ENERGY AUDITING

A Tool to Increase
ENERGY EFFICIENCY
Energy Conservation
By
Anil Palamwar
[email protected]

1
 • “ You cannot Manage,

what you cannot Measure”

(Accurately)
• Jack Welch,

• CEO, General Electric.

2
 Why Energy Audit ???
• What is Audit?
• Details of Inputs and Outputs.
• Output is never equal to Input
• Why?
• There are losses.
• Audit identifies these losses.
• Then we can attempt to reduce them.
• This will improve Efficiency.

3
 Management Support

• It will come when ,

• There is profit increase.

• Environmental Impact.
• Better Safety.
• Mandatory.

4
 Laws of Thermodynamics
The first law, also known as Law of Conservation of
Energy, states that energy cannot be created or
destroyed in an isolated system.
The second law of thermodynamics states that the
entropy of any isolated system always increases.
The third law of thermodynamics states that the
entropy of a system approaches a constant value
as the temperature approaches absolute zero.

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 Entropy
• The word entropy finds its roots in the Greek entropia, which means
"a turning toward" or "transformation."
• The word was used to describe the measurement of disorder by
the German physicist Rudolph Clausius and appeared in English in
1868.
• A common example of entropy is that of ice melting in water.
• The resulting change from formed to free, from ordered to
disordered increases the entropy.
• In thermodynamics it is a thermodynamic quantity representing
the amount of energy in a system that is no longer available for
doing mechanical work.
• HEAT CAN BE CONVERTED INTO WORK BUT ALL THE HEAT
CAN NOT BE CONVERTED INTO WORK.
• ENTROPY REPRESENTS THE HEAT THAT CAN NOT BE
CONVERTED INTO WORK.
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 WHAT IS ENERGY AUDIT (EA)?
 Pool of activities (systematic procedure) focused on
analysis of current energy need and consumption
going out of valid technical standards,
 Analysis of problems (weaknesses and deficiencies),
 EA identifies and in detail quantifies effective
possibilities of energy savings tailored to the object
being analyzed,
 “field-work” economy tool having dynamic character,
often basis for grant financing of projects.

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 WHAT IS THE AIM OF EA?
 Minimize costs for energy
 Minimize operational costs
 Minimize costs for repairs and reconstruction
 Increase quality of environment that contributes to increased
work productivity
In case of EA as Mandatory duty*, (Industrial consumers with
annual energy consumption over 5,5 GWh/year) the procedure of
EA as well as content of the report is determined by Regulation
No. 429/2009.
In case of voluntary EA - It is the content and focus as well as
target given by customer’s requirement.
* Duty – Kartavya.

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 MAIN TOPICS/AREAS OF EA

Subject of energy consumption analysis are the energy

resources consumed in the industrial area, i.e.:
 Electricity
 Natural gas
 Steam
 Coal
 Wood, wood chips/pellets
 Fuels (petrol, oil, propane-butane).....

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 MAIN TOPICS/AREAS OF EA

• Thermal-technical protection of buildings,

• Heating systems
• Hot water preparation,
• ventilation systems and air-conditioning (buildings and
technology)
• electric appliances (administrative and technological incl.
electrical connection, transformation, distribution network, el.
switchboards, el. compensation)
• gas or other energy resources consuming appliances (furnaces,
cleaning devices,..)
• Indoor/outdoor lighting,
• measurement and regulation.
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 WHAT EA OFFERS TO THE CUSTOMER?
 identifies highest achievable potential of energy and costs
savings and its effort,
 points out on often visible as well as hidden
technical/hygienic/safety deficiencies of buildings and
building and production technology equipment,...
 recommends technical parameters of measures,
 calculates investment needs of measures, their asset -
economical, technical, environmental,
 proposes procedure for realisation of measures,
 it is very effective technical, economical and management
tool for investment decision processes going out of
economical modeling,
 it is solid base for effective control of energy consumption
and herewith also operational costs
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 ENERGY AUDIT - PRACTICE
1. Identification of subject of EA
2. Data collection, analysis and evaluation of
current status
3. Proposal of EE and RES measures
4. Economy and environmental evaluation of
measures
5. Proposal of at least two variants for
implementation of measures and
recommendation of optimal variant
6. Drafting of written report from EA
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Bureau of Energy Efficiency
Regulations, 2008.

