Energy Audit A Case Study of Pashupati Candle filter Udhyog And Country food Pvt.Ltd

Final Year Project Report

Submitted To

Thapathali Campus

Department of Industrial Engineering

TRIBHUWAN UNIVERSITY

INSTITUTE OF ENGINEERING

THAPATHALI CAMPUS

Energy Audit A Case Study of Pashupati Candle filter Udhyog

And

Country food Pvt.Ltd

Prepared By:

BidurGhimire

BikramBasnet

Bikram Dahal

Prakash Jamar Kattel

Samir BabuBhetwal

ShekharGhimire

Sarbin Shrestha

UddhavBasnet

Project Supervisor

Er. BhismaPandit

25th May, 2014

Energy Audit

Final Year Project | 2014 1

Energy Audit Team

Bidur Ghimire

Bikram Basnet

Bikram Dahal


Samir Babu Bhetwal

Shekhar Ghimire

Sarbin Shrestha

Uddhav Basnet

Energy audit

Optimization

Cost saving

Energy Audit

Project Supervisor

Mr. BhishmaPandit

Senior Energy Expert

GIZ, EEC, FNCCI

Energy Audit


DECLARATION

We hereby declare that we carried out project work reported in this report in the Department of

Industrial Engineering, Tribhuwan University, under the supervision of Er. Bhisma Pandit

(senior energy expert). We solemnly declare that to the best of our knowledge, no part of this

report has been submitted here or elsewhere in a previous application for award of a degree. All

sources of knowledge used have been duly acknowledged.

Energy Audit Project Team

Bidur Ghimire ………………………..

Bikram Dahal ………………………..

Bikram Basnet ………………………..

Prakash Jamar Kattel ………………………..

Samir Babu Bhetwal ………………………..

Sarbin Shrestha ………………………..

Shekhar Ghimire ………………………..

Uddhav Basnet ………………………..

Energy Audit


WORDS FROM THE SUPERVISOR

I am very glad to work with final year industrial engineering students who have chosen

“Energy Audit” as major project. Energy is growing issue in modern industries and optimum

use of energy enhances efficiency, reduces the cost and energy consumption. The project is

very important from the scenario of energy saving. At least some of industries will be aware

about optimization of energy and that will be fruitful to effort project team has made.

The project was successfully completed under my supervision in Pashupati Filter Candle

Udhyod (LPG Regulator Division), Ramkot, Kathmandu and Country food Pvt. ltd. The

team has really made great effort under my guidance to search energy saving opportunities in

the industry. The data collected and measures recommended are authentic and valuable as far

as possible.

I would like to thank the project team for their excellent teamwork and best wishes for their

success in future.

Thank you,

With regards

Er. Bhishma Pandit

Project supervisor (Energy Audit project)

Senior energy expert

EEC, GIZ, FNCCI

Energy Audit


CERTIFICATE OF COMPLETION

To whom it may concern

This is to certify that final year industrial engineering project team specified below from

Thapathali Campus has successfully completed “Energy Audit” project dated 7th – 12th

February 2014 in Pasupati Candle Filter Udhyog (LPG Regulator Division). The

project was carried under the supervision of Er. BhismaPandit (senior energy expert) .

The following are the enthusiastic members of energy audit student project team.

BidurGhimire

BikramBasnet.

Bikram Dahal


Samir BabuBhetwal

Sarbin Shrestha

ShekharGhimire

UddhavBasnet

The project team has created valuable output for industry and recommended effective

measures to reduce energy cost and consumption. The team is spectacular with their work

completion, dedication and has stunned us with their performance. On behalf of

company, I would also like to admire their report and presentation.

I would like to thank the project team for their excellent teamwork and best wishes for

their success in future.

……………………………………….

Sushil Kumar Agrawal

Managing director

Pasupati Candle Filter Udhyog.

Kathmandu

Energy Audit


Energy Audit


Letter of approval from Pashupati Filter Candle Udhyog

Energy Audit


ACKNOWLEDGEMENT

This project report couldn’t have been accomplished without the splendid support and

cooperation of all those unnamed inspires who encouraged us during our project. This final year

project report has been prepared and submitted as a part of industrial engineering program BIE

(IV/I).

We wish to express our sincere gratitude to Thapathali Campus, particularly Department Of

Industrial Engineering for providing us an opportunity for undertaking this project on “Energy

Audit”. This project bears on imprint of many peoples. We have no words to express our

gratitude for the facilitation and encouragement provided to us by Er. Bhisma Pandit and Er.Ram

Sundar Kusi . We are extremely thankful for the support of Industrial Energy Management

Project (IEMP). We sincerely thank Er. Sudan Neupane of Industrial Department for integral

support to carry out the study and all other teachers for their valuable suggestions.

We also wish to express our gratitude to the officials and other staff members of Pashupati Filter

and Candle Udhyog and Country Food Pvt.Ltd for their support and cooperation during the

energy audit for retrieving the required information. Our special thanks to Sushil Kumar

Agrawal, Pradip Regmi of Pashupati filter Candle Udhyog and Santosh Lal Shrestha, Meena

Kumari Chidi of Country Food Pvt. Ltd for allowing us to perform audit in the factory.

We are thankful to our seniors, friends of Thapathali Engineering Campus for their smart support

and inspiration. Where this report succeeds we share the credits where it errors we particular

group accept the responsibility.

Energy Audit


EXECUTIVE SUMMARY

Energy itself is growing issue at present scenario and its effective management has growing

scope in the field of industrialization. As Industrial Engineer, we must have sound knowledge of

energy management, which would be integral part when we enter the field of our engineering.

This is the main reason behind selection of “Energy Audit”. The project is supervised by Er.

Bhisma Pandit(senior energy expert) and audit instrument support from Thapathali Campus and

IEMP. The project is carried with permission in Pashupati Filter Candle Udhyog (LPG LPG

Regulator Division)and Country foods Pvt.Ltd.

Energy audit is the verification, monitoring and analysis of use of energy including submission

of technical report containing recommendations for improving energy efficiency with cost

benefit analysis and an action plan to reduce energy consumption. It is carried in three phases,

preliminary audit, detail audit and post audit phase. With the authentic test procedure and

instrument provided, we performed energy saving calculation and recommended various

measures suitable for industries specifying financial investment and payback period. At the

beginning, preliminary data was taken on energy share and financial saving was evaluated based

on same data. After the energy audit performed under the supervision, we compiled report and

presented in both industries.

We discovered different areas of energy saving like excess air control in furnace, use of capacitor

bank, condensate water recovery, DG loading etc. The project emerged to be successful both

from technical and financial point of view. The financial saving from both industries is quite

appreciable with the measures recommended by our project team. To attain objective of project

wasn’t easy we had great challenge in industries confirmation and certain practical limitation. At

last, the group team effort made it possible on time.

