clinker or cement produced (cement plant)
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)
• Shuffling of compressors to
match needs.
• Periodic review of insulation
thickness
• Identify potential for heat
exchanger networking and
process integration.
• Optimisation of transformer
operation with respect to load
Fuel and Energy Substitution
Fuel substitution
• Natural gas is increasingly the fuel of choice as
fuel and feedstock in the fertilizer, petrochemicals,
power and sponge iron industries.
• Replacement of coal by coconut shells, rice
husk,etc
• Replacement of LDO by LSHS
Energy substitution
• Replacement of electric heaters by steam heaters
• Replacement of steam based hot water by solar
systems
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.
Energy Audit
cumulative readings with print outs at
specified intervals.
Fyrite:
Contact thermometer:
Contact thermometer:
Lux meters: