Energy Audit Sample Report

Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

ENERGY AUDIT REPORT OF A Major Japanese Auto Component Manufacturer, MANESAR

CHAPTER 1 EXECUTIVE SUMMARY

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

1

EXECUTIVE SUMMARY

This energy audit was carried out the report containing recommendations for improving energy efficiency with cost benefit analysis by certified energy auditor (Bureau of energy efficiency, Ministry of Power) during sept-12. The energy audit study as summarized below: A. B. C. D. E. F. G. H.

Electrical parameters Power quality study Harmonics DG Furnace Compressor Cooling Tower Lighting

1. This contract demand is never exceed 1654 kVA with earlier period. Therefore, it’s recommended that the Contract Demand be reduced from existing 1990 kVA to 1690 kVA. This will reduce the monthly bill Rs. 36,000 per month. This will lead to saving of Rs. 4.32 Lakhs per annum.

2. Average power factor of the plant is 0.98. Management has been doing a great job by maintaining power factor in the range of 0.98-0.995. Presently for the last 3-4 months, it’s close to 1.

3. Measurements of various Electrical parameters including Harmonics by Power Analyzer indicate that the quality of Power is good, but for STB 2 current harmonies is exceeding the allowable 12% THD limit. By installing APFC system along with filters, the harmonics will get suppressed. This is required for the protection of sophisticated Electronic equipment.

4. Performance study of 5 DG sets shows that the Specific fuel consumption varies from 3.11 to 4.16 kWh/litre of HSD. The Average SEC of all DG set is 3.75 kWh/litre of HSD and the Cost of generation works out Rs. 14.70 to Rs. 16.25/kWh. The specific fuel consumption of efficient DG set is 4.5 – 5 kWh/litre of HSD. Use of best operating practices can increase the performance of DG sets.

5. Performance of coil-2 furnace is better than coil-1 furnace due to waste heat utilization system. But coil-1 performance is deprived due to any recovery of heat from waste gases. Performance of the furnace must be improved via utilization of waste heat recovery, heat loss through radiation and convection loss.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

6. Performance of both tempering furnaces is underprivileged, due to more furnace area & insulation failure. So it’s strongly recommended to properly insulate the tempering furnace. It will lead to a saving of 13.24 Lakhs/annum for coil-1 & 11.54 Lakhs/annum for coil-2.

7. It’s strongly recommended to install air –pre heater for coil-1 heating furnace, this will lead a saving of 4.8 Lakhs/annually.

8. Performance study of compressor shows that the present capacity is different from the design capacity. Capacity shortfall is 40 % with respect to design capacity.

Which indicates compressor performance needs to be investigated further.

9. It’s strongly recommended to stop the leakage of the entire compressed air system. A thermal image shows that internal leakage of the compressors (3& 5). This will lead to a saving of 0.88 Lakhs/annum.

10. In cooling towers, Inlet water flow nozzle is not functioning, its result having reduced the volume with high power consumption. So check the flow nozzles and rectify the problems.

11. The power consumption in cooling towers is effected by the CT fan blade angle. A higher CT fan blade angle results in higher power consumption during winter and rainy seasons. A reduction in the blade angle of the cooling tower fan from 50 to 45 degree resulted in reduction of power consumption by about 20% and rationalized air flow.

12. The plant is using 40 Watt T/L with conventional electromagnetic choke. These can be replaced by LED -19 w. This will save up to 6.23 Lakhs/annum with a payback period of 2 years. OR management can replace T-12 lights with the T-5 lights. This will save up to 4.53 Lakhs/annum with a payback period of 0.7 years.

13. With the help of solar light pipes we can reduce the electricity consumption in day time. This will lead to a saving of 13.92 Lakhs/annum with a payback period of 01.2 years. Solar light pipes are maintenance free, and having a life span of 15-25 years.

14. It’s strongly recommended to place the AHU inlet units on a clean surface (preferably plastered and raised platform) to avoid the infiltration effects. For better results the units may be placed in well covered and shaded areas.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

1.2 ENCON TABLE:-

Sr. No.

Measured parameter

Savings in Lakhs /annum

Investment in Lakhs

Payback period in years

1

Change in contract demand

4.32

Nil

Immediate

2

Install the waste heat recovery of Air pre heater

4.80

3.00

0.62

3

Insulation to control the heat loss

25.0

2.50

0.1

4

Arrest the compressor air leakage system

0.88

0.50

7

5

Install “lighting Energy Saver� in lighting circuit

6.43

6.00

0.93

6

Replacement of MV(400 W) to metal halides(300W) lamp

1.52

5.04

3.1

7

Replacement of MV(300 W) to metal halides(150W) lamp

1.37

1.36

0.12

8

Replacement of MV (250 W) to metal halides(150W) lamp

0.12

0.18

1.5

9

Replacement of MV (150 W) to metal halides(90W) lamp

0.19

0.36

1.89

10

Replacement of T12 (40+14 W to T5(28W)lamps

4.53

3.22

0.51

11

Install the solar light pipe system

13.9

82.8

5.94

12

Install the solar street lights

3.70

Process

-

66.8

104.9

1.57

TOTAL

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

ENERGY AUDIT REPORT OF A Major Japanese Auto Component Manufacturer, MANESAR 9

CHAPTER 2 ABOUT THE COMPANY

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

2

ABOUT THE COMPANY

2.1 PROFILE OF THE COMPANY A Major Auto Components Japanese company has created a niche in Automobile Industry as manufacturer of Automotive Components for passenger Cars and Utility Vehicles by keeping its pace with changing market situations.

Company aims to become a world class quality component manufacturer, providing customers with the products that meet their requirements.

Company is drawing upon the strengths of its Joint Venture Partners to upgrade its systems, skills and production values to offer its customers the finest quality in its product category.

Company is striving for ever higher levels of quality with manufacturing that puts priority on quality from engineering to production.

Customer satisfaction, through reduction in customer complaints, identifying customer needs.

Technology up-gradation, through continuous improvement under the guidance of experts from Japan.

Employee satisfaction, by creating suitable working environment, which includes teamwork, motivation, training, education, safety and employees involvement.

Leadership, by capturing maximum market share.

Care for environment, by paying attention to pollution, effluent disposal and adhering to basic needs of the green earth.

Company has been awarded the ISO 14001 certification in 2003. Company is striving, as a good global corporate citizen, to make environmental preservation efforts in all steps of production.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

2.3 PRODUCTS AND CUSTOMERS Company has been a major supplier to Ford India, Honda Siel Cars India, Mahindra & Mahindra, Maruti Suzuki, and Toyota Kirloskar Motors & Hindustan Motors. Company offers world class quality components for passenger cars and jeeps to its customers. We are committed to rapid expansion of our product range and clientele by continuously investing in contemporary and environment friendly technology.

Company commitment to maintaining quality and customer satisfaction is reflected in the quality awards it has received from its Vendors.

Quality Award from Maruti Udyog Limited Appreciation Certificate from Hyundai Motor India Ltd. Best Quality Supplier Award from Toyota, Honda Siel and Ford

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

ENERGY AUDIT REPORT OF A Major Japanese Auto Component Manufacturer, MANESAR

P. LTD. MANESAR

CHAPTER 4 INTRODUCTION TO ENERGY AUDIT & METHODOLOGY

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

4

INTRODUCTION TO ENERGY AUDIT AND METHODOLOGY

4.1 AUDIT OBJECTIVE & PURPOSE OF ENERGY AUDIT The objective of this study is to carry out investment grade audit of XXXX., Manesar followed by submission of detailed energy Audit Report to the management & maintenance department along with implementation support.

4.2

APPROACH The Energy Audit & Investment Grade Audit was planned in five parts: Part-I: Energy Audit This part involves performance assessment of the key energy consuming equipment such as induction furnaces, dryers, heaters, ovens, compressors, A/C machines, Fans, Lighting, and all major electrical motors to establish margins for improvement.

Part-II: Energy Conservation This part as a fall out of the Energy Audit Study would involve identification of Energy Saving measures, detailing of measure to achieve improvements in efficiency and reduction in energy consumption, backed by operational trial data wherever possible, in-depth analysis and techno-economic feasibility studies along with relevant vendor information.

Part-III: Preparation of Investment Grade Proposals This part involves preparation of Investment Grade proposal, based on the identified Energy Conservation Options with cost benefits with payback periods and vendor details.

Part – IV: Preparation of Draft Report Initially, the draft report prepared and submitted to the Management.