Energy Audit


TABLE OF CONTENTS

DECLARATION ………………………………………………………………………………...2

WORDS FROM SUPERVISOR………………………………………………………..…….…..3

CERTIFICATE OF COMPLETION ………………………………………………….…….…4-5

CERTIFICATE OF APPROVAL……………………………………………………….….……..6

ACKNOWLEDGEMENT…….………………………………………………………………….7

EXECUTIVE SUMMARY…………………………………………………………………..…..8

LIST OF TABLES…………………………………………………………………………..…..11

LIST OF CHARTS………………………………………………………………………………12

ABBREVIATION………………………………………………………………………………..13

NOTE……………………………………………………………………………………………14

1 INTRODUCTION ................................................................................................................ 14

2 POTENTIAL OF ENERGY AUDIT IN NEPAL:................................................................ 16

3 OBJECTIVE ......................................................................................................................... 18

4 LIMITATIONS ..................................................................................................................... 19

5 LITERATURE REVIEW: .................................................................................................... 20

5.1 Existing technology ........................................................................................................ 20

5.2 Swot analysis .................................................................................................................. 23

5.3 Existing policy: .............................................................................................................. 23

5.4 Related Organizations: ................................................................................................... 24

5.5 International vs. National ............................................................................................... 24

6 METHODOLOGY: .............................................................................................................. 25

Energy Audit


7 CASE STUDY: A) PASHUPATI FILTER CANDLE UDHYOG (LPG LPG REGULATOR

DIVISION) ................................................................................................................................... 33

7.1 Overview Of Industry..................................................................................................... 33

7.2 Distribution Of Energy Sources ..................................................................................... 34

7.3 Energy Scenario ............................................................................................................. 35

7.4 Energy Audit And Savings ............................................................................................. 38

8 CASE STUDY (B) COUNTRY FOOD PVT.LTD. ............................................................. 49

8.1 Overview Of Industry..................................................................................................... 49

8.2 Energy Audit And Savings ............................................................................................. 50

8.3 Other energy saving opportunity that could not be quantified ....................................... 59

8.4 Energy saving opportunity in future .............................................................................. 59

9 FINDINGS AND ANALYSIS ............................................................................................. 60

10 CONCLUSION ..................................................................................................................... 61

11 RECOMMENDATION ........................................................................................................ 62

12 REFERENCES ..................................................................................................................... 63

APPENDIX…………………………………………………………………………………..63-68

Energy Audit


LIST OF TABLES

Table 5.1: Energy Audit Instrument ............................................................................................ 20

Table 6.1: Plan of action of Energy Audit ................................................................................... 30

Table 7.1: Overview of Industry .................................................................................................. 33

Table 7.2: Distribution of Electrical Energy ................................................................................ 34

Table 7.3: Distribution of Diesel consumption ............................................................................ 34

Table 7.4: Distribution of LPG Consumption .............................................................................. 35

Table 7.5: list of energy sources .................................................................................................. 35

Table 7.6: Energy ratio evaluation ............................................................................................... 36

Table 7.7: Quantification of loss and savings .............................................................................. 39

Table 7.8: Investment and Payback for Compressor Leakage Maintenance ............................... 40

Table 7.9: Investment and payback for the insulation cap ........................................................... 42

Table 7.10: melted metal and diesel consumed by melting furnace ............................................ 43

Table 7.11: Showing Diesel Consumed and Piece Manufactured ............................................... 44

Table 7.12: Savings in lighting system ........................................................................................ 48

Table 8.1: Overview of Industry .................................................................................................. 49

Table 8.2: Electricity tariff depending on time of day ................................................................. 50

Energy Audit


LIST OF CHART

Chart 2.1: Energy consumption scenario of Nepalese Industries ............................................................ 17

Chart 7.1:Distribution of expenses in energy sources (for year 069/070) ............................................... 33

Chart 7.2: Consumption of Diesel and Electricity .................................................................................. 37

Chart 7 3: Cost of diesel with respect to monthly turnover..................................................................... 37

Energy Audit


ABERRATION

kJ : Kilo Joule

Kg : Kilogram

kW : Kilo Watt

kVA : Kilo Volt Ampere

kVAR : Kilo Volt Ampere (Reactive)

kWh : Kilo Watt Hour

Kg/hr : Kilogram per Hour

Kcal : Kilo Calorie

M3/min: Cubic meter per minute

FAD:- Free Air Delivery

Tph: Ton Per Hours

LPG:- Liquified Petroleum Gas

F/A : From and At

GoN: Government of Nepal

FNCCI : Federation of Nepalese Chamber of Commerce and Industries

NEEP : Nepal Energy Efficiency Program

CNI : Chambers of Nepalese Industries

GiZ : Deutsche Gessellschaft fur Internationale Zusammenarbeit

VFD:- Variable frequency drive

Energy Audit


1 INTRODUCTION

1.1 DEFINITION

Energy audit is defined as the verification, monitoring and analysis of use of energy

including submission of technical report containing recommendations for improving

energy efficiency with cost benefit analysis and an action plan to reduce energy

consumption.

Need for energy audit:

Three top operating expenses are energy (both electrical and thermal), labor and

materials.

Energy would emerge as a top ranker for cost reduction

primary objective of Energy Audit is to determine ways to reduce energy

consumption per unit of product output or to lower operating costs

Energy Audit provides a “ bench-mark” (Reference point) for managing energy in

the organization

Type of energy audit

The type of Energy Audit to be performed depends on:

Function and type of organization

Depth to which final audit is needed, and

Potential and magnitude of cost reduction desired

Thus, Energy Audit can be classified into the following two types.

1. Preliminary Audit

2. Detailed Audit

Energy Audit


1. Preliminary Audit

Preliminary energy audit is a relatively quick exercise to:

Establish energy consumption in the organization

Estimate the scope for saving

Identify the most likely and the easiest areas for attention

Identify immediate (especially no-/low-cost) improvements/ savings

Set a ‘reference point’

Identify areas for more detailed study/measurement

Preliminary energy audit uses existing, or easily obtained data

2. Detailed Energy Audit

A comprehensive audit provides a detailed energy project implementation plan for a

water distribution and water treatment facility, since it evaluates all major energy

using systems.

This type of audit offers the most accurate estimate of energy savings and cost. It

considers the interactive effects of all projects, accounts for the energy use of all major

equipment’s (Like pumps, electrical motors, transformers, electrical system lighting

etc. and includes detailed energy cost saving calculations and project cost.

In a comprehensive audit, one of the key elements is the energy balance. This is based

on an inventory of energy using systems, assumptions of current operating conditions

and calculations of energy use. This estimated use is than compared to utility bill

charges.

Energy Audit


2 POTENTIAL OF ENERGY AUDIT IN NEPAL:

Nepalese industries offer a huge potential to cut production cost by using energy more

efficiently. The energy makes the machine to operate and form the product/service that

industry is willing to give its customer. Nepalese industry still lack in energy awareness

and it is necessary to quantify energy saved equivalent to money saved because it is what

attracts the management and motivates to take step to save energy. Energy audit had

emerged in Nepal only 4-5 years ago so it is still beyond the approach of many industries

in Nepal that haven’t realized how fruitful it is to them. It is necessary to motivate the

industries as it has increased production with the increase of energy consumption. We

always have problem of limited resources and energy available is limited and should be

optimized in consumption.

A drop of petroleum product saved per day also results in higher saving when calculated

in long term. The saving of fuel counts a lot from environment and financial point of

view. The more the energy is consumed the more saving opportunities can be discovered.

We can see large amount of potential in Nepal for energy audit as it is just in growing

phase and energy is consumed in large amount.

Energy Audit


Chart 2.1: Energy consumption scenario of Nepalese Industries

Industrial energy consumption by fuel type in percentage 2008/2009 (source: DOI 2009/10;DCSI

2009/10) total final energy consumption 13.4 MGJ

coal, 58.7electricity, 23.2

agri residue, 10

fuel wood, 5.4

HS Diesel, 1.8

other petroleum, 0.9

kerosene, 0.8

L diesel, 0.1 coal

electricity

agri residue

fuel wood

HS Diesel

other petroleum

kerosene

L diesel

Energy Audit


3 OBJECTIVE

3.1 MAIN OBJECTIVE

To perform the Energy Audit in different industries.

3.2 SPECIFIC OBJECTIVE

To reduce energy cost through energy conservation and planning

Estimate of the proportion of costs and opportunities for businesses to reduce costs

for each area of energy use;

Identify priority conservation; - assessment of the energy saving potential in selected

areas;

Examination of energy efficiency performed or planned in the company of

innovation;

Development of effective measures for the implementation of the identified potential

energy savings;

Development of proposals for the organization of the energy management system in

the enterprise;

Making energy efficiency programs during the energy audit.