(the manner and intervals of time for

conduct of energy audit)
Intervals of time for conduct of energy audit
(1) Every designated consumer shall have its first energy audit
conducted, by an accredited energy auditor within 18 months
of the notification issued by the Central Government under
clause (i) of section 14 of the Act.

(2) The interval of time for conduct and completion of subsequent

energy audits shall be three years with effect from the date of
submission of the previous energy audit report by the accredited
energy auditor to the management of the designated consumer.
Manner of energy audit
 (1) Verification of data of energy use
(a)Verify the information submitted to the designated
agency under the Energy Conservation Act (the
form and manner for submission of report on the
status of energy consumption by the designated
consumers- Rules, 2007) for the previous two years
(b)Establish specific energy consumption for the
year referred to in clause (a);
(c) de-segregate the energy consumption data and
identify major energy using equipment, processes
and systems.
 (2) Scope of energy audit
The accredited energy auditor, jointly with the energy

manager of the designated consumer shall-

(a)Develop a scope of work for the conduct of energy audit

required under the Act to ensure adequate coverage in terms

of the share of total energy use that is covered in the energy

audit;

(b) select energy intensive equipment or processes for energy

auditing;
 (2) Scope of energy audit
(c) agree on(i) best practice procedures on measuring
the energy efficiency performance of selected equipment
and on (ii)algorithm to estimate energy performance
and energy savings;
(d)collect energy consumption, and production data for the
equipment and processes covered within the scope of
energy audit,
operating data, and schedule of operation,
non proprietary process flow charts,
production level de-segregated by product, if applicable,
and such other historical data as may be considered
essential by the accredited energy auditor for achieving
the purpose of energy audit.
 
• Energy conservation refers to reducing
energy consumption through using less of an
energy service.
• Energy conservation differs from efficient
energy use, which means using less energy
for an equivalent service.
• For example, driving less is an example of
energy conservation.
• Driving the same amount with a higher mileage
vehicle is an example of energy efficiency.
• Energy conservation and efficiency are both
energy reduction techniques.
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& ENERGY EFFICIENCY

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 • WHAT ENERGY CONSRVATION DOES ???
• Energy conservation reduces energy INPUT,
• It also result in increased environmental
quality,
• National security,
• Personal financial security and higher savings.
• It is at the top of the sustainable energy
hierarchy.
• It also lowers energy costs by preventing
future resource depletion
21
 • I may repeat here.

• “ You cannot Manage,

what you cannot Measure”

(Accurately)
• Jack Welch, CEO, General Electric.
22
PATTERN OF ENERGY CONSUMPTION IN A T.P.S.

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Typical Boiler Losses: Break-up of 11% Loss

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Turbine Cycle Losses : Break-up of 44.7% Loss

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 USEFULNESS OF ENERGY AUDIT IN
THERMAL POWER STATION

 Identifies Wastage of Fuel, Power and Water &

Air Utilization.
 Reduction in cost of generation.
 Increases power generation by efficient
utilization of steam in turbine cycle.
 Reduction in Aux Power Consumption.
 Maintenance planning and availability
improvement.
 Identification and Rectification of errors in on-
line Instruments.

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 USEFULNESS OF ENERGY AUDIT IN
THERMAL POWER STATION
 Leads to reduction in Green House Gases.
 Utilizes specialized services of experienced
Engineers.
 Training of O&M staff for Efficient Control of Unit
Operation.
 Improves competitiveness by reducing unit
generation cost.
 Creates bench mark for all equipment and
systems.
 Fulfils the Mandatory requirement of Energy
Audit of Bureau of Energy Efficiency. (BEE)
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• Note:- TG Cycle Heat rate is considered 2000 K.Cal/KWH
• Coal C.V. = 4000 K.Cal /Kg.
• Landed Cost of Coal = Rs. 2000 per MT.
• Loss increases with machine size.