Part – V: Final Report Submission After submission of Draft report and getting comments from Management, the final report submitted after incorporating all the comments and suggestions.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

4.3 METHODOLOGY FOR CARRYING OUT ENERGY AUDIT “This study has been conducted by the Energy consultant and Auditors of United Growth MSS Pvt. Ltd. & AMTL and consists of the following components.”

Preliminary visits to each of the sub-systems to obtain an overview. Brief discussions with concerned executives, preparation of data collection forms/checklists instrumentation requirements, etc.

Carried out field studies in each of the sub-systems, involving performance assessment trials of furnaces, compressors, heaters & Air Conditioners, vis-àvis existing conditions. To the extent possible, trials have been conducted without disturbing normal operation of working equipment.

Detailed analysis of field data outputs and evaluation of energy performance of equipment studied, with respect to operation efficiencies, comparison of these values with Performance Guarantee, or typical industry norms and establishing margins for improvements.

Identification of Energy Conservation opportunities (ECON).

The ENCON's has been prioritized under three categories, viz., short term (involving little or no investments), medium term and long term.

We have used diagnostic instruments for power measurement, Water Flow measurement, Thermograph study, Lux meter, Infra-red and conventional temperature measurement instruments, and have also drawn inferences from on-site instrumentation data, etc.

4.4

SCOPE OF WORK The scope of work for energy audit study covers the following: Electricity consumption pattern and Energy Monitoring & Accounting System.

Heavy machinery (electric motors) & their loading patterns.

Existing electrical distribution system & Lighting system.

Water pumping systems & cooling towers.

Furnace, Blowers & ID fans.

Diesel Generator sets, compressors & energy conservation options & Cost benefit analysis of each energy conservation options.

Preparation and submission of Detailed Energy Audit Report.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

4.5

DETAILS OF THE INSTRUMENTS USED Table 4.A - List of Instruments

Sr. no.

Instruments

Model

OEM

1

Power Analyzer

ALM 30 ALM 35

KRYKARD INDIA

2

Flue Gas Analyzer

330 – 2

TESTO GERMANY

3

Thermal Imager

881 – 2

TESTO GERMANY

4

Infrared Thermometer

62 Mini

FLUKE USA

5

Digital Thermo Hygrometer

288 ATH

HTC CHINA

6

Digital Anemometer

AM 4201

LUTRON CHINA

7

Digital Lux Meter

LX 101

LUTRON CHINA

8

Digital Multimeter

801 AUTO

MECO INDIA

9

Digital Clamp meter

DT 3150

MECO INDIA

10

Digital TDS Meter

CD 610

HANNA ITALY

Flow meter

TRANSPORT PT878

GE NEW YORK

11

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

ENERGY AUDIT REPORT OF A Major Japanese Auto Component Manufacturer, MANESAR

CHAPTER 5 ENERGY CONSUMPTION PROFILE

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

5

ENERGY CONSUMPTION PROFILE

5.1. Tariff & Demand:A Major Japanese Auto Components Manufacturer receives power from Dakshin Haryana Bijli Vitran Nigam, Haryana through an 11 KV line. XXXX has a contract demand of 1990 KVA (Sanctioned load 1870 Kw). The average monthly bill is Rs.23.12 Lakhs and the annual energy bill is Rs 277.54 Lakhs. The basic tariff details are as follows:-

TABLE 5.A:- DAKSHIN HARYANA BIJLI VITRAN NIGAM TARIFF SCHEDULE FOR H1 CONSUMER Connection Type

H1- 11 kV supply voltage

Supply voltage

11 KV

Contracted Demand

1990 KVA

TARRIF SCHEDULE Demand Charges

(Rs/kVA/Month)

130/kVA/Month

Energy charges

(Rs/kVAh)

4.70/kVAh

Purchased Vs. generated Power Main load of the plant is electric motors, furnaces, compressors, welding machines & boiler. DG sets have been used as backup. Break up for generated power & purchased power is given below:TABLE 5.B:- TOTAL KWH PURCHASED/GEENRATED Sr. no.

Power( Purchased /generated)

KWH/Year

1

Purchased from electricity board

51,94,320

2

Generated from DG sets

18,87,736

3

Generation from Diesel for Furnaces

52,87,379

4

Generation from LPG for boiler & furnaces

5

Generation from Diesel for Boiler

1,74,10,535 1,78,376

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

FIGURE 5.A:- TOTAL KWH PURCHASED/GENERATED

TABLE 5.C:- TOTAL COST OF PURCHASED/GENERATED UNITS/YEAR Sr. no.

Power( Purchased /generated)

RS

1

Purchased from electricity board

2,77,54,670

2

Generated from DG sets

1,98,20,869

3

Generation from Diesel for Furnaces

1,87,60,550

4

Generation from LPG for boiler & furnaces

9,47,69,633

5

Generation from Diesel for Boiler

6,32,909

FIGURE 5.B:- TOTAL COST OF PURCHASED/GENERATED POWER

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

Review of Electricity Bill:Electricity bill components are shown in the table:TABLE 5. D: - ELECTRICITY BILL COMPONENTS

Month/Year Mar-12 Feb-12 Jan-12 Dec-11 Nov-11 Oct-11 Sep-11 Aug-11 July-11 Jun-11 May-11 Apr-11

Sanctioned demand (KW) 1870 1870 1870 1870 1870 1870 1870 1870 1870 1870 1870 1870

Contract demand (KVA) 1990 1990 1990 1990 1990 1990 1990 1990 1990 1990 1990 1990 TOTAL

Maximum demand (KVA) 1490 1434 1434 1434 1434 1398 1206 1206 1434 1434 1398 1082

Power Factor 0.99 0.99 0.98 0.98 0.98 0.99 0.99 0.99 0.98 0.98 0.99 0.98

KVAH

Net payable electricity charge

682080 418360 591480 355900 492220 410420 359829 359829 355900 492220 410420 350880 5279538

3554648 2190090 2964347 1865395 2511025 2219262 1972675 1972675 1865395 2511025 2219262 1908869 2,77,54,670

FIGURE 5.C:- ELECTRICITY CHARGE MONTH WISE

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

FIGURE 5.D:- DEMAND PATTERNS

FIGURE 5.E:- KVAH PATTERNS

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

From the above data 1.

The average monthly consumption is 4, 32,860 kWh/month while total purchased electricity is 51, 94,320kWh/annum.

2.

Average Monthly billing is Rs. 23.12 Lakhs / month and total billing for last one year is Rs.277.54 Lakhs.

3.

The Average Power factor for the month is 0.98 and its variation is between the ranges 0.98 – 1.

TRANSFORMERS

There are mainly 2 transformers installed in the premises. Detailed description of the transformers is as follows:TABLE 5.E:- TRANSFORMER DETAILS

Sr. No.

Location of the transformer

Transformer capacity (In KVA)

Used for

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

1

FOR COIL SECTION

2500

COIL SECTION

2

STB SECTION

1000

STB SECTION

Voltage Ratio Phase ratio Connection Frequency

: : : :

11/0.433 KV 3/3 HV- delta, LV- star 50 Hz

NOTE:A. These transformers cater to demands of the whole plant.

B. These transformers are in continuous operation as long as power is available from electricity board.

5.5 RECOMMENDATIONS:-

TABLE 5.F:- SAVINGS FROM IMPROVED CONTRACT DEMAND Month/ Year Mar-12 Feb-12 Jan-12 Dec-11 Nov-11 Oct-11 Sep-11 Aug-11 Jul-11 Jun-11 May-11 Apr-11

sanctioned demand (KW)

Proposed contract demand(KVA)

1870 1870 1870 1870 1870 1870 1870 1870 1870 1870 1870 1870

1690 1690 1690 1690 1690 1690 1690 1690 1690 1690 1690 1690 TOTAL

Savings In Savings Power KVA in RS Factor 300 300 300 300 300 300 300 300 300 300 300 300

36000 36000 36000 36000 36000 36000 36000 36000 36000 36000 36000 36000 432000

0.99 0.99 0.98 0.98 0.98 0.99 0.99 0.99 0.98 0.98 0.99 0.98

KVAh 682080 418360 591480 355900 492220 410420 359829 359829 355900 492220 410420 350880 5279538

KWh 672800 412400 582220 348300 482920 404740 355120 355120 348300 482920 404740 344740 5194320

* For the month of June & July 2012, maximum demand is 1654 & 1631 kVA respectively. * For last 4 months power factor is in the range of 0.996-0.998.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

1. Contract demand of the plant is 1990 kVA, and the average maximum demand of the plant is 1366 kVA. The contract demand is never exceed 1654 kVA in the earlier.