Energy Audit


4 LIMITATIONS

Inadequate availability of test equipment for the various tests to be performed in the

industries. Also, available equipment’s are of lower performance.

Less availability of factual data from the industries as they have no proper records.

Difficult to manage time of inspection and testing as per the production schedule.

Forecasted energy saving may alter according to the change in production system and

volume

Some data which cannot be measured and quantified are assumed and considered

theoretically.

Costing related to recommended change and parts replacement are according to current

market price which may vary accordingly.

Some quantification were beyond our knowledge and approach

Energy Audit


5 LITERATURE REVIEW:

5.1 EXISTING TECHNOLOGY

Energy performance assessment consists of several instruments that facilitate the energy

audit in simple way. Energy audit has flourished in construction and building at

international level but it is still in progressive phase at Nepal. The concept of energy audit

is increasing in Nepal in past few years. The concept of energy audit not only confined

within the energy saving but also simultaneously helps in establishment of safe working

environment within the industries. The measures which assists in energy saving will also

helps in safety management of machines, equipment, materials and method of work to be

performed

Table 5.1: Energy Audit Instrument

Energy Audit Instrument with image Description

1.Flue Gas Analyzer:

Used for optimizing the combustion efficiency by

measuring/monitoring the oxygen and CO levels

in flue gas of boilers, furnaces etc. and calculation

of CO2 percentage in excess air level and

efficiency.

2.Luxmeter

Used for measurement of illumination level.

Illumination levels are measured with a lux meter.

It consists of a photo cell which senses the light

output, converts to electrical impulses which are

calibrated as lux

Energy Audit


3.Tachometer:

In any audit exercise, speed measurements are

critical as they may change with frequency, belt

slip and loading. A simple tachometer is a contact

type instrument which can be used where direct

access is possible.

4. Fyrite kit:

A hand bellow pump draws the flue gas sample

into the solution inside the fyrite. A chemical

reaction changes the liquid volume revealing the

amount of gas. A separate fyrite can be used for

O2 andCO2 measurement.

5. Anemometers

Anemometers are used to measure airflow and

volume at registers and in ducts. Vane

anemometers measure airflow independent of the

air density making them ideal for many

applications where measurement without the need

for corrections is desired. Hot Wire anemometers

are used for low velocity measurements and

require corrections for high accuracy

measurements. Hot wires are ideal for airflow

measurements at fume hoods and other low flow

applications.

Energy Audit


6.Infrared thermometer

A non-contact or infrared thermometer allows the

measurement of temperature without physical

contact between the thermometer and the objects

of which temperature is determined.

7. Ultrasonic Leak detector

Ultrasonic leak detector is used to detect leaks of

compressed air and other gases which are

normally not possible to detect with human ear.

8. Clamp meter

Clamp-on meter or power analyzer are used to

measure main electrical parameters such as KVA,

KW, PF, Hertz, KVAr, Amps, and volts. Some of

these instruments also measure harmonics. Instant

measurements can be taken with hand- held

meters, while more advanced ones facilitates

cumulative readings with print out as specified

intervals. These are very useful instruments for

measuring above parameters in a wire without

having to make any live electrical connections

Energy Audit


5.2 SWOT ANALYSIS

Strength

Habitual with industrial

environment

Emerging topic in present

scenario

Familiar with production

activities

Weakness

Equipment limitation

Lack of authentic data for baseline

It isn't mandatory (strategic issue)

Opportunity

Career development

Energy and cost savings

Personal relationship with

industrial personnel

Threat

Minor miscalculation may lead to

false output

Rejection of energy audit

performance due to confidential

information of company

5.3 EXISTING POLICY:

There is limited policy made by the Government of Nepal for the energy audit and

it’sManagement to be done in the industrial sector. But there is a government project

namely “Industrial Energy Management Project” (IEMP) which is doing energy audit for

the industries and also providing some trainings and seminars to the Energy related

professionals and industrial workers. Beside energy being the major problem in the

country, wastage of energy in the industrial sector is major problem. The GoN had no

strong and effective policy regardaing the energy management in Nepalese industries.

Energy audits are not mandatory in Nepalese industries.

Energy Audit


5.4 RELATED ORGANIZATIONS:

The Energy Efficiency Centre (EEC) under FNCCI is the implementing partner of NEEP

component-3. EEC is a not for profit autonomous body which aims to provide energy

efficiency services to the Nepalese industrial sector. Other organizations like IEMP and

CNI are working in industrial and commercial sectors to manage energy consumption

with proper utilization and management through Energy Auditing.

5.5 INTERNATIONAL VS. NATIONAL

Energy audit is just at growing phase

Lack of energy auditors in Nepal

Energy audit isn’t mandatory and there is no legal provision.

Lack of complex energy audit instrument.

Limited organization uplifting and encouraging about energy efficiency.

At international level we can even find energy audit in buildings and construction.

Energy Audit


6 METHODOLOGY:

6.1 SITE VISITS

M/S Pashupati Filter candle Udhyog (LPG LPG Regulator Division) and M/S

Country Food Pvt.Ltd was visited daily for a week and consulted with the technician

and plant managers to get the relevant help regarding our project work and to get

details about the processes and technical factors in the respective industries.

Energy efficiency centre (EEC) office in FNCCI building, Teku was visited

frequently for grasping the experts’ opinion regarding the project matters

Industrial Energy Management Project (IEMP) office at Tripureshwor was visited for

grasping the experts’ opinion regarding the project matters and support of energy

audit equipment.

6.2 DATA COLLECTION

Base line data were collected from respective industries’ record book.

The power consumed by various machineries and equipment were recorded with

respect to time and loading. The instrument used to measure the power is clamp on

meter.

The temperature on the surface of furnace, boiler body and steam pipeline were

recorded by using the infrared thermometer.

The air intake from the FD in the boiler was recorded using the Anemometer.

Overall inspection of the plant machineries, safety approach, and the work flow was

inspected visually and recorded.

6.3 ANALYSIS

The collected data were analyzed and saving opportunities were suggested.

The suggestion for the energy saving were made as per the technical and financial

feasibility

Energy Audit


Over all industrial process were analyzed from the prospective of safety and the

relevant suggestion were made to improve the safe practice and occupational health

within the industries.

Energy Audit


6.4 TEST PERFORMED

Boiler Efficiency test:

Boiler efficiency can be calculated by two methods namely direct and indirect method.

We applied direct method for the calculation of boiler efficiency. The percentage output

in the form of steam with respect to fuel input is calculated as efficiency.

Efficiency (h) = 𝑄1∗(ℎ2−ℎ1)

𝑄2∗𝐺𝐶𝑉 𝑜𝑓 𝑓𝑢𝑒𝑙 * 100 %

Where,

Q1 = Quantity of steam generated per hour

Q2 = Quantity of fuel consumed per hour

h1 = Enthalpy of inlet feed water

h2 = Enthalpy of steam generated

GCV = Gross Calorific value

Furnace Efficiency test:

We applied direct method for the calculation of furnace efficiency. The amount of metal

melted is weighted and the fuel consumed is measured. The efficiency is calculated by

following formula

Efficiency (h) =𝑚𝐶𝑝(𝑡2−𝑡1)+𝑚𝑙

𝑄∗𝐺𝐶𝑉 𝑜𝑓 𝑓𝑢𝑒𝑙* 100 %

Energy Audit


Where,

M = mass of metal melted (kg/hr)

Cp = specific heat capacity of metal (KJ/kg-hr)

T1 = initial temperature of metal (0C)

T2 = melting temperature of metal (0C)

L = latent heat of melting of metal (KJ/kg)

Q = Quantity of fuel consumed (Kg/hr)

GCV = Gross Calorific Value. (KJ/kg)

Excess air test

The air intake in the boiler through FD was measured. The instrument used to measure

the flow of air was anemometer. The percentage intake of air via FD with respect to the

theoretical air requirement of the fuel is calculated as excess air quantity.

