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Energy Audit for cost reduction in Textile Processing Units

by

I.Thanumoorthi Fellow Industrial Energy group The Energy & Resources Institute (TERI) Bangalore Centre
Email: ithanu@teri.res.in

Energy Audit Study

The energy audit cover an in-depth study of all the major energy consuming equipment/sections in

the plant
It involves exploring practically achievable energy saving measures through a systematic and scientific approach. Sophisticated portable instruments are used in

measurement of various parameters related to the

performance assessment of major energy consuming equipments, to realistically estimate the losses and potential for energy savings.

 The study mainly focus on improving energy usage

efficiency and identifying energy saving opportunities at various equipment and processes.
The analyses would include simple payback

calculations where investments are required to be made to implement recommendations, to establish their economic viability. The study would also provide sizing and sourcing of retrofits and equipment
During the audit, there would be continuous interaction between the audit team and plant personnel to allow for possible concurrent implementation and to ensure that the suggestions made are realistic, practical and implementable.

List of Instruments Used

Sophisticated three Phase power analyzers (Portable load managers) used for electrical systems To measure, monitor, log, diagnose the electrical parameters with computer interface & software Hand held three Phase power analyzers to measure loading parameters of motors, MCC and distribution boards

Ultrasonic flow meters to measure water flow rate of pumps and pipe lines Multifunction kit which measures and records temperature, RH, velocity, pressure, with computer interface and in built printers Digital pressure indicators to measure the pressures of water and compressed air

Stroboscope for measuring of speed of rotating equipment such as chiller compressors, pumps, fans, etc Infrared pyrometers for measuring temperatures without physical contact of the surface Tiny tags to measure and record the RH and temperatures in user areas of air conditioning Anemometers to measure velocity and evaluate air flow rates of fans and compressors Digital temperature indicators with probes Laptops for down loading the measured and recorded parameters and for analysis

Digital hygrometers to measure dry bulb temperature and relative humidity Digital multi-meters Pressure and draft gauges

Energy monitors
Lux meters to measure illumination intensity

Thermometers for low temperatures such as cooling and chilled water

Stop watch, measuring tape, thickness gauges and others

List of Energy Audit Instruments

Instrument type Portable power analysers

Portable power analysers & recorders

Ultrasonic flow meters Flue gas analysers

Multifunction kits
Infrared pyrometers Stroboscopes Digital temperature & RH meters Digital thermometers Fyrite kits Temperature & RH recorders Lux meters

ENERGY AUDIT INSTRUMENTS

Ultra-sonic Flow Meter

Application: Flow measurement of Liquids Parameters measured: Velocity & discharge of liquid flow Make: Panametrics, Ireland No of Sets: 02 Range: 0.03 to 12.2 m/s (pipe size 2 to 24 inches)

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Multi Function Kit

Application: Thermal and mechanical Parameters - velocity, temperature, pressure, humidity Make: Testo, Germany No of Sets:02 Range: 0.4 to 60 m/s, -200 to 1200oC, 0 to 100 hpa, 0 to 100% RH

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Non Contact Tachometer Stroboscope

Application: Speed Measurements Parameters measured: Speed of Rotating Element Make: Testo, Germany No of Sets: 2 Range: 20 to 20000 rpm

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Digital temperature & humidity data logger

Parameters measured: Dry bulb temperature & humidity Make: Gemini, USA No of Sets:04 Range: -15 to 150oC and 0-99 % RH

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Temperature Data Logger

Application: Measurement of Temperatures Parameters measured: Temperatures (8 temp. channels) Make: Grant, UK No of Sets:01 Range: 0-1200oC

Non Contact Type Infrared Temperature Indicator

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Application: Measurement of Surface Temperatures Parameters measured: Surface Temperatures Make: Raytek, USA No of Sets:01 Range: -18 to 870oC

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Infrared Pyrometer

Application: Measurement of Surface Temperatures Parameters measured: Surface Temperatures Make: Raytek, USA No of Sets:02 Range: -18 to 870oC

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Digital Temperature & Hygrometer

Application: Measurement of Temperatures & humidity Parameters measured: Dry bulb temperature & humidity Make: Center, Taiwan No of Sets:01 Range:-20 to 60oC, 0 to 100% RH

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Combustion Test (Fyrite) Kit

Application: Measurement of Flue Gas quantities Parameters measured: Co2 & O2 Make: Testo, Germany No of Sets:06 Range: 0 to 20% Co2; 0 to 21% O2

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Flue Gas Analyser

Application: Measurement of Flue Gas Parameters Parameters measured:o2, Co, No, No2, So2, Humidity Make: TESTO, Germany Range:02-0 to 21%, CO-0 to 20000 ppm, NO- 0 to 3000,No2-0 to 500 ppm, Humidity- 0 to 100%

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3-Phase Power Analyser

Application: Measures all Electrical and Harmonic Parameters Parameters measured: V, A, PF, KW, kVA, kVAr, Hz, first 50 Harmonics Make: Chauvan Arnaoux, France No of Sets: 01 Range: 830V, 3000A