2. It is recommended that the Contract Demand be reduced from existing 1990 kVA to 1690 kVA. This will reduce the monthly bill by Rs. 36,000per month. This will lead to saving of Rs. 4.32 Lakhs per annum.

Savings = (1990– 1690) x 120 x 12 = Rs. 4, 32,000/3. Average power factor of the plant is 0.98. Management has been doing a great job by maintaining power factor in the range of 0.98-0.995.Presently for the last 3-4 months, it’s close to 1.

4. A comprehensive register or computerized file should be maintained to monitor the energy bill parameters on monthly basis. It is also advised to note the readings of energy meter twice on daily basis as per the format below:TABLE 5.G:- SAMPLE FOR CAPACITOR BANK READINGS S.N. Date Voltage

Current Instantaneous Kwh power factor

kVAh Power factor Maximum till date demand

1. It is required that all the existing capacitors are identified with their capacity and serial number, so that monitoring of capacitor current is possible and done on weekly basis. The failed and weak ones (consuming less than 70% of their rated current capacity) must be replaced immediately.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

ENERGY AUDIT REPORT OF A Major Japanese Auto Component Manufacturer, MANESAR

CHAPTER 6 HARMONICS & POWER SUPPLY QUALITY

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

6

HARMONICS & POWER SUPPLY QUALITY

6.1 GENERAL DETAILS:

The majority of loads connected to the electricity supply system draw power which is a linear (or near linear) function of the voltage and current supplied to it. These Loads do not usually cause disturbance to other users of the supply system. Examples include lighting, heating, directly driven motors, pumps etc. Some types of loads cause a distortion of the supply voltage / current waveform due to their non-linear impedance.

The most common devices causing such problems are electronic controllers (such as motor drives) and AC to DC power supply convertors for equipment such as computers.

The nature of these devices is that the waveform is switched or chopped (Commutated) very rapidly in order to control power flow or to convert to a DC output, typically using solid state components such as diodes and thyristor.

Some types of florescent lighting or the controllers for such lighting can also cause these effects. Problems occur when such activity causes interference or permanent damage to equipment that is connected adjacent to the disturbing load (Within the same building or in nearby premises).

The measurement of such interferences has been established by the parameter known as harmonic current/voltage. This is simply a measure of the extent of distortion of the normal AC sinusoidal voltage/current supplied by the power system, caused by the disturbing load.

The distortion may be exhibited by a change in the sinusoid shape or by short notches in the waveform. The method of measurement is based on disaggregating the distorted waveform into a normal 50Hz waveform plus smaller, superimposed waveforms taken at integer multiples (or sub-multiples) of the fundamental frequency.

The total harmonic distortion is expressed as the sum of the harmonic waveforms (rms values) operating at the 1st, 2nd, 3rd etc. multiples of the fundamental frequency. In addition to the operation on the sinusoidal supplies, the harmonic behavior becomes important as the size and rating of the transformer increases.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

Disadvantages of Harmonics:

Failed capacitor banks

Breakers and fuses tripping

Increased Hysteresis losses

Erroneous register of electric meters

Distorted voltage and current waveforms

Wasted energy/higher electric bills-kVA & kVAh

Wasted capacity – Inefficient distribution of power

Increased maintenance of equipment and machinery

Unreliable operation of electronic equipment, and generators

Overheating of transformers (K -Factor), and rotating equipment

Neutral overloading / unacceptable neutral - to-ground voltages

THD (Total Harmonics Distortion) Planning limits :-

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

Planning limits of harmonics at 6.6 kV -20 kV :-

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

FIGURE 6.A:- MAIN PANEL OF COIL SECTION:-

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

FIGURE 6.B:- MAIN PANEL OF STB1 SECTION:-

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

FIGURE 6.C:- MAIN PANEL OF STB 2 SECTION:-

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

6.2 RECOMMENDATIONS:-

It has been observed that plant is working within the permissible limits of THD. This plant can also consider following points for future reference for maintaining the THD in the prescribed limit : Tuned Harmonic filters consisting of a capacitor bank and reactor in series are designed and adopted for suppressing harmonics, by providing low impedance path for harmonic component.

The Harmonic filters connected suitably near the equipment generating harmonics help in Reducing THD to acceptable limits. In present Indian context where no Electro Magnetic Compatibility regulations exist as a application of Harmonic filters is very relevant for industries having diesel power generation sets and co-generation units.

Take care with equipment selection and isolate sensitive electronics from noisy circuits.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

FIGURE 6.D:- ANALYZER PATTERNS FOR COIL SECTION

(i) VOLTAGE & CURRENT RMS

(ii) KW

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

(iii) KVAR

(iv) POWER FACTOR

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

(v) KVA FIGURE 6.E:- ANALYZER PATTERNS FOR STB 1 SECTION

(i) VOLTAGE & CURRENT RMS

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

(ii) KW

(iii) KVAR

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

(iv) POWER FACTOR

(v) KVA

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

FIGURE 6.F:- ANALYZER PATTERNS FOR STB 2 SECTION

(i). voltage & current RMS

(ii) KW

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

(iii) POWER FACTOR

(iV) KVAr

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

(v) KVA

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

ENERGY AUDIT REPORT OF A Major Japanese Auto Component Manufacturer, MANESAR

CHAPTER 7 DIESEL GENERATOR SETS

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

7

DIESEL GENERATOR SET

7.1 DG PERFORMANCE

Company has 6 DG sets (750x2, 525x2, 250 & 25 kVA) for power backup purposes. DG sets is running in the pair of 750x525 kVA for coil section & 750x525 kVA for STB section.

250 kVA DG set is used for rest of the applications. 25 kVA DG set is rarely used as this DG set is kept for emergency situation. Month wise diesel consumption & kWh generation is shown in the tables:-

TABLE 7.A:- DG SETS DIESEL CONSUMPTION (IN LTRS)

DIESEL CONSUMPTIOPN(LITRES)

MONTH DG 1

DG 2

DG 3

DG 4

DG 5

Apr-11

17785

17380

620

31800

28060

May-11

22765

7430

350

48580

14310

Jun-11

8658

4685

6128

19420

3070

Jul-11

4170

955

11120

14185

3070

Aug-11

5920

4900

8155

30175

855

Sep-11

7330

140

3813

17582

180

Oct-11

3940

3520

4550

3235

22310

Nov-11

2770

150

591

3235

8047

Dec-11

6710

2235

3190

2105

17620

Jan-12

6930

450

2120

2380

13250

Feb-12

5370

955

2090

2380

13150

Mar-12

5005

955

2270

445

18030

TOTAL

97353

43755

44997

175522

141952

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 7.B:- DG SETS UNIT GENERATED (IN kWh)

UNITS GENERATED(kWh)

MONTH

DG 1

DG 2

DG 3

DG 4

DG 5

Apr-11

62205

76260

2030

115367

106223

May-11

73508

31238

1200

179527

53696

Jun-11

25055

18277

10650

70612

11049

Jul-11

11747

3830

44950

50759

11049

Aug-11

18352

20456

33170

111608

2896

Sep-11

22326

596

14200

68631

584

Oct-11

11431

14786

17400

11786

85827

Nov-11

8415

588

2400

11786

30810

Dec-11

21326

8657

13300

7518

114783

Jan-12

21851

1901

8700

9170

73813

Feb-12

17938

4163

8620

9170

50800

Mar-12

15864

4163

9300

1549

37871

TOTAL

310018

184915

165920

647483

579400

7.2 OBSERVATIONS:1.

2.

There are 6 DG sets, mainly used for power back up.

A good data is maintained regarding DG operating hours, maintenance and diesel consumption. .

3.

DG consumes 5,03,579 liters of diesel to generate 18, 87,736 kWh. Total generation cost is 198.20 lakhs annually.

4.

The average SEG for the DG set is 3.75kwh/liters .

5.