Excess air quantity: 𝑄1

𝑄2 * 100%

Q1: Quantity of air inlet via FD (kg/hr)

Q2: Quantity of theoretical air required for combustion of fuel (kg/hr)

Q1 is calculated by measuring the inlet velocity of the air via FD and the diameter of FD

opening. The air inlet is obstructed by the damper.

Q1: 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑎𝑖𝑟 ∗ 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑖𝑛 𝑜𝑓 𝐹𝐷 ∗ % 𝑜𝑓 𝑢𝑛𝑑𝑎𝑚𝑝𝑒𝑑 𝑎𝑖𝑟 𝑖𝑛𝑙𝑒𝑡

𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑔𝑟𝑎𝑣𝑖𝑡𝑦 𝑜𝑓 𝑎𝑖𝑟

In case of theoretical air requirement, the amount of actual air required will be about 20-

25% more than the theoretical air requirement. The theoretical air requirement for various

fuels is listed in appendix.

Energy Audit


FAD test:

This test is performed as a performance assessment test in the compressed air system.

FAD = (P2-P1)/Po * (V/T)

Where,

P2 = final pressurekg/cm²

P1 = initial pressurekg/cm²

Po = atmospheric pressure in kg/cm²

T =time taken to build P2 pressure in minutes

V = volume of compressor cylinder

Energy Audit


6.5 PLAN OF ACTIONS

Table 6.1: Plan of action of Energy Audit

Step Plan of action Purpose/Results

1 Phase I-Pre Audit Phase

Plan and organize

Walk through audit

Informal interview with

energy manager,

production/plant

manager

Resource planning, establish/organize an

energy audit team

Organize instruments and time frame

Macro data collection (suitable to type of

industry)

Familiarization of process/plant activities

First hand observation and assessment of

current level operation and practices

2 Conduct of brief

meeting/awareness

programmed with all

divisional heads and

person concerned (2-

3hrs).

Building up cooperation

Issue questionnaire for each department

Orientation, awareness creation

3 Phase II-Audit Phase

Primary data gathering,

process flow diagram

and energy utility

diagram

Historic data analysis, baseline data

collection

Prepare flow charts

All service utilities system diagram

(example: single power distribution

diagram, water, compressed air and steam

distribution)

Design, operating data and schedule of

operation

Annual energy bills and energy

consumption pattern (refer manual, log

Energy Audit


sheet, name plate, interview)

4 Conduct survey and

monitoring.

Measurements :Motor survey, insulation,

and lighting survey with portable

instruments for collection of more and

accurate data. Confirm and compare

operating data with design data

5 Conduct of detail

trials/experiments for

selected energy guzzles.

Trials/Experiments:

24 hours power monitoring

(MD, PF, kwh etc)

Load variations trends in

pumps, fans compressor etc

Boiler/Efficiency trials for

(4-8 hours)

Furnace efficiency trials

6 Analysis of energy use Energy and material balance

Energy loss/waste analysis

7 Identification and

development of energy

conservation (ENCON)

opportunities

Energy and material balance and energy

loss/waste analysis

Identification and consolidation on

ENCON measures

Conceive, develop, and refine ideas

Review the previous ideas suggested by

unit personal

Review the previous ideas suggested by

energy audit if any

Use brainstorming and value analysis

techniques

Contact vendors for new/efficient

technology

Energy Audit


8 Cost benefits analysis Assess technical feasibility, economic

viability and prioritization of ENCON

option for implementation

Select the most promising projects

Prioritize by low, medium, long term

measures

9 Reporting and

presentation to the top

management

Documentation, report presentation to the

top management

10 Phase III-Post Audit Phase

Implementation and

follow up

Assist And implement ENCON recommendation

measures and monitor and performance

Action plan, schedule for implementation

Follow up and periodic review

Energy Audit


7 CASE STUDY: A) PASHUPATI FILTER CANDLE UDHYOG (LPG LPG

REGULATOR DIVISION)

7.1 OVERVIEW OF INDUSTRY

Table 7.1: Overview of Industry

Name Pashupati Filter Candle Udhyog

Location Dadapauwa, Ramkot

Type Small Scale Industries

Standards

achieved NS, ISO- 9001/2008

Products LPG regulators

Filter candle

Brands

Indo LPG regulator

Mauria LPG regulator

Hari International

No of

workers 20-25

Energy

required

Electricity

thermal

compressed Air

Distribution

of energy

Chart 7.1:Distribution of expenses in energy sources (for year 069/070)

diesel , 75%

LPG, 5%

Coal, 9%

electricity, 11%

Energy Audit


7.2 DISTRIBUTION OF ENERGY SOURCES

7.2.1 Electrical Energy

Table 7.2: Distribution of Electrical Energy

Major Utilities

Compressor

Die casting with aluminum melting furnace

Drilling Machines

Drying Furnace

lighting

Approved demand 30 kW

No of units consumed 12769

Demand charge (for 30 kVA

fixed demand) 12*3000 Rs 36000

Cost of energy @ Rs 8 per kWh Rs 102152

Total electrical energy charge Rs. 138152

7.2.2 Diesel Consumption

Table 7.3: Distribution of Diesel consumption

Major uses

Diesel Generating Set

Aluminum melting furnace

DG capacity 62 kVA

Furnace capacity 100kg/hr

Diesel consumption in litre 8800

Cost of diesel @ Rs 103 per litre Rs. 906400

Energy Audit


7.2.3 LPG Consumption

Table 7.4: Distribution of LPG Consumption

Major uses

1. LPG furnace

2. LPG geyser

Furnace capacity 1000 piece /lot

Geyser capacity 100 ltr/hr

LPG consumption (kg) 987.6

Cost of LPG @107.3 per kg 105969.5

7.3 ENERGY SCENARIO

Table 7.5: list of energy sources

Fuels Kcal/Kg Unit (kg) Total Kcal kWh Total Cost(Rs)

Diesel 10000 7480.00 74800000.0 86976.74 906576.00

Coal 4000 505.00 20260000.0 23558.14 65845.00

LPG 11800 987.60 11653680.0 13550.79 105969.48

Electricit

y

(kWh)

12769.0

10981357.2 12769.00 134701.00

Total

Energy

117695037.2 136854.70 1213091.48

Energy Audit


7.3.1 Energy Consumption

Table 7.6: Energy ratio evaluation

Particulars Quantity

Total energy consumed (kWh) 136854.70

Total cost of energy Rs.1213091.48

Annual turnover of 069/70 in pieces 141933.00

Annual turnover of 069/70 Rs.23285714.00

Cost of Energy per piece Rs.8.546

% of energy cost over annual turn over 5.2%

Energy Audit


Chart 7.2: Consumption of Diesel and Electricity

Chart 7 3: Cost of diesel with respect to monthly turnover

0

20000

40000

60000

80000

100000

120000

140000

160000

180000

shra

wan

bh

adra

asw

in

kart

ik

man

gsh

ir

po

ush

mag

h

falg

un

chai

tra

bai

sakh

jest

ha

ash

ar

2069 2070

cost of diesel

electricity bill

0

20

40

60

80

100

120

140

160

0

500

1000

1500

2000

2500

3000

3500

shra

wan

bh

adra

asw

in

kart

ik

man

gsh

ir

po

ush

mag

h

falg

un

chai

tra

bai

sakh

jest

ha

ash

ar

2069 2070

Total turnover

Cost of diesel

Turn

ove

r in

,00

0

cost

of

die

sel i

n ,0

00

Energy Audit


7.4 ENERGY AUDIT AND SAVINGS

7.4.1 Air Compressors:

During our trial, we find significant loss of compressed air on the pipeline as well as in

the compressor itself. We perform free air delivery test (FAD) and leakage test on

compressor to quantify the losses. From our trial and testing, we came to following

conclusion

Significant savings can be made by tracking the losses of compressed air in pipeline

Loss of pressure in cylinder, if compressor is standby which can be eliminated to have

significant saving

Efficiency of compressor can be increased by decreasing the room temperature of

compressor room in summer days.