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29
HP / IP Turbine Efficiency

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Vacuum

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EFFECT ON HEAT RATE FOR PARAMETER
DEVIATION (500MW UNIT)

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33
 CONFORMITY FOR ENERGY AUDITS

 FOLLOW TEST CODES

 ASME PTC -6 For Steam Turbines
 ASME PTC -4.1 for Boilers
 CALIBRATION LAB
 Govt. Accredited i.e. NABL Labs

 TEST SCHEME
 To be Furnished And Approved

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 HEAT LOSS METHOD
BOILER EFFICIENCY = 100 -% AGE LOSSES

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D = Duct Depth (Internal); W = Duct Width (Internal)
Tx= Traverse (x) (Pockets); x =1 to 5 (Width wise)
Nxy= NODExy
Grid measurement for gas sampling and temperature measurement
at 3 to 5 locations on APH inlet & at 3 to 5 locations on APH outlet
ducting as close to APH as possible shall be taken.
Flue gas sampling and temperature measuring probe shall be
inserted at each location and traversed to collect data at these
points in each location. Air temperature at inlet and outlet of APH
shall be measured at two points each in case spare pockets are
available.
Ambient temperature, barometric pressure & RH is measured near
F.D. fans.
Note1 :Utility to provide the test pockets in each of the Air and
Gas path for inserting test instrument.
Note2 :Test instruments shall be used for the above.

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Turbine cycle heat rate.

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41
ENERGY AUDIT SCHEME FOR 210 LMW STEAM TURBINE

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43
PERFORMANCE TEST PROCEDURE FOR PUMPS

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FREQUENCY OF READINGS FOR ACCURATE DATA COLLECTION

• TURBINE CYCLE AUDIT

• Pressure- 5 Minutes
• Temperature- 5 Minutes
• Flow- 1 Minute
• Power- 1 Minute
• Levels- 10 Minutes
• BOILER UNIT AUDIT
• Temperature- 15 to 30 Minutes
• Flue Gas Composition- ½to one hour
• DURATION OF AUDIT TEST
• Turbine Cycle- 2 Hrs
• Boiler Unit- 4 Hrs 45
 TEST INSTRUMENTS ACCURACY, CODE &
CALIBRATION

 Pressure Measuring Instruments:- 0.1Acc.

 Temperatures:- 1/2 DIN Tolerance Or ASME CLASS ‘A’

 Aux. Power Measuring Instruments:- 0.2 % Acc
 Generator Power Measurement:- 0.1 % Acc.

 Flue Gas Analysis:- 0.5 % Acc.

 Data Logger:- 0.03 % Acc.
 Ultrasonic Flow Meter:- 0.5 % Acc.

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 METHODOLOGY FOR ENERGY Audit.

INTER-ACT WITH PLANT ENGINEERS AND OBTAIN

DATA ON:-
 Various equipment problems.
 Present performance level i.e. unit Heat rate, fuel
consumption, DM Water and raw water consumption.
 Plant design data for the main and auxiliary equipment.
 Boiler TG Cycle layout, condensate, feed and steam
pipe line schematics.
 Performance / Guarantee test reports of the tests
carried out on equipment.
 Plant electrical power distribution system.

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SCOPE OF WORK FOR ENERGY AUDIT OF T.P.S.

Energy Audit should cover evaluation of the present performance

level of all major equipment,
Identify the controllable losses and
Suggest remedial measures for improvements with cost benefit
analysis and pay back period.
The detailed scope of work covering the following is given as
under.
•Boilers
•Turbine including regenerative cycle and condenser
•Electrical system
•Fans and Pumps in the above areas
•Insulation
•Balance of Plant including Station auxiliaries power consumption,
Coal Handling plant, ash handling system, DM Plant, Station
Compressed air system, CW system and Air conditioning.
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 Preliminary Energy Audit, Preliminary Checking / Hot walk down

 Check the complete unit steam, condensate and

feed water system along with the functioning of Heat
cycle equipment like Boiler, Condenser Regenerative
system Turbine Cylinders etc. during HOT WALK
DOWN.
 Problem if any, shall be brought to the notice of the
authority for rectification and arranging provisions
for mounting audit instruments during Audit
Preparatory Activities, prior to start of the detailed
EA.