Management can consider new efficient DG set for future Replacements.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

FIGURE 7.A:- UNITS GENERATION COMPARISON (IN KWH PERCENTAGE)

FIGURE 7.B:- COST WISE COMPARISON (IN RS PERCENTAGE)

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

Table 7.C:- SEG (KWH/LTR) & UNIT (RS/KWH)

DG SET DG 1

SEG (KWH/LTR)

RS/KWH

3.11 4.16 3.72 3.68 3.92

DG 2 DG 3 DG 4 DG 5

12.69 9.49 11.19 10.7 10.75

FIGURE 7.C:- SEG (KWH/LTR) & UNIT (RS/KWH)

7.3 RECOMMENDATIONS:-

1. DG set running with the low percentage of loading is (below 40%) consumes more diesel and hence lower specific fuel consumption.

2. Regular maintenance should be planned for DG set. It will improve their life span as well as SEG also.

3. The average SEG for the DG sets is 3.75 kWh/liters. Depending upon the load SEG is ranging between 3.25-4.16 kWh/liters. Presently there are more efficient DG sets available in the market having a SEG of 4.5-5.5 kWh/liters.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

ENERGY AUDIT REPORT OF A Major Japanese Auto Component Manufacturer, MANESAR

CHAPTER 8 FURNACES

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

8

FURNACE

8.1 BRIEF DESCRIPTION Furnace should be designed so that in a given time, as much of material as possible can be heated to a uniform temperature as possible with the least possible fuel and labor. To achieve this end, the following parameters can be considered.

Determination of the quantity of heat to be imparted to the material or charge.

Liberation of sufficient heat within the furnace to heat the stock and overcome all heat Losses.

Transfer of available part of that heat from the furnace gases to the surface of the heating

Equalization of the temperature within the stock.

Reduction of heat losses from the furnace to the minimum possible extent

It’s divided into two sections. - Each section has 3 types of furnaces (heating, tempering & hardening) with automatic charging & discharging of material. Fuel used for furnace is HSD & LPG. Furnace specifications are as follows:TABLE 8.A:- FURNACE DETAILS

PARMETERS Capacity (kg/h) Temp. of furnace(degree C) Fuel type Fuel consumption (lit/hr.)

Furnace dimensions(L x W)mm Product type * data not available

HEATING FURNACE 1000 900-1000 HSD 102 1620x400 Straight bars

TYPE OF FURNACE TEMPERING HARDENING FURNACE FURNACE 1000 1335 350-500 900-1000 HSD(main), LPG LPG(Pilot) (main),LPG(Pilot) 81 * * * Straight bars Coil springs

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

8.2 PERFORMANCE EVALUATION OF FURNACES Performance evaluation of heating & tempering furnaces of Company. are as follows:TABLE 8.B:- PERFORMANCE OF HEATING FURNACE Performance of Heating Furnace Parameters Design Parameter Design Capacity Design Fuel consumption Actual Parameter Average fuel HSD consumption Calorific value of HSD Specific gravity of HSD Ambient temperature Inlet Air temperature Flue gas temperature Number of Piece Diameter of the piece Length of piece Weight of the Material Total Weight of Material Specific heat of material Initial material temperature final material temperature Surface temperature of roof and side walls Surface temperature, if others Performance of Furnace efficiency Heat Input Heat Output Furnace efficiency Specific Fuel consumption

Unit

Section 1

Section-2

kg/h LPH

1000 102

1000 102

LPH kcal/kg C C C No’s Mm Mm Kg kg/h kcal/kg/C C C C C

40 10900 0.88 40 40 290 370 9.9 1900 1.15 424.9 0.11 40 960 125 110

30 10900 0.88 40 180 190 600 10.9 1990 1.46 874.7 0.11 40 960 120 110

kcal/h kcal/h % litre/Tonnes

383680 42995 11.21 94.15

287760 88523 30.76 34.30

Comments: Performance of section-2 furnace is better due to waste heat utilization system.

But section-1 performance is not good.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 8.C:- PERFORMANCE OF TEMPERING FURNACE XXXX- Performance of Tempering Furnace Parameters Design Parameter Design Fuel Design Capacity Design HEAT capacity Actual Parameter Average fuel HSD consumption Calorific value of HSD Specific gravity of HSD Ambient temperature Inlet Air temperature Flue gas temperature Number of Piece Diameter of the piece Length of piece Weight of the Material Total Weight of Material Specific heat of material Initial material temperature final material temperature Surface temperature of roof and side walls Surface temperature, if others Performance of Furnace efficiency Heat Input Heat Output Furnace efficiency Specific Fuel consumption

Unit

kg/h kcal/h LPH kcal/kg C C C No’s mm mm Kg kg/h kcal/kg/C C C C C kcal/h kcal/h % litre/Tonnes

Section1

Section-2

HSD 1000 882900

LPG 1800 1500000

42 10900 0.88 40 40 180 370 9.9 1900 1.15 424.9 0.11 50 440 125 110

40 10900 0.88 40 40 170 600 10.9 1990 1.46 874.7 0.11 50 441 120 110

402864 18694 4.64 98.86

383680 38584 10.06 45.73

Observations: Performance of both tempering furnaces is very poor, due to more furnace area & insulation failure.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

8.3 IR THERMOGRAPHY IR thermograph image of furnaces are as follows:FIGURE 8.B FURNACE HEAT LOSS – IR THERMOGRAPHY

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

8.4 CALCULATIONS:A. HEAT LOSS CALCUALTION:About 30–40% of the fuel input to the furnace generally goes to make up for heat losses in Intermittent or continuous furnaces. The appropriate choice of refractory and insulation materials goes a long way in achieving fairly high fuel savings in industrial furnaces. The heat losses from furnace walls affect the fuel economy considerably. The extent of wall Losses depend on: Emissivity of wall Thermal conductivity of refractory’s Wall thickness Whether furnace is operated continuously or intermittently

Heat losses can be reduced by increasing the wall thickness, or through the application of Insulate bricks. Outside wall temperatures and heat losses of a composite wall of a certain thickness of firebrick and insulation brick are much lower, due to lesser conductivity of insulating brick as compared to a refractory brick of similar thickness. In the actual operation in most of the small furnaces the operating periods alternate with the idle periods.

During the off period, the heat stored in the refractory during the on period is gradually dissipated, mainly through radiation and convection from the cold face.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 8.D:- HEAT LOSS DUE TO UNINSULATED AREA IN COIL-1 FURNACE Heat Loss calculation through radiation: IR probe survey Accoun ted area for heat loss

Un insulated area Description

L

Leng Dia th, m

B

are a, m2

no

m2

To tal Ar ea, m 2

Tem p, deg C

Heat Lost, kcal/hr

Coil-1 Heating furnace Furnace outlet to Exhaust duct Furnace Exhaust Duct

11 00 80 0

950 700

Chimney

800

Fuel and air mixing Line Flue gas exhaust duct

30 0

manhole door

50 0 10 00 15 00

Manhole door leakage Furnace casings

400

500 0

400 800 450 50 400 0

400 0

1.0 5 0.5 6 12.

57 0.1 2 10.

05 0.2 3 0.0 5 6.0 0

1.05

3

0.56

1

12.57

1

0.12

3

10.05

1

0.20

2

0.05

3

6.00

3

3.1 4 0.5 6 12.

57 0.3 6 10.

05 0.4 1 0.1 5 18.

00

100

1139

300

1751

130

8652

250

832

110

4699

95

127

350

604

130

12394

Coil-1 Heating furnace Furnace side casings Furnace casings- Front and Rear Flue gas exhaust duct

30198 25 00 25 00 18

Tempering Furnace 100 25.

25.00 00 00 280 7.0 6.98 0 0 120 2.1 2.16

2 2 2

50.

00 13.

96 4.3

90

13188

125

8818

165

4803

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

00

0

Chimney line

38 8000 0 30 1919 0 0

Conveying Section

6 9.5 5 18.

09

9.55

1

18.09

1

2 9.5 5 18.

09

125

6034

110

8454

kcal /h

32842

110

9424

Hardening Furnace Furnace side casings

21 00

320 0

Total Heat loss measured Total Heat loss measurable error 10 % Total heat loss of Coil-1 Furnace FUEL LOSS Calorific value of HSD Total Fuel loss per hour Working hours per annum Total annual fuel loss Cost savings Fuel cost Fuel cost Savings

6.7 2

6.72

3

20.

16

kcal /h kcal /h kcal /h kcal /h liter s hrs liter s kl Rs

72465 7246 65218

10800 6 6000 36232

36553 132439 8

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 8.E:- HEAT LOSS DUE TO UNINSULATED AREA IN Sectionn-2 FURNACE Heat Lost calculation through radiation: IR probe survey Accounted area for heat loss No.