Losses of compressed air in pipeline and savings:

FAD test

P2 = 1.097 kg/ cm²,

Po =12 kg/cm²,

V = 420lit= 0.42m³,

T =6.06 min

FAD = (P2-P1)/Po * (V/T)

= (12-1.0197)/1.0197 *(0.42/6.1)

=0.7414 m³/min

(Where P2=final pressure, P1= initial pressure, Po= atmospheric pressure in kg/cm²

T=time taken to build P2 pressure in min

Similarly for another compressor V=350 lit, T=8.41 min; FAD=0.448 m³/min

Energy Audit


Leakage test

(For 420 lit receiver volume capacity compressor)

Time taken for load (T) =2.17 min,

Time on unload (t) =12.25min ,

Q=compressor capacity in m³/min=0.7414m³/min

Leakage % = (T/ T+t)*100

= 15%,

Leakage quantity = (T/ T+t)*Q=0.11m³/minute

Table 7.7: Quantification of loss and savings

Description Value

FAD 0.7414m³/min

Load(rated) 7.5 kw

leakage qty 0.11m³/min

specific power consumption 0.1686 kwhr/m³

energy lost due to leakage 8.902 kwhr/day

annual leakage 2492.56 unit

cost of leakage annual Rs. 34,272.7

Savings 60 % of leakage Rs. 20,563.62

Energy Audit


Compressed Air Losses Due to Plant Shutdown

The cylinder of the compressor must hold the pressure with the maximum decrease of

pressure not more than 5%, if compressor is not connected with the supply. The

significant decrease in pressure indicates the leakage in valve of compressor or joints of

cylinder. Such leakage in compressed air facility increases with time if not accounted.

During our trial over 7.5 kW compressors with cylinder capacity 420 liter, we found that

the pressure in the cylinder drops to ‘0’ in the morning even if it was maintained in 9

kg/cm2 before shut down.

Quantification of loss and savings

Time to raise pressure to 9 kg/cm2 = 7.65 min (0.1275 hrs)

Leakage in terms of kWh/day = 0.1275 x 7.5 = 0.95625 kWh

No. of days of operation = 280 days

Annual leakage in kWh = 280 x 0.95625 = 267.75 kWh/year

Average cost per unit (Rs/kWh) = Rs. 13.75/kWh

Annual savings = Rs 3681.5625

Investment and payback

Table 7.8: Investment and Payback for Compressor Leakage Maintenance

S.N Particulars Investment Simple payback

1 Change valve 2000-4000 0.54-1.08 yrs

2 Regular monitoring - -

Energy Audit


Energy loss due to the location of Air Compressor:

The efficiency of the compressor highly depends upon the temperature of the inlet air.

The efficiency of the compressor decrease with the rise in room temperature of

compressor room. Higher the temperature more the work compressor needs to do to

compress the air hence more power is consumed. It is that for every rise in 40C in room

temperature the efficiency decreases by 1-2% for the single stage and 2-3 % for double

stage compressor.

Details of compressor room

No. of compressor = 3

Height of roof = less than 10 feet

Roof type = zinc coated plates

No. of windows = 1

Temperature in winter days = 20-25 0C

Temperature in summer days = 30-35 0C

We can increase the efficiency of the compressors by decreasing the room temperature of

the compressor room during summer days. We can maintain the room temperature to 20-

25 0C, during summer days simply by covering the roof externally or internally.

Losses quantification and Savings

Decrease in temperature = 100C

Increase in efficiency = 5%

No. of months = 6 months

Units saved = 126.35 units

Energy Audit


Annual savings = Rs. 1705.725 (from 1 compressor)

Overall saving from 3 compressors = Rs. 4000. (Approx.)


Table 7.9: Investment and payback for the insulation cap

S.N Particulars Investment Simple payback

1 Internal covering from plywood 5000 1.25 yrs

2 External covering jute sacks and straw 2000 6 months

Energy Audit


7.4.2 Furnace:

Increasing air flow

Initially flame of the fuel burnt was observed and it was very yellowish which is not

appropriate. It was due to less air supply then requirement so fuel was not completely

giving its full usable energy so additional air was required. For that, the adjustment was

done to supply more air and the corresponding fuel consumption and its output work

were noted as below and the efficiencies before and after is mentioned.

Table 7.10: melted metal and diesel consumed by melting furnace

Furnace Melted amount Melting Stock Weight

S.N Day Kg diesel(ltr) No. of Stock Pieces

1 1 (without adjustment) 439.8(M1) 35 1402

2 2 (with air adjustment) 528(M2) 34 1640

Initial temperature of alloy brick (T1) = 250c

Final temperature of melted alloy (T2) = 3200c

Specific heat capacity of alloy Cp = 417 J/Kg/K

Latent heat of fusion of alloy La = 110 KJ/Kg/K

Efficiency of furnace without adjustment (as it is condition)

Heat used (output) Q1 = M1 x Cp x (T2-T1) +M1 x La

= 439.8 x 417 x (320-25) +439.8 x 110 x 1000

=101929807.2 J

Heat input(Q2) = (oil ltrs x sp. Gravity) x GCV x 4.2 x 1000 J

Energy Audit


=1249500000 J

Efficiency = (Output (Q1)/Input (Q2)) x 100%

= 8.16%

Efficiency of furnace with air adjustment

Heat used (output) (Q1) = 123031920 J

Heat input (Q2) = 1213800000 J

Therefore efficiency = 10.136%

Table 7.11: Showing Diesel Consumed and Piece Manufactured

Manufactured pieces Diesel consumed (liters) Diesel consumed per piece

1402 (day 1) 35 0.02496 ltr/pcs

1640 (day 2) 34 0.02073 ltr/pcs

Savings after adjustment of air

Avg. annual production = 141933 pcs.

Saving per pcs of production = 0.02496-0.02073 ltr/piece

Annual savings = 0.00423 x 141933

= 600.37659 ltr

=Rs. 61,838.788

Savings due to stocks Pre-heating=

Alloy bars can be preheated by the flue gas and its temperature can be increased before

melting in the furnace. By doing so, significant amount of fuel can be saved.

Energy Audit


Pre heating can be done by using stand of iron bars placed in the flue gas-escaping vent.

For this simple mechanical structure can be used, its investment and savings are as below.

Initial temperature of alloy to be melted = 25 0C

Temperature can be maintained after pre-heat = 800C (minimum)

Specific heat capacity of alloy = 417 j/kg0C

Gross Calorific Value of Diesel = 10000 kcal/litre

= 8500 kcal/kg

Metal melting to per piece ratio= (wt melted/ piece manufactured) = 0.315

Forecasted wt of annum = 141933 x 0.315

= 44708.895 kg

Heat energy saved = [44708.895 x 417 x (80-25)]

= 1025398507 J = 1025398.5 kJ = 2444142.5016 kcal

Savings = Heat energy saved / (GCV of diesel x efficiency of furnace)

= 2444142.5016/ (10000 x 0.10136)

= 283.37 litres

Rate of fuel (diesel) = Rs 103/litre

Savings in Rupees = Rs. 29187.37832

Investment required=

Approximately for iron bar structure = Rs. 10,000

Simple Payback period = 0.34 yrs

Energy Audit


Saving due to covering Furnace during idle hours:

Initial temperature of melting vessel = 700C (without cap, in the beginning of the day)

Alloy residue temperature = 700C (without cap, in the beginning of the day)

Weight of vessel = 180 Kg (cast iron)

Weight of alloy in vessel = 10-15 Kg

Temp can be maintained after insulation = 2000C

Heat saving per day = 180 x 460 x (200-70) + 12.5 x 417 x (200-70)

= 11441625 J

Saving in term of oil (ltr) = heat saving per day/ GCV of oil* efficiency

= 3.16 ltr/Day

Annual saving = 3.16 x 280

= 884.8 liters

In amount = Rs. 91134.4

Saving in half hr break time

Oil saved in that half hr = 0.4 ltr per day

= 280 x 0.4

= 112 ltr

= 112 x 103

= Rs. 11536

Total saving = Rs 102670.4

Energy Audit



Area of furnace cap = 5857.53 cm²

Type of insulation = Glass fibre

Cost of insulation = 5000-6000 per sq. Meter

Overall cost of insulation and installation = 6,000 max.

