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Energy Audit for cost reduction in Textile Processing Units

Energy Audit for cost reduction in Textile Processing Units. by I.Thanumoorthi Fellow Industrial Energy group The Energy & Resources Institute (TERI) Bangalore Centre Email: ithanu@teri.res.in . Energy Audit Study.

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Energy Audit for cost reduction in Textile Processing Units

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  1. Energy Audit for cost reduction in Textile Processing Units by I.Thanumoorthi Fellow Industrial Energy group The Energy & Resources Institute (TERI) Bangalore Centre Email: ithanu@teri.res.in

  2. Energy Audit Study • The energy audit cover an in-depth study of all the major energy consuming equipment/sections in the plant • It involves exploring practically achievable energy saving measures through a systematic and scientific approach. • Sophisticated portable instruments are used in measurement of various parameters related to the performance assessment of major energy consuming equipments, to realistically estimate the losses and potential for energy savings.

  3. The study mainly focus on improving energy usage efficiency and identifying energy saving opportunities at various equipment and processes. • The analyses would include simple payback calculations where investments are required to be made to implement recommendations, to establish their economic viability. • The study would also provide sizing and sourcing of retrofits and equipment • During the audit, there would be continuous interaction between the audit team and plant personnel to allow for possible concurrent implementation and to ensure that the suggestions made are realistic, practical and implementable.

  4. List of Instruments Used • Sophisticated three Phase power analyzers (Portable load managers) used for electrical systems • To measure, monitor, log, diagnose the electrical parameters with computer interface & software • Hand held three Phase power analyzers to measure loading parameters of motors, MCC and distribution boards • Ultrasonic flow meters to measure water flow rate of pumps and pipe lines • Multifunction kit which measures and records temperature, RH, velocity, pressure, with computer interface and in built printers • Digital pressure indicators to measure the pressures of water and compressed air

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

  6. Digital hygrometers to measure dry bulb temperature and relative humidity • Digital multi-meters • Pressure and draft gauges • Energy monitors • Lux meters to measure illumination intensity • Thermometers for low temperatures such as cooling and chilled water • Stop watch, measuring tape, thickness gauges and others

  7. List of Energy Audit Instruments

  8. ENERGY AUDIT INSTRUMENTS

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

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

  11. Non Contact Tachometer -Stroboscope Application: Speed Measurements Parameters measured: Speed of Rotating Element Make: Testo, Germany No of Sets: 2 Range: 20 to 20000 rpm

  12. Digital temperature & humidity data logger Parameters measured: Dry bulb temperature & humidityMake: Gemini, USA No of Sets:04 Range: -15 to 150oC and 0-99 % RH

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

  14. Non Contact Type Infrared Temperature Indicator Application: Measurement of Surface Temperatures Parameters measured: Surface Temperatures Make: Raytek, USA No of Sets:01 Range: -18 to 870oC

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

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

  17. Combustion Test (Fyrite) Kit Application: Measurement of Flue Gas quantities Parameters measured: Co2 & O2Make: Testo, Germany No of Sets:06 Range: 0 to 20% Co2; 0 to 21% O2

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

  19. 3-Phase Power Analyser Application: Measures all Electrical and Harmonic Parameters Parameters measured: V, A, PF, KW, kVA, kVAr, Hz, first 50 Harmonics Make: Chauvan Arnaoux, France No of Sets: 01 Range: 830V, 3000A

  20. 3-Phase Power Analyser Application: Measures all Electrical and Harmonic Parameters Parameters measured: V, A, PF, KW, kVA, kVAr, Hz, first 50 Harmonics Make: RCC Technologies, Canada No of Sets: 01 Range: 600V, 1000A

  21. 3-Phase Power Analyser Application: Measures all Electrical and Harmonic Parameters Parameters measured: V, A, PF, KW, kVA, kVAr, Hz, Harmonics (first 25th) Make: Dossena, Italy No of Sets: 01Range: 600V, 1000A

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

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

  24. Sample Energy Audit Scope

  25. Electrical Systems • The scope covers the study of electrical system comprising the electrical substations • Transformer loading practices • Transformer load management • Power factor and demand management • Incoming voltage conditions and distribution losses • Detailed analysis would help in arriving at possible measures to improve the same

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

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

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

  29. Detailed study on AHUs • Air flow rate measurements across the AHUs (supply, return and fresh air) • Study of return air, supply air and fresh air components • Measurement of temperature and RH of supply and return air • Estimation of TR generation by AHUs • Speed measurements of AHU fans • Power consumption and other electrical parameters • Major heat loads in air conditioning area • Measurement and recording of temperature and relative humidity over a period of 2-24 hours in major users and critical areas by using microprocessor based tiny tags. • User area analysis to arrive at energy conservation measures • Application potential for various energy saving retrofits

  30. Cooling Water Pumping System • Flow and head measurement of pumps by using sophisticated energy audit equipment and ultra sonic flow meters • Measurement of power parameters • Evaluation of efficiency of pumps • Study of user areas of cooling water with respect to present/design requirement of water and respective heat loads • Measurement of water flow rates to the major users • Evaluation of sankey diagram or water balance of individual cooling towers • Application and matching of drive • Application of efficient flow control methods • Application of retrofit for energy savings

  31. CoolingTowers • Measurement of inlet, outlet water temperatures • Simultaneous measurement of dry and wet bulb temperatures • Evaluation of range and approach there by evaluating the performance with respect to design of cooling towers • Water balance of cooling tower (based on different major inlets and outlets) • Measurement of power parameters of cooling tower fans • Application potential to rationalize water circulation based on requirement • Application potential for energy saving retrofits

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

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

  34. Lighting A detailed audit in lighting system, normally results in considerable energy savings. Illuminance readings with a lux meter would act as a basis for comparative purpose. Application of retrofits such as, • Timer control • Photocell control for street lighting • Installation of voltage controllers for lighting or installation of separate lighting transformer • Application and use of energy efficient lighting • Use of energy efficient lighting

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