Un insulated area Description A

B

Dia

Length, m

area, m2

m2

Total Area, m2

Temp, deg C

Heat Lost, kcal/hr

Section-2 Heating furnace Furnace Exhaust Duct Chimney Fuel and air mixing Line Flue gas exhaust duct manhole door Manhole door leakage Furnace casings Coil-2 Heating furnace

900

380

850

0.77

0.77

1

0.77

300

2392

650

6000 12.25 0.17

12.25 0.17

1 3

12.25 0.52

115 265

6386 1336

800

1800

4.52

4.52

1

4.52

120

2606

460

500

450

0.23

0.20

2

0.41

95

127

1000

50

0.05

0.05

3

0.15

350

604

1500 4000

6.00

6.00

3

18.00

130

12394 25844

Tempering Furnace Furnace side casings Furnace

2350 8750

20.56

20.56

2

41.13

95

12868

2400 2600

6.24

6.22

2

12.44

125

7857

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

casingsFront and Rear Flue gas exhaust duct Chimney line Coil-2 Tempering furnace

1900 1250

380

6000

2.38

2.38

2

4.75

145

4107

7.16

7.16

1

7.16

120

4126

kcal/h

28957

105

8362

Hardening Furnace

Furnace 2100 3200 side casings Total Heat loss measured Total Heat loss measurable error 10 % Total heat loss of Coil-2 Furnace FUEL LOSS Calorific value of HSD Total Fuel loss per hour Working hours per annum Total annual fuel loss Cost savings Fuel cost Fuel cost Savings

6.72

6.72

3

20.16

kcal/h kcal/h kcal/h kcal/h litres hrs litres Rs/kl Rs

63164 6316 56847 10800 5 6000 31582 36553 1154411

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 8.F:- CALCULATION FOR HEAT LOSS DUE TO EXHAUST FLUE GAS ON Section-1 HEATING FURNACE

Calculation for heat loss due to Exhaust flue gas on Section-1 Heating Furnace Place

Unit

Fuel Fuel consumption LPH Fuel consumption Kg/h Combustion air quantity (1: Kg/h 14) Flue gas produced Kg/h Excess air (50%) Kg/h Flue gas produced Kg/h GCV of fuel Kcal/kg combustion air temperature C Flue gas Exhaust Temperature C Specific heat flue gas temperature

Before implementation

After implementations HSD 40 35.2 493

HSD 40 35.2 493

533 267 800 10800 40 300 0.25

533 267 800 10800 140 160 0.25

Heat Loss due to flue gas

Kcal/kg

1300

600

Heat Loss due to flue gas Energy Savings: After implementations savings Fuel savings per hour Working hours Annual Fuel savings Annual Fuel savings (10% margin) Cost Savings HSD cost Annual Cost Savings

%

12.03

5.55

% Litre Hr Litre Litre

Rs/kl Rs

6.47 2.58 6000 15538 13984

36553 5,11,162

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

8.5 RECOMMENDATIONS 1. Performance of Section-2 furnace is better due to waste heat utilization system. But Section-1 performance is not good due to any recovery of heat from waste gases.

Performance of the furnace must be improved via utilization of heat loss through radiation and convection loss.

2. Performance of both tempering furnaces is very poor, due to more furnace area & insulation failure. So it’s strongly recommended to properly insulate the tempering furnace. It will lead to a saving of 13.24 Lakhs/annum for coil-1 & 11.54 Lakhs/annum for coil-2.

3. Its strongly recommended to install air –pre heater for coil-1 heating furnace, this will lead a saving of 5.1 Lakhs/annually.

4. Moreover, Typical energy efficiency measures for an industry with furnace are:

Complete combustion with minimum excess air Correct heat distribution Operating at the desired temperature Reducing heat losses from furnace openings Maintaining correct amount of furnace draught Optimum capacity utilization Waste heat recovery from the flue gases Minimum refractory losses Use of Ceramic Coatings

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

ENERGY AUDIT REPORT OF A Major Japanese Auto Component Manufacturer, MANESAR

CHAPTER 9 COMPRESSED AIR SYSTEM

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

9

COMPRESSED AIR SYSTEM

9.1 COMPRESSED AIR SYSTEM The compressed air system is not only an energy intensive utility but also one of the least energy efficient. Company Plant has six compressors. During normal operation four compressors are operated.

9.2 MEASUREMENT OF FREE AIR DELIVERY (FAD) OF THE COMPRESSOR BY PUMP UP METHOD The Free Air Delivery of the compressor is done by Pump up Method - also known as receiver filling method. The capacity of a compressor is the full rated volume of flow of gas compressed and delivered under conditions of total temperature, total pressure, and composition prevailing at the compressor inlet. It sometimes means actual flow rate, rather than rated volume of flow. This is also called free air delivery (FAD).

Due to the inefficient operation of the compressor or faulty components, delivery of the free air is less than the designed value. Sometimes, other factors such as poor maintenance, fouled heat exchanger and effects of altitude also tend to reduce free air delivery. In order to meet the air demand, the inefficient compressor may have to run for more time, thus consuming more power than actually required. The power wastage depends on the percentage deviation of FAD capacity.

During the compressor FAD test, the leakage test indicated that lot of air leakages are there in the compressed air system.

The control of compressed air leakage in the system will reduce the power consumption by 15%. The regular implementation and follow-up will also results in many other associated benefits such as stable pressure, reduction in generation pressure, long life of the equipment, etc.

The steps involved in no-load test are: To switch off all user equipment (during non-operating of the equipment) To pressurize the pipelines and note down loading and unloading times of compressors.

During the test two compressors were operated to monitor loading and unloading of the compressors. It was observed that these two compressors were on-load for about 50% of the time. The following table gives the details about the no load test.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 9.A:- CALCULATIONS FOR FAD TEST

Description

Make/Model no/Type Capacity Capacity Receiver volume Others Total Volume Initial pressure Final pressure Time taken by pressure Atmospheric pressure Electrical Parameters : Average Voltage Average Current KVA Power Factor Power Motor efficiency Performance of Compressor Actual FAD Actual FAD Actual FAD Difference compressor design and actual Specific power consumption

XXXX- A Major Japanese Auto Component Manufacturer, Manesar Calculation Sheet for Compressor FAD test Compressor- Compressor- CompressorUnit 1 2 3 GA 18 plus FF GA 22 plus FF GA 22 plus FF l/s 54 63 63 Cfm 114 133 133 m3 0.0150 0.015 0.015 m3 0.0041 0.0041 0.0041 m3 0.0191 0.0191 0.0191 kg/cm2 0.1 0.1 0.1 kg/cm2 7 7 7 Sec 4.1 3.7 3.1 kg/cm2 1.026 1.026 1.026 Volt Amps Voltamps Kw %

414 35.6 25.52 0.88 22.46 0.89

415 48.8 35.07 0.88 30.87 0.89

415 46.2 33.20 0.88 29.22 0.89

m3/min l/s Cfm Cfm

1.93 32.15 68.13 46.29

2.14 35.63 75.50 57.97

2.19 36.52 77.39 56.09

kW/m3/h r

0.194

0.241

0.222

Comments: Capacity shortfall with respect up to designed value is 40 %.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

VSD Technology: Energy can represent over 70% of a compressor’s lifecycle costs (LCC). Generating compressed air can account for more than 40% of a plant’s total electricity bill. Most production environments have a fluctuating air demand depending on the time of day, week, or even months per year. The VSD technology mirroring compressed air requirements, fluctuating demand no longer equals high energy costs.

Traditional compressors working with a full load, no load control operate between two set pressure points. When maximum pressure is reached the compressor goes off load. During periods of medium to low air demand, the no load power consumption can be excessive – wasting large amounts of energy. Because there is no unnecessary power generated, the VSD can reduce energy costs by 35% or more. Lifecycle costs (LCC) of the compressor can be reduced by an average of 22%. In general, the extra cost of a VSD compressor compared to a fixed speed one can be earned back after just one to two years.