Simple payback period= less than a month

7.4.3 Performance Evaluation of DG set:

Diesel generator sets of 62.5 KVA provide the backup in case of power failure.

In general, diesel set accounts for 20% of total electrical energy used. During our trial, it

was found that loading was only 33%.

According to manufacture Manual

At 33% loading, DG generates 2.5 kWh/litre

At 70-80% loading, DG generates 3.5 kWh/litre

Considering 15kwh energy is consumed per hour for 3 hours a day,

Average saving per day =5.14litres

Saving per Year = 1440 liter of diesel

Savings in amount = 1.48 lakhs


Cost of new generator = 7 lakh

Payback period = 4.72 years

Energy Audit


7.4.4 Savings due to Lighting Systems:

Nine bulbs were used as light indicator, which is operated 24 hrs a day each of 20 watt,

which is unwanted, and instead 3-4 watt diode or CFL can be used as indicator.

Table 7.12: Savings in lighting system

Bulbs 9 each 20 watts

Operation 24hrs each day

Cost per unit Rs 13.75

Total kWh saved 1182.5

Total saving Rs. 16260.75

Energy Audit


8 CASE STUDY (B) COUNTRY FOOD PVT.LTD.

8.1 OVERVIEW OF INDUSTRY

Table 8.1: Overview of Industry

Name Country Food Pvt.Ltd

Location Chittapol-1. Bhaktapur

Type Small Scale Industries

Products Fresh milk

Butter

Brands Nova

No of workers. 10-15

Energy Required Electricity

Thermal

Energy Audit


8.2 ENERGY AUDIT AND SAVINGS

8.2.1 Plant Energy Systems

Electrical Energy and Load management Practices=

The approved maximum demand of the plant is 160 kVA. The dairy receives electric

power from Nepal Electricity Authority, through a 160 kVA transformer at 11 kV and

stepped down to 415.

The monthly demand charges as charged by Nepal Electricity Authority is at the rate of

.230/KVA. The minimum billable demand is 50 % of approved demand of 160 KVA.

The energy tariff depends on the time of the day and currently, is as follows

Table 8.2: Electricity tariff depending on time of day

Period ./kWh

Peak time (6 PM to 11 PM)-R1 8.75

Off peak time (11 PM to 6 AM)-R2 4.30

Other time (6 AM to 6 PM)-R3 7.10

A Diesel generator sets of 125 KVA each, provide the backup in case of power failure.

Maximum Demand variation and Charges:

The billing demand charged by NEA is seen to be 80 kVA though the actual demand

recorded is less. This is because the contract maximum demand of the plant is 160 kVA

and NEA charges demand charge for 50 % of the contract maximum demand or actual

demand recorded in the Energy meter (whichever is higher).

Energy Audit


Current scenario

Current approved demand =160 KvA

Current minimum charge =80 Kva

Current maximum demand =71 Kva

So company is paying 9Kva extra charge.

Cost per Kva =Rs. 230

Extra Cost paid =9*230*12

=Rs. 24840 per year

Recommendation

Reduce demand charge to 100Kva.

Process

An official Letter from company to NEA.

Approved demand can be changed by just sending letter if future demand

increases.

Energy Audit


Power Factor Variation

The power factor at tail end of various loads as measured, is from 0.7 to 0.9.It is

appreciated that the plant has installed capacitor bank with automatic power factor

control to ensure achieving a power factor of 0.95 to optimize maximum demand and

charges thereof.

Used of capacitor bank if demand is reduce

Current maximum demand = 71 Kva

Current power factor = 0.8

Proposed power factor = 0.95

Current power =56 Kw

Capacitor required =56*(tanᴓ1-tanᴓ2)

=23.45 Kva

= 25 Kva

Cost =25*1000

=Rs. 25000

Proposed maximum demand = 59 Kva

Saving = 12*230*12

=Rs. 33120

Payback period = 0.75 years

Energy Audit


Thermal Energy System

Boiler Detail

Type of boiler = husk pac boiler

Capacity = 1000 kg F/A at 1000C

Fuel used for boiler = wood (low grade, pine wood bark)

GCV of fuel used = 3200 kcal/kg

No of hours running = 6 – 8 Hours Per day (depending upon requirement)

Efficiency calculation of boiler

By direct method

Type of boiler = Wood Fired

Quantity of Steam (Dry) generated = 0.133 TPH = 133.33 kg/hr.

Steam pressure (gauze/temp) = 8 kg/cm2 at 1500C

Quantity of wood consumed = 0.07 TPH = 70 kg/hr.

Enthalpy of steam at 8 kg/cm2 @ 1500C =2516 KJ/kg

Enthalpy of inlet fed water at atmospheric pressure at 200C = 84 kJ /kg

Efficiency (h) = { 1000 * 0.1333 * (2516 – 84)}/ {0.07 * 1000 *3200 * 4.2}

= 34.45 %

Evaporation Ratio = 133.33/70

= 1.9

Energy Audit


Efficiency of boiler is found to be extremely low, so as the evaporation ratio. This is

because the boiler is operated with low loading. Lower the loading lower will be the

efficiency. The boiler is operated with approximately 20% loading. Besides loading

efficiency of boiler can be increased by quantifying and minimizing the losses some

which are discussed in this report

Excess Air calculation For Boiler:

Air is pushed via FD in the boiler. From our observation, we found that the boiler is

operated automatically. The running and rest time of boiler depends upon the pressure of

supply line. If the pressure of supply line is high, that is the steam in supply line in not

being used the boiler remains in rest condition during this state no air is blown by the FD.

From our inspection and the demand requirement we concluded that the run time is 2/3 of

total operating hours..

For 1 hour operating time

We have, Run time = 40 minutes

Rest time = 20 minutes

Average speed of air = 3.825 m/sec

Diameter of FD = 38 cm (0.38m)

Volume of inlet air = 3.825 * (p * 0.382)/ 4 *0.70

= 0.303 m3/sec

(Note= 70 % of air is allowed to pass through the FD by damping phenomena)

For an hour of operating time, we have air inlet as

=40 * 60 * 0.303

= 728.78 m3/hr.

Energy Audit


= 607.31 kg/hr.(Specific gravity of air is 1.2 kg/m3)

Wood consumed in an hour = 70 kg (average)

Theoretical air requirement for low grade wood= 6.5 kg/kg of wood

Total theoretical air required in an hour= 455 kg

Excess air % = (607.31/455) %

= 133.4 %

Savings from air adjustment

We know we can’t get good burn without some excess air. In case of low grade wood the

practically required air to burn is somewhat 20% - 25% excess than the theoretical air

requirement. So the actual air requirement be;

Actual air requirement= 455 + 0.25 * 455 = 568.75 kg/hr.

Excess air supplied =(607 – 568.75) = 38.25 kg/hr.

Heat loss from excess air =mcpdt

= 38.25*1 * (200-25)

= 6693.75 kj/hr.

Amount of fuel saved =heat loss by excess air / gcv of wood

= 6693.75 / (3200 * 0.3445)

= 6.07 kg of wood/hr.

= Rs. 42.5 / hr.