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3-Phase Power Analyser

Application: Measures all Electrical and Harmonic Parameters Parameters measured: V, A, PF, KW, kVA, kVAr, Hz, first 50 Harmonics Make: RCC Technologies, Canada No of Sets: 01 Range: 600V, 1000A

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3-Phase Power Analyser

Application: Measures all Electrical and Harmonic Parameters Parameters measured: V, A, PF, KW, kVA, kVAr, Hz, Harmonics (first 25th) Make: Dossena, Italy No of Sets: 01 Range: 600V, 1000A

Handheld Power Harmonic Analyser

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Application: Measures all power and Harmonic Parameters Parameters measured: V, A, PF, kW, kVA, kVAr, Hz, Harmonics Make: Fluke, WA No of Sets:02 Range: Up to 600V, 1000A, 600 kW, up to 31st Level harmonics Accuracy

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Digital Lux Meter

Application: Measurement of Light Levels Parameters measured: Light level in lux and/or foot-candles Make: Physics No of Sets:01 Range: 0 to 50000 lux

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Sample Energy Audit Scope

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Electrical Systems
The scope covers the study of electrical system comprising the electrical substations Transformer loading practices

Transformer load management

Power factor and demand management

Incoming voltage conditions and distribution losses

Detailed analysis would help in arriving at possible measures to improve the same

Electric Drives and Motors

Measurement of kW, KVA, pf, Hz, A, V Measurement of speed using stroboscope Evaluation of Loading on motors Proper sizing of motor Application potential for various energy saving measures for Under loaded motors Variable loads Continuous operating loads Efficiency improvement Power factor improvement Efficient transmission Operational controllers Non linear loads

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Boiler & Steam System

Efficiency and various losses evaluation of boiler by BIS method Study of distribution network for pressure drop, steam trapping, leakages, etc Evaluation of Specific steam generation Pressure drop in the system Insulation aspects including insulation surveys Quantification of steam leakage, if any Condensate recovery and optimization Study of distribution network of various sections to identify the energy saving opportunities based on loss reduction Optimization of steam utilization at major loads

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Air-conditioning System
Estimation of actual TR generation by the chillers Measurement of power consumption and estimation of specific power i.e. kW/TR for A/C compressors, chilled water pumps, cooling water pumps, major users, AHU fans, etc Operational features of compressors such as temperatures, pressure control Study of auxiliary components for energy efficiency and there impact. The auxiliary components included are: Chilled water pumps Condenser water pumps Cooling tower fans AHU fans High ventilation fans Study of distribution network (Pressure drop and temperature)

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Detailed study on AHUs Air flow rate measurements across the AHUs (supply, return and fresh air) Study of return air, supply air and fresh air components Measurement of temperature and RH of supply and return air

Estimation of TR generation by AHUs

Speed measurements of AHU fans Power consumption and other electrical parameters Major heat loads in air conditioning area

Measurement and recording of temperature and relative humidity over a period of 2-24 hours in major users and critical areas by using microprocessor based tiny tags.
User area analysis to arrive at energy conservation measures Application potential for various energy saving retrofits

Cooling Water Pumping System

Flow and head measurement of pumps by using sophisticated energy audit equipment and ultra sonic flow meters Measurement of power parameters Evaluation of efficiency of pumps Study of user areas of cooling water with respect to present/design requirement of water and respective heat loads Measurement of water flow rates to the major users

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Evaluation of sankey diagram or water balance of individual cooling towers

Application and matching of drive Application of efficient flow control methods

Application of retrofit for energy savings

Cooling Towers
Measurement of inlet, outlet water temperatures Simultaneous measurement of dry and wet bulb temperatures

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Evaluation of range and approach there by evaluating the performance with respect to design of cooling towers
Water balance of cooling tower (based on different major inlets and outlets) Measurement of power parameters of cooling tower fans Application potential to rationalize water circulation based on requirement Application potential for energy saving retrofits

Compressed Air System

Free air delivery assessment (output of compressors) Estimation of specific energy consumption (kW consumption per cfm) Quantification of compressed air leakage (No load test) Study of distribution network for Pressure drop, Piping, Leakage, etc. Loading and unloading pattern of compressors Inter-cooler and after-cooler effectiveness Optimisation of compressed air utilisation

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Fans, Blowers and other Water Pumps

Flow and head measurement of major fans, blowers and pumps by using sophisticated energy audit equipment Measurement of power parameters (kW, kVA, pf, frequency, current, voltage) Measurement of speed by using stroboscope Evaluation of efficiency of major pumps, fans and blowers Application and matching of drive Application of efficient flow control methods in pumps, fans and blowers Application of energy saving retrofits based on user requirement

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Lighting
A detailed audit in lighting system, normally results in considerable energy savings. Illuminance readings with a lux meter would act as a basis for comparative purpose. Application of retrofits such as, Timer control

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Photocell control for street lighting

Installation of voltage controllers for lighting or installation of separate lighting transformer Application and use of energy efficient lighting Use of energy efficient lighting