VSD (Variable Speed Drive) technology mirrors air usage – automatically adjusting the motor speed depending on demand. Lowered system pressure minimizes energy use across the production to reduce energy costs. With VSD technology, having major energy cost savings a reality.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 9 D VSD CALCULATIONS Description

XXXX- A Major Japanese Auto Component Manufacturer, Manesar Calculation Sheet for Compressor with VSD Technology Unit

Excited load

After implementations

Make/Model no/Type GA 22 plus FF Design Capacity l/s 63 Design Capacity Cfm 133 Actual FAD l/s 36.52 Actual FAD Cfm 77.39 Proposal: Using VSD technology for one compressor (saving 20 %) Electrical Parameters : Average Voltage Volt 415 Average Current Amps 48.8 KVA Voltamps 35.07 Power Factor 0.88 Power kW 30.87 Motor efficiency % 0.89 Energy Savings: After proposal Energy savings kW Average working hours Hrs Annual Energy savings kWh Annual savings( PF 0.98) kVAh Annual savings( 10 % margin) kVAh Cost Savings Unit Rate Rs Annual Cost Savings Rs Payback Period Cost of VSD Rs Payback Period Months

GA 22 plus FF 63 133 36.52 77.39

415 39.04 28.06 0.88 24.69 0.89 6.17 6000 37029 37785 34006 4.7 159830 100000 8

The VSD reduces energy costs by:

Eliminating the inefficient transition period from full to no load power.

Avoiding excessive off load power consumption.

Maintaining the net pressure band to within 0.10 bars, 1.5 psi.

Reducing overall average working pressure.

Minimizing system leakage due to a lower system pressure.

Increasing flexibility with soft starting gradual motor ramp-up to avoid electricity surges.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

9.3 AIR LEAKAGE IN THE PLANT: TABLE 9.B:-AIR LEAKAGE OF THE PLANT Compressor

Actual FAD l/s

Compressor-1 Compressor-2 Compressor-3 Compressor-4

52 54 54 50

% loading during leakage test 12 15 10 18

*Actual compressed air leakage: 28.74 L/s, *Total compressed air consumption: 210 L/s, *% leakage in the system: 13.7 %

FIGURE 9.A:-AIR LEAKAGE OF THE PLANT

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

RECOMMENDATIONS:1. Its strongly recommended to stop the leakage of the entire compressed air system. A thermal image shows that internal leakage of the compressors (3& 5). Leakage is also source of energy wastage in industrial compressed air system. A typical plant that has not been well maintained will likely have a leak rate equal to 20 percent of total compressed air production capacity. On the other hand, proactive leak detection and repair can reduce leaks to less than 10 percent of compressor output. This will lead to a saving of 0.88 Lakhs/annum.

TABLE 9 C.:- CALCUALTION FOR THE AIR LEAKAGE OF THE PLANT

Description

XXXX- A Major Japanese Auto Component Manufacturer, Manesar

After Unit implementations (4%) Make/Model no/Type GA 22 plus FF GA 22 plus FF Design Capacity l/s 210 210 Design Capacity cfm 445 445 Leakage FAD l/s 28.74 8.4 leakage FAD cfm 61 17.42 Recommendations: arrest the leakages of entire compressor plant (saving 10 %) Electrical Parameters : Average Voltage volt 415 415 Average Current Amps 48.80 43.96 KVA voltamps 35.07 31.56 Power Factor 0.88 0.88 Power kW 30.87 27.78 Motor efficiency % 0.89 0.89 Energy Savings: After proposal Energy savings kW 3.09 Average working hours hrs 6000 Annual Energy savings kWh 18540 Annual savings( PF 0.98) kVAh 18918 Cost Savings Unit Rate Rs 4.7 Annual Cost Savings Rs 88916 Payback Period Cost of replacement or modification Rs 50000 Payback Period Months 7 Excited load (14%)

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

ENERGY AUDIT REPORT OF A Major Japanese Auto Component Manufacturer, MANESAR

CHAPTER 10 COOLING TOWERS

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

10

COOLING TOWERS

10.1 COLLING TOWERS:-

Cooling towers are a very important part of an industrial unit. The primary task of a cooling tower is to reject heat into the atmosphere. Company uses 4 round bottle cooling towers of fiberglass reinforced plastic material. The fans are directly driven, axial flow type made of lightweight Aluminum casting. The water is discharged at low pressure out of holes of PVC pipes and evenly distributed over PVC fills to achieve maximum wetted surface area. The honeycombed fills are made of PVC.

The performance of cooling towers is evaluated to assess present levels of approach and range against their design values, identify areas of energy wastage and to suggest improvements. During the performance evaluation the following major parameters are measured: 1. Wet bulb temperature of air 2. Dry bulb temperature of air 3. Cooling tower inlet water temperature 4. Cooling tower outlet water temperature

The measured details of the cooling towers as follows: TABLE 10.A:- DETAILS OF COOLING TOWERS Sr.No.

Capacity Inlet Temp (C) Outlet Temp (C) Relative (TR)

Dry Bulb Temp Wet Bulb

Humidity (%) (C)

Temp(C)

1

250

32.4

30.8

77

31.6

30.2

2

250

29.2

27.4

73

30.9

28

3

150

30.2

28.2

77

30.7

28.4

4

150

28.6

27.8

64

33.33

30.3

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 10.B:- PERFORMANCE OF COOLING TOWER XXXX- A Major Japanese Auto Component Manufacturer, Manesar Calculation Sheet for Cooling Tower CT-1 CT-2 CT-3 CT-4 Unit Actual Actual Actual Actual TR 250 250 150 150 ºC 32.4 29.2 30.2 28.6 ºC 31.8 27.6 28.2 27.8 Bar 1.013 1.013 1.013 1.013 ºC 31.6 28 28.4 30.3 ºC 28.58 25.29 26.85 23.65 kg/m3 1.15 1.15 1.15 1.15 kcal/kg 540 540 540 540 Ppm 225 325 326 327 Ppm 75 75 76 77 3.00 4.33 4.29 4.25 kW 2.58 7.6 6.11 6.77 Customer

Description Cooling capacity Cooling water inlet temperature Cooling water outlet temperature Atmospheric pressure at the plant Dry bulb temperature Wet bulb temperature Air density Latent heat evaporation CT water TDS Make up water TDS COC Total power consumption on CT Performance of Cooling Tower Range Approach %CT effectiveness CT water flow Cooling duty handled Cooling duty handled Evaporation loss % of Evaporation loss Blow down loss % of Blow down loss Make up water requirement

ºC ºC % kg/h kcal/h TR m3/h % m3/h % m3/h

0.6 3 15.707 212000 127200 42 0.19 0.08 0 0.04

1.6 2 40.921 180245 288392 95 0.44 0.18 0 0.05 1

2 1 59.701 132850 265700 88 0.41 0.27 0 0.08 1

0.8 4 16.162 142350 113880 38 0.17 0.12 0 0.04

10.2 RECOMMENDATIONS:1. Inlet water flow nozzle is not working, its result having reduced the volume with high power consumption. So check the flow nozzles and rectify the problems.

2. The power consumption in cooling towers is effected by the CT fan blade angle. A higher CT fan blade angle results in higher power consumption during winter and rainy seasons. A reduction in the blade angle of the cooling tower fan from 50 to 45 degree resulted in reduction of power consumption by about 20% and rationalized air flow.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

ENERGY AUDIT REPORT OF A Major Japanese Auto Component Manufacturer, MANESAR

CHAPTER 11 ILLUMINATION & LIGHTING

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

CHAPTER 11

LIGHTING

11.1 LIGHT INVENTORY:

1. There are various types of light fittings in the plant. Mainly mercury vapor lights, HPSV and T12 are used for lighting the plant. Total lighting load in plant is 133 kW. Detailed list of lights are as follows:TABLE11.A: - LIGHT INVENTORY SR. NO.

LAMP TYPE

WATTAGE

QUANTITY

LOAD (KW)

(Nos.)