= Rs. 340/day (considering 8 hour daily boiler operation)

Energy Audit


= Rs. 102000/ year (considering 300 days of operation

annually)

Condensate Recovery System

Steam condensate carrying lot of heat energy from the pasteurization process which is

flowing out in the drainage can be recovered for the proper utilization and energy saving.

Heat carrying condensate, can be pumped into the feed water tank in the boiler to save

successive amount of heat energy. Calculations from the data taken during audit,

condensate and its recovery with cost of system to be applied with its payback are

calculated as below:

Condensate can be obtained = 300lts. /day

Milk processed = 2500lts. /day

Temperature of condensate = 85-90˚C

Temperature of feed water =25˚C

Total heat recovered from condensate

= 300*1*(87.5-25)

= 18750kcal/day

Total wood saved after recovery in boiler

= Total heat recovered/ GVC of wood*Efficiency of boiler

= 18750/3200*0.3445

= 17kg/day

Energy Audit


= 17*30*12 kg/year

= 6120 kg/year

Total energy source saved in amount

= 6120*7

=Rs.42840 per year

Setup required for condensate recovery

Pipes with proper insulation

Pump

Installation and transportation cost

Estimated cost for the condensate recovery system setup =Rs. 50,000 (approx.)

Payback period = Investment required/savings

= 50,000/42,840

= 1.17 years.

Losses from Steam Trap Quantification

We know during the flow of steam in supply pipe, some of the steam loss heat to the tube

surface and form condensate. Such condensate formed cannot be further supplied but are

needed to be separated from the steam. The steam trap performs the function to separate

steam and condensate so that only steam is supplies further. Steam trap releases the

condensate through pipeline connected. During our observation, we found some steam

leakage from the pipeline connected to steam trap. That means the steam trap is not

functioning properly. The losses due to improper functioning of steam tram can be

quantified as below.

Plume length of steam= 0.5 meter

Energy Audit


Losses of steam per hr= 6 kg (approx.) from graph in appendix

Kg of wood saved = 3.15 kg/hr.

Saving in rupees = 22.1/ hr.

= Rs. 176.84/ day (considering 8 hour daily boiler operation)

= Rs. 53052.63/ year (considering 300 days of operation annually)

Energy Audit


8.3 OTHER ENERGY SAVING OPPORTUNITY THAT COULD NOT BE QUANTIFIED

Air curtain not functioning and losses due to opening of cold storage.

Ammonia leakage, steam leakage in different areas. (like in steam trap, pipes, valve

sides etc.)

Front side boiler insulation saving.

COP improvement of refrigeration system.

Regenerative efficiency calculation and method of improvement for proper savings.

8.4 ENERGY SAVING OPPORTUNITY IN FUTURE

Use of refrigeration system at off hour. ( During the night time when the electricity

demand charge is low refrigeration at optimum cooling can be done to be used in the day)

Separate cooling space for butter and milk in the cold storage so as to create different low

temperature required.

High quantity of steam condensate can be recovered when capacity of production will be

increased.

Desuperheater at ammonia compressor discharge.

VFD(variable frequency drive) in chiller motor and other motor.

Energy Audit


9 FINDINGS AND ANALYSIS

The following are the areas we explored and found the energy saving opportunities in related

field with the financial analysis listed in the given table:

S.N Saving opportunities Fuel saved Total amount

saved/ year

Investment Payback

period

1 Boiler excess air saving 14568 kg

wood/year

Rs. 102000/

year

nil

2 Condensate Recovery

System

`

5100 kg

wood

Rs.42840 per

year

Rs. 50,000 1.17 yr

3 Losses from Steam Trap

Quantification

945 kg wood Rs. 53052.63/

year

nil

4 Use of capacitor bank Rs. 33120 Rs. 25000 .75 yr

5 Reducing demand (kva) Rs. 24840 nil

6 Furnace air control 600.37 ltr

diesel

Rs.

61,838.788

nil

7 Furnace stock preheating 283.37 ltrs Rs.

29187.37832

Rs. 10,000 0.34yr

8 Furnace insulation cap 884.8 liters Rs 102670.4 Rs 6000 Less than

month

9 DG set 1440 liter of

diesel

1.48 lakhs 7 lakh 4.72yr

10 Lighting system 1182.5 kwh Rs. 16260.75 nil

Other findings

DG efficiency depends upon loading

Boiler efficiency depends upon loading

Energy Audit


10 CONCLUSION

Almost all industries from small, medium to large scale uses energy and this energy cost carries

high percentage of factory overhead. In case of energy management process, they are not doing

suitable methods of procedure and utilization, this result heavy energy cost due to losses. With

the possibility of energy efficiency practices and technology, it is possible to cut down energy

cost significantly in the industries without altering the productivity. Safe working environment

can be obtain within the industry through the process of energy auditing as it involves various

measures to improve efficiency of the machines and equipment which also maintain the safe

operation of the machineries and equipments.

Proper methodology of operation, effective utilization, management and improvement of energy

related works can produce massive savings. But there are several constrains for energy auditing

in industries which significantly affects in auditing works. With proper policy from

governmental sector for the energy, auditing some percentage of energy crises going within

country can be minimized.

Energy Audit


11 RECOMMENDATION

There is need of proper energy management policy from the Governmental sector.

Proper operational process, maintenance and safety manual must be created for the

energy consuming machineries.

Adequate technological advancement for the proper utilization and saving of energy.

Appropriate education and skill development trainings must be given for the energy

related workers and industrialist.

Energy Audit


12 REFERENCES

“Guide to Energy Management”, Fourth Edition, by Barney L. Capehart PhD, CEM;

Wayne C. Turner PhD, PE, CME; William J. Kenedy PhD, PE. ISBN 0-203-91129-6

master e-book

“Energy Management handbook”, Wayne C. Turner, Steve Doty

“A research paper on energy efficiency of industrial utilities”, Er. Pratap Jung Rai

Energy efficiency centre/energy efficiency module, Neplease context

Bureau of energy efficiency, 2004

“Guide Book For National Certification Examination For Energy Managers And

Energy Auditors”, Bureau of Energy Efficiency (A Statutory Body under Ministry of

Power, Government of India) 4 Floor, Sewa Bhawan, R. K.Puram, New Delhi

www.bee-india.nic.in

www.nea.org.np

www.BSKtechnology.com

www.mitchellinstrument.com

http://www.nea.org.np/

http://www.bsktechnology.com/

http://www.mitchellinstrument.com/

Energy Audit


APPENDIX1

List of various fuels and their respective calorific values.

Fuel

ufFuels

Approx heating value Kcal/Kg Natural State

Dry state

A BIOMASS 1 Wood 1500 3500 2 Cattle dung 1000 3700 3 Bagasse 2200 4400 4 Wheat and rice straw 2400 2500 5 Cane trash, rice husk, leaves and vegetable wastes 3000 3000 6 Coconut husks, dry grass and crop residues 3500 3500 7 Groundnut shells 4000 4000 8 Coffee and oil palm husks 4200 4200 9 Cotton husks 4400 4400 10 Peat 6500 6500 B FOSSIL FUELS 1 Coal 4000-

7000 2 Coke 6500 3 Charcoal 7000 4 Carbon 8000 5 Fuel oil 9800 6 Kerosene and diesel 10000 7 Petrol 10800 8 Paraffin 10500 9 Natural gas 8600 10 Coal gas 4000 11 Electrical (Kcal(KW) 860 12 Bio gas(Kcal/cu mtr) (12 kg of dung produces 1 cu. Mtr gas) 4700-

6000

Source : www. Engineeringtoolbox.com/fuels-higher- calorific-values

Energy Audit


APPENDIX 2

Composition of Various Fuels

Wood Compositon:

4785

KCal/Kg

Carbon % 45.6

Hydrogen % 3.96

Sulphur % 0.07

Oxygen % 37.45

Moisture % 9.33

Ash % 3.14

N % 0.45

Diesel Compositon:

Carbon % 87.3

Hydrogen % 12.6

Sulphur % 0.22

Oxygen % 0.04

sg 0.86

Ash % 0.01

N % 0.006

Coal Compositon:

Carbon % 44.03

Hydrogen % 3.1

Sulphur % 0.32

Oxygen % 4.77

Moisture % 3.84

Ash % 43.12

N % 0.82

Source: FNCCI, Energy project.

Energy Audit


APPENDIX3

Graph showing amount of steam loss with respect ot plume length leakage

Source:www.innovatechnica.com

Energy Audit


APPENDIX4

Steam table

T P vl vlg vg ul ulg ug hl hlg hg sl slg sg

0C kPa m3/kg m3/kg m3/kg kJ/kg kJ/kg kJ/kg kJ/kg kJ/kg kJ/kg kJ/kg.K kJ/kg.K kJ/kg.K

5 0.8726 0.001000 147.02 147.02 21.020 2360.4 2381.4 21.021 2488.7 2509.7 0.07626 8.9473 9.0236

10 1.2281 0.001000 106.32 106.32 41.986 2346.3 2388.3 41.988 2476.9 2518.9 0.1510 8.7476 8.8986

15 1.7056 0.001001 77.896 77.897 62.915 2332.3 2395.2 62.917 2465.1 2528.0 0.2242 8.5550 8.7792

20 2.3388 0.001002 57.777 57.778 83.833 2318.2 2402.0 83.835 2453.4 2537.2 0.2962 8.3689 8.6651

25 3.1690 0.001003 43.356 43.357 104.75 2304.1 2408.9 104.75 2441.6 2546.3 0.3670 8.1888 8.5558

30 4.2455 0.001004 32.895 32.896 125.67 2290.0 2415.7 125.67 2429.6 2555.3 0.4365 8.0148 8.4513

35 5.6267 0.001006 25.219 25.220 146.58 2275.9 2422.5 146.59 2417.8 2564.4 0.5050 7.8461 8.3511

40 7.3814 0.001008 19.527 19.528 167.50 2261.7 2429.2 167.50 2405.9 2573.4 0.5723 7.6827 8.2550

45 9.5898 0.001010 15.262 15.263 188.41 2247.5 2435.9 188.42 2393.9 2582.3 0.6385 7.5244 8.1629

50 12.344 0.001012 12.036 12.037 209.31 2233.3 2442.6 209.33 2381.9 2591.2 0.7037 7.3708 8.0745

55 15.752 0.001015 9.5716 9.5726 230.22 2219.0 2449.2 230.24 2369.8 2600.0 0.7679 7.2217 7.9896

60 19.932 0.001017 7.6733 7.6743 251.13 2204.7 2455.8 251.15 2357.7 2608.8 0.8312 7.0768 7.9080

65 25.022 0.001020 6.1986 6.1996 272.05 2190.3 2462.4 272.08 2345.4 2617.5 0.8935 6.9360 7.8295

70 31.176 0.001023 5.0437 5.0447 292.98 2175.8 2468.8 293.01 2333.1 2626.1 0.9549 6.7991 7.7540

75 38.563 0.001026 4.1323 4.1333 313.92 2161.3 2475.2 313.96 2320.6 2634.6 1.0155 6.6658 7.6813

80 47.373 0.001029 3.4078 3.4088 334.88 2146.7 2481.6 334.93 2308.2 2643.1 1.0753 6.5359 7.6112

85 57.815 0.001032 2.8279 2.8289 355.86 2132.0 2487.9 355.92 2295.5 2651.4 1.1343 6.4093 7.5436

90 70.117 0.001036 2.3607 2.3617 376.86 2117.1 2494.0 376.93 2282.7 2659.6 1.1925 6.2859 7.4784

95 84.529 0.001040 1.9818 1.9828 397.89 2102.2 2500.1 397.98 2269.7 2667.7 1.2501 6.1653 7.4154

100 101.32 0.001043 1.6726 1.6736 418.96 2087.1 2506.1 419.06 2256.6 2675.7 1.3069 6.0476 7.3545

105 120.79 0.001047 1.4190 1.4200 440.05 2072.1 2512.1 440.18 2243.4 2683.6 1.3630 5.9326 7.2956

110 143.24 0.001052 1.2095 1.2106 461.19 2056.7 2517.9 461.34 2230.0 2691.3 1.4186 5.8200 7.2386

115 169.02 0.001056 1.0359 1.0370 482.36 2041.1 2523.5 482.54 2216.3 2698.8 1.4735 5.7098 7.1833

120 198.48 0.001060 0.8911 0.8922 503.57 2025.5 2529.1 503.78 2202.4 2706.2 1.5278 5.6019 7.1297

125 232.01 0.001065 0.7698 0.7709 524.82 2009.7 2534.5 525.07 2188.3 2713.4 1.5815 5.4962 7.0777

130 270.02 0.001070 0.6676 0.6687 546.12 1993.7 2539.8 546.41 2174.0 2720.4 1.6346 5.3926 7.0272

135 312.93 0.001075 0.5813 0.5824 567.46 1977.5 2545.0 567.80 2159.4 2727.2 1.6873 5.2907 6.9780

140 361.19 0.001080 0.5079 0.5090 588.85 1961.2 2550.0 589.24 2144.6 2733.8 1.7394 5.1908 6.9302

145 415.29 0.001085 0.4453 0.4464 610.30 1944.5 2554.8 610.75 2129.4 2740.2 1.7910 5.0926 6.8836

150 475.72 0.001090 0.3918 0.3929 631.80 1927.7 2559.5 632.32 2114.1 2746.4 1.8421 4.9960 6.8381

155 542.99 0.001096 0.3457 0.3468 653.35 1910.7 2564.0 653.95 2098.4 2752.3 1.8927 4.9010 6.7937

160 617.66 0.001102 0.3060 0.3071 674.97 1893.3 2568.3 675.65 2082.3 2758.0 1.9429 4.8074 6.7503

165 700.29 0.001108 0.2716 0.2727 696.65 1875.7 2572.4 697.43 2065.9 2763.3 1.9927 4.7151 6.7078

170 791.47 0.001114 0.2417 0.2428 718.40 1857.9 2576.3 719.28 2049.2 2768.5 2.0421 4.6241 6.6662

175 891.80 0.001121 0.2157 0.2168 740.22 1839.7 2579.9 741.22 2032.1 2773.3 2.0910 4.5344 6.6254

180 1001.9 0.001127 0.1929 0.1940 762.12 1821.3 2583.4 763.25 2014.6 2777.8 2.1397 4.4456 6.5853

185 1122.5 0.001134 0.1730 0.1741 784.10 1802.5 2586.6 785.37 1996.6 2782.0 2.1879 4.3580 6.5459

190 1254.2 0.001141 0.1554 0.1565 806.17 1783.4 2589.6 807.60 1978.2 2785.8 2.2358 4.2713 6.5071

195 1397.6 0.001149 0.1399 0.1410 828.33 1764.0 2592.3 829.93 1959.5 2789.4 2.2834 4.1855 6.4689

200 1553.6 0.001156 0.1261 0.1273 850.58 1744.1 2594.7 852.38 1940.1 2792.5 2.3308 4.1004 6.4312

Energy Audit


APPENDIX 5

Cost of diesel: Rs. 100

Cost of electricity for Pashupati Regulator Factory: Rs.13.68

Cost of wood: Rs. 7/Kg

All saving are calculated per Annual basis.

All formula are taken from “Guide Book For National Certification Examination For Energy

Managers And Energy Auditors”, Bureau of Energy Efficiency (A Statutory Body under

Ministry of Power, Government of India) 4 Floor, Sewa Bhawan, R. K.Puram, New Delhi

www.bee-india.nic.in

Energy Audit