1

Sodium vapour lamp

2

Mercury vapour

250

75

19

300

38

1.8

200

1

25

150

12

1

400

63

2

250

5

7

150

13

11

70

94

0.2

3

Dome lights

400

85

34

4

T-12

53 (40+13)

586

31

Total Load in KW

133

11.2 RECOMMENDATIONS: 1)

The plant is using 40 Watt T/L with conventional electromagnetic choke. These can be replaced by LED -19 w. This will save up to 6.23 Lakhs/annum with a payback period of 2 years. OR management can replace T-12 lights with the T-5 lights. This will save up to 4.53 Lakhs/annum with a payback period of 0.7 years.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 11.B:- LIGHT REPLACEMENT OPTIONS

TOTAL(NOS.) Lamp type Total load in kw Operational Hours Total consumption in KWH Proposed solution

63 MV400 25 12 302 MH300

Remarks no of days in a year 320 Total Proposed kWh 226 Total Savings kWh per Day 75.6 Total Savings kWh per Annum 24192 Unit Rate 6.3 Total Savings Rs. Per Annum 152409 Replacement Cost per unit 8000 Total Replacement Cost 504000 SPP (Year) 3.3 SPP( Months) 39.7 Total Savings kWh per Annum 24192 Total Savings Rs. Per 15240 Annum 9

5 MV-250 1 12

13 MV150 2 12 23

38

11 12

1 MV200 0.2 12 2.4 MH90

MV-300

586 T12-40 31 16

15 MH150

MH-90

136 MH150

496 LED - 19 T5-28 W w

320 9

320 14

320 68

320 1

320 187

320 271

6

9.36

68.4

1.32

309.4

225.0

1920 6.3

2995 6.3

21888 6.3

422 6.3

9901 6.3

71998 6.3

12096

18869

137894

2661

623766

453591

3600 18000 1.5 17.9

2800 36400 1.9 23.1

3600 136800 1.0 11.9

1920

2995.2

21888

2800 2800 1.1 12.6 422.

4

2100 1230600 2.0 24 99010.5 6

12096

18869

137894 2661

623766

550 322300 0.7 9 71998.

72 45359 1

2) All the tube light fittings should have a reflector and it should be cleaned regularly as per schedule. In this way a single tube light can be used in place of double tube lights in each fitting. This will lead to a saving of 50% energy for these lights.

3) 20% energy can be saved by installing “lighting Energy Saver� in lighting circuit. Energy Saver for lighting circuit is basically step down transformer; which reduces the supply

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

voltage. 20% reduction in supply voltage for fluorescent lamps reduces the energy consumption by 20% while lux reduction is only 5%. This lux reduction is so small that our eyes cannot differentiate the reduction in lighting lux.

Hence expected saving = 0.2 x 133 kW x 12 hrs x 320 days = 1, 02,144kW per annum = Rs. 6.30 x 102144 kW

=Rs. 6, 43,507 RS / Annum

4) SOLAR LIGHT PIPE:A light tube is a tube which is designed to be installed in a ceiling or wall to allow natural light to pass into a room. Light tubes are also known as light pipes or solar tubes, and they are an increasingly common feature in design and architecture. There are a number of advantages to light tubes, ranging from security to savings on energy bills. Many home supply stores carry light tubes which are ready to be installed, and they can also be custom designed.

The most basic light tube design is simply a straight cylinder, capped with a dome on one end and a diffuser on the other. The dome end is pointed outside, allowing the dome to concentrate and collect light so that it can pass down the tube, and the diffuser diffuses the light into the room so that hot spots do not develop. Light tubes can also be bent and lined with reflective materials to pass the light on, and they can have other innovative features as well.

Light tubes have a number of advantages over skylights, another type of window commonly installed to allow more light into a space. Light tubes are much easier to install, and less likely to contribute to the development of leaks and weak spots in a roof. They are also more secure, as people cannot fit through a light tube.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 11.A:- SOALR LIGHT PIPE

Why should you go for it?

An affordable way of lighting spaces using daylight.

Eco friendly & large coverage area Reduces costs in set-ups where conventional lighting usage is becoming expensive Add-ons like dimmers, softening effect lenses, shades, frost, etc., Easy installation & maintenance Post-sales support Where can it be used?

Offices Factories & warehouses Classrooms, libraries & labs Swimming pools, gyms & stadiums Homes Restaurants

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

SOLAR LIGHT PIPE CALCULATIONS FOR THE NHK:Energy saving calculations is shown in the table.

TABLE 11.C:-YEARLY ELECTRICITY CONSUMPTION

Replacement option

sodium vapour lamps (250W)

mercury lamp (400 w)

mercury lamp ( 70w)

dome lights (400 w )

75 18.75 7

63 25.2 7

84 5.88 7

85 34 7

131 6.3 827 330 272869

176 6.3 1111 330 366736

41 6.3 259 330 85572

238 6.3 1499 330 494802

Total quantity (NOS) Total load in kw Operational Hours Total consumption in KWH unit price Electricity cost per day working days cost of electricity (RS)

* Assuming 7 sunshine hours in a day.

TABLE 11.D:- YEARLY OPERATIONAL & MAINTENANCE CHARGES FOR LIGHTS maintenance (lamp cost=replacement in 2 years) (fixture cost=replacement in 5 years) maintenance charge per light overall maintenance charges for 15 years yearly maintenance charges yearly light maintenance and consumption charges

lamp cost

fixture cost

lamp cost

fixture cost

lamp cost

1000

1100

900

1000

800

6000

3300

5400

3000

4800

fixtu re cost 800 240 0

lamp cost 1000 6000

fixtu re cost 110 0 330 0

9300

7800

7200

9300

697500

491400

604800

790500

46500

32760

40320

52700

319369

399496

125892

547502

* Normally HPSV and MV lamp having a life of 16000hrs. * Lamp fixture having a life span of 5 years

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 11.E:- YEARLY OPERATIONAL & MAINTENANCE CHARGES FOR SOALR LIGHT PIPES Replacement option (LIGHT PIPE ) Unit price Cost of replacement (RS) Maintenance charge Yearly charges yearly light maintenance and consumption charges SPP(in years) SPP(in Months ) savings through solar lights (yearly) Investment on solar lights (yearly)

330 DS 30000 2250000 37500 150000

330 DS 30000 1890000 31500 126000

160 DS 19000 1596000 42000 106400

330 DS 30000 2550000 42500 170000

187500 1 7

157500 0 5

148400 1 14

212500 0 5

1392258 705900

With the help of solar light pipes we can reduce the electricity consumption in day time. This will lead to a saving of 13.92 Lakhs/annum with a payback period of 01.2 years. Solar light pipes are maintenance free, and having a life span of 15-25 years.

Solar light pipes are useful only in daytime. At night we have to go for normal lamps.

A photo sensor (light dimmer) based lighting system automatically switch to solar as well as normal lamps depending upon the lighting needs.

5) SOLAR STREET LIGHTS:Solar street lights are raised light sources which are powered by photovoltaic panels generally mounted on the lighting structure. The photovoltaic panels charge a rechargeable battery, which powers a fluorescent or LED lamp during the night.

Most solar panels turn on and turn off automatically by sensing outdoor light using a light source. Solar streetlights are designed to work throughout the night. Many can stay lit for more than just one night not if sun in not available for a couple of days. Older models included lamps that were not fluorescent or LED. Solar lights installed in windy regions are generally equipped with flat panels to better cope with the winds.

Latest designs use wireless technology and fuzzy control theory for battery management.

The street lights using this technology can operate as a network with each light having the capability of performing on or off the network.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

Types Solar street lights are generally classified into two types.

Standalone solar street lights Standalone solar street lights have photovoltaic panels mounted on the structure. Each street light has its own photovoltaic panels and is independent of the other lamps.

Centrally operated solar street lights In this type, the photovoltaic panels for a group of street lights are mounted separately. All the street lights in a particular group are connected to this central power source.

Advantages • • • • •

Solar street lights are independent of the utility grid. Hence, the operation costs are minimized.

Solar street lights require much less maintenance compared to conventional street lights.

Since external wires are eliminated, risk of accidents is minimized.

This is a nonpolluting source of electricity

Disadvantages • •

Initial investment is higher compared to conventional street lights.

Risk of theft is higher as equipment costs are comparatively higher.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 11.F:- LAMP ELECTRICITY CONSUMPTION ANNUALLY

LAMP TYPE SECTION/LOCAT Sodium ION vapour lamps (150W) 1 street lights 2 OUTSIDE 3 MAIN GATE 4 OUTSIDE OUTSIDE 5 12 LIGHTING TOTAL(QUANTITY) 12 total load in kw 1.8 working days 365 Operational Hours 10 Total consumption in KWH 6570 unit charge 6.3 SR. NO.

consumption charges Total charges

41391 370311.5

Mercur y lamp (250 w)

Mercur y lamp ( 70w)

300 w

Table light 40 w

38 10 18 5

5 1.25

10 0.7

38 11.4

365 365 365 10 10 10 4562.5 2555 41610 6.3 6.3 6.3 28743.7 26214 5 16096.5 3

18 0.954 365 10 3482.1 6.3 21937.23

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

ENERGY AUDIT REPORT OF A Major Japanese Auto Component Manufacturer, MANESAR

CHAPTER 12 AIR HANDLING UNITS

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

12

AIR HANDLING UNITS

12.1 AIR HANDLING UNITS The major heating and cooling costs in a facility can be saved by better insulation of the walls and roof, and reduction of air leakage (infiltration and exfiltration) through the building envelope. Air leakage and excessive heat transfer through an AHU casing causes the fans, pumps and chillers or condensing units to work harder. Company uses AHUs in Coil and STB plants for circulation of air in the work place. The measured parameters of the AHUs may be tabulated as follows:

TABLE 12.A:- AHU PARAMETERS FOR COIL PLANT

Locati on Coil Plant

AHU AHU 1

AHU 2

C.S.Area at inlet (Sqm)

Air Air Tem C.S. Area Velocity R.H. Velocity p of duct at inlet (%) at outlet (C) (mm) (m/s) (m/s)

3050X190 3.3 0 1050X970 1.0

33.3 69

33.9 69

Temp (C)

R.H. (%)

25X45

8.6

33.3

64

25X90

7.5

33.5

63

25X45

6.0

33.6

65

25X45

5.5

33.9

68

25X45

5.2

33.8

63

25X45

6.2

33.7

68

25X45

6.9

33.1

63

25X45

4.5

33.5

60

25X45

5.6

32.9

65

25X45

7.1

32.7

68

25X45

8.3

33.1

68

25X45

9.6

33.4

65

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 12.B:- AHU PARAMETERS FOR STB PLANT

Locati AHU on

C.S.Area Air Tem R.H. C.S. Area at inlet Velocity p (%) of duct (Sqm) at inlet (C) (mm) (m/s)

Air Temp Velocity (C) at outlet (m/s)

R.H. (%)

STB Plant

880X890

8

33.8

64

3.5

33.3

67

AHU 3

0.8

33.3 71

25X45

AHU 4

1300X109 1.5 0

34.9 69

25X45

4.5

33.1

65

AHU 5

Not working

34.5 68

25X45

___

33.5

68

AHU 6

1040X900 2.5

34.5 70

25X45

5.1

33.1

65

25X45

10.1

32.8

67

25X45

8.5

33.7

66

25X45

8.1

32.6

63

25X45

8.3

33.3

68

25X45

9.6

33

68

12.2 OBSERVATIONS:During the audit it was observed that the inlet side of the AHUs were placed directly on the ground and exposed to the surroundings thus causing infiltration effects. In addition to this Air handling units are also susceptible to exfiltration effects which may be caused to poor insulation or improper sealing. Both types of leakage increase the amount of energy required to supply conditioned air to the work place and increased power consumption.

Uncontrolled infiltration results in control of mixed air and increases cooling energy and maintenance costs. Exfiltration increases the fan loading to compensate for loss in air supply.

For every 1% of unconditioned air that leaks into or out of the unit 1% more air must be filtered, cool, and moved. Hence for every 1% an air handling unit leaks it consumes 1% more energy.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

12.3 RECOMMENDATIONS:Hence it is proposed to place the AHU inlet units on a clean surface (preferably plastered and raised platform) to avoid the infiltration effects. For better results the units may be placed in well covered and shaded areas.

A higher value of thermal resistance (R) of the insulation in the walls of an air-handling unit results in lesser heat transfer through the walls. The thermal resistance of insulation is based on two factors: a) The thermal conductivity “K-value” of the insulation b) Thickness of the insulation: R = (1/K) X Thickness.

Fiberglass (K=0.25 btu·in/hr·ft2·°F) or closed-cell foam insulation (K=0.16 btu·in/hr·ft2·°F) may be used for insulation for AHUs. An insulation of 2inch thickness gives the following values of “R” 1. R = (1/0.25) X 2 = 8 (for Fiberglass) 2. R = (1/0.25) X 4 = 16 (for closed-cell foam) Using the values of R so obtained the heat transfer through the casing of the air handling units may be computed as follows: ΔQ = ΔT X A X (1/R) Where: ΔQ = Heat flow, Btu/h ΔT = Temperature difference, F° A = Surface area, ft2 R = Thermal resistance, (hr·ft2·°F)/ Btu For saving energy, consistent casing insulation throughout an air handling is also very important. Reduced thickness or complete lack of insulation in different sections of the AHU can lead to both increased energy consumption, and the formation of condensation on the skin of the unit. The frame must be insulated and sealed and the panel insulation must be consistent throughout the unit.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

ENERGY AUDIT REPORT OF A Major Japanese Auto Component Manufacturer, MANESAR

CHAPTER 13 ENERGY MONITORING SYSTEMS

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

13

ENERGY MONITORING SYSTEMS

13.1 ENERGY MONITORING SYSTEM "DO NOT Estimate when you can calculate, DO NOT Calculate when you can Measure" Monitoring of energy consumption and identification of energy guzzlers creates interest towards reduction of energy consumption and hence saving of energy and money. Energy meters along with appropriate current transformers (CTs) may be installed to measure actual energy consumption after the primary utility energy meter. Sub metering allows monitoring of energy usage for individual sections / departments / individual equipments of higher capacity to account for their actual energy usage and consumption pattern.

The installation of sub meters provides a record of actual energy usage of different sections, departments, or higher capacity equipment which is different from estimation. Sub meters provide an effective means of monitoring, measurement & verification of energy conservation programs. Other benefits include: Accurate monitoring of energy consumption pattern.

Sub meters act as concise energy management tools. Sub metering coupled with building / energy management systems provides detailed energy data giving the users an opportunity to control their energy usage. Automatic Meter Reading (AMR) system may be used which act as a "watchdog" to keep an eye on performance.

Sub metering provides an accurate knowledge and identifies the areas of maximum energy usage.

Sub meters may be installed to measure actual energy consumption after the primary utility energy meter. Sub metering allows monitoring of energy usage for individual sections, departments, individual equipments of higher capacity to account for their actual energy usage and consumption pattern.

13.2 PROPOSED SUB METERING FOR Company: The installation of the sub meters for the different power feeders may be recommended based upon the energy consumption patterns and amount of energy used by different facilities. A summary of the sanctioned load and actual load of different facilities is as follows:

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

TABLE 13.A :- ACTUAL LOAD OF PLANT Sl. No.

Facility

Load (kW)

Actual Load (Amp)

1

STB 1

1283

938

2

STB 2

550

500

3

Coil 1

727

700

4

Coil 2

758

800

5

Coil 3 (proposed)

557

800

3875

3837

Total

The installation of sub meters may be segregated as follows: 1. Facility Wise Sub meters may be installed at the input supply of each facility. The manufacturing plant consists of following major facilities: a) Office/ Administrative Block b) Canteen/ Cafeteria c) Coil Plant d) STB Plant Sub meters may be installed at the input supply side of each of these facilities to identify the maximum energy consuming facility and hours of maximum energy consumption. However, it is proposed to install the sub meters at Office/ Administrative Block, Coil Plant and STB Plant.

2. Section Wise: Within each Section/ Building sub meters may also be installed depending upon the operating processes involved. a) Plant: The major operations carried out in this section are machining, powder coating, phosphate, casting, polishing etc. The facility is operational in two sub-sections: 1. Plant 1 2. Plant 2 3. Plant 3 (Proposed) Hence a sub meter may be installed at these sub- sections.

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Energy Audit of XXXX - A Major Japanese Auto Components Manufacturer , Manesar

b) STB Plant A sub meter may installed at the input supply side of the STB plant may capture and provide a record of the energy consumption pattern of the facility and the loading pattern of the equipments in the facility. The facility is operating in two sub-sections: 1. STB 1 2. STB 2 A sub meter may be installed at each of these sub- sections ant the input supply side for accurately monitoring the pattern and amount of energy consumed.

TABLE 13.B:- SUMMARY OF PROPOSED SITES FOR INSTALLATION OF SUB-METERS

Sr. Facility Wise

Load (in kW)

Installation of sub-meters Section Wise Section

1

Office/ Administrative Block

2

Coil Plant

3

STB Plant

No. of sub-meters required

Load (in kW) 1

2042 kW

1833 kW

Total No. of sub-meters required

Coil 1

727 kW

Coil 2

758 kW

Coil 3*

557 kW

STB 1

1283 kW

STB 2

550 kW

4

3

8

* Proposed Load Hence installation of a total of 8 sub meters is recommended to monitor and measure the pattern of power consumption across various sub units and facilities in the plant.

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