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 DETAILED ENERGY AUDIT
A) Energy Audit Of Boilers
• Performance of Boiler and APH be established by measuring
exit flue gas temperature and its analysis at around nine to
fifteen points in flue gas duct cross section before and after
APH to eliminate effect of gas stratification as per international
practice.
• This is because boiler efficiency differs by around 2.0% by this
method than if the measurements are taken at single point.
Scope will include the following –
• Conduct boiler efficiency measurements as per above test
scheme by indirect method i.e heat loss method, evaluate
Boiler efficiency and identify potential areas for improvements
such as.

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a. Heat loss due to heat in dry flue gas.
b. Heat loss due to moisture in as fired fuel.
c. Heat loss due to moisture from burning of
hydrogen in fuel
d. Heat loss due to moisture in air.
e. Heat loss due to surface radiation and
convection.
f. Heat loss due to formation of carbon monoxide.
g. Heat loss due to combustibles in bottom and fly
ash.
Check up air ingress in boiler from LTSH area
downwards up-to I.D fans.

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Determine Air preheater performance to establish.
a. Gas Side Efficiency–As ratio of gas temperature drop
corrected for no air leakage to temperature heads.
b. Air leakage as percentage of air passing from airside to
gas side.
c. X-Ratio i.e. heat capacity of air passing through the air
heater to the heat capacity of gas passing through the air
heater.
d. Air side and gas side pressure loss across the air heater.
Input power measurement of ID FANS / FD fans, PA fans,
Fan Loading & combined efficiency of fan and motor and
their specific power consumption .
Energy Audit test has to be carried out for four hours by
recording parameters at every 15 minutes and average of
data to be utilized for evaluation. 52
 B) Energy Audit of steam turbine cycle and it auxiliaries

For Energy Audit of steam turbine cycle, all the parameters

are to be measured simultaneously by hooking up the
calibrated instruments to a data logger.
The recording has to be at least for a minimum period of
two hours with each measurement being recorded at an
interval of one minute.
Average of the data so collected to be utilized for
evaluation of the following and suggestions for deficient
areas for improvements to be made.
• 1.Turbine cycle heat rate.
• 2.HP and IP cylinders efficiency
• 3.Turbine pressure survey

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4.TTD & DCA of HP / LP heaters performance
5.Condenser performance i.e. Condenser back
pressure after duly considering the effect of
present C.W inlet temp. C.W flow, heat load on
condenser and air ingress to condenser vis-à-vis
design conditions
•C.W side pressure drop in condenser.
6.Cycle losses
7.Performance of turbine glands
8.Ejector performance

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 For accurate heat rate determination, Turbine inlet flow
and reheat flow need to be evaluated as per international
practice by measuring condensate flow through
measurement of Δp of plant condensate flow orifice after
checking its condition and using evaluated drip and
extraction to de-aerator flows through heat and mass
balance across heaters and de-aerator as per scheme.
 Fall in de-aerator level and HPTV and IPV leak off flow
are also considered.
 Alternately by mass balance across de-aerator if flow
orifices are installed in drip and extraction lines to de-
aerator.
 De-aerator outlet feed flow shall then be taken as the
main steam flow after considering for RH spray tap off
from Boiler feed line.

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 C. Electrical system

1 Transformers
 Assessment of the health & Transformer load loss of GT, UAT,
Station Service transformers etc.
 Identification of possible Energy conservation options in this
area.
2 Motors
 Assessment of Loading condition of HT and LT motors of Boiler
area, Turbine area and Balance of Plant area.
 Assessment of operating parameters like load variation, Power
factor, of HT and LT motors consuming power more than 50
KW.
 Identification of possible Energy conservation options in this
area (with latest techniques).
56
 Capacitors
 Assessment of health of capacitors.
 Plant Lighting system
 Lighting load survey and Assessment of installed
load efficacy.
 Assessment of present lighting controls
 Identification of Energy Conservation
Opportunities.
 (Use of better fixtures, daylight use etc.)

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 D Fans and Pumps Performance

 Performance of fans consuming power more than 50 KW

such as ID, FD, PA fans etc.
• Input power measurement
• Fan loading and combined efficiency of fan and motor
• Specific energy consumption
 Pump performance for BFPs, CEPs, Aux C.W.P & C.W.P.
and pumps consuming power more than 50 KW etc.
• Check Performance of the pumps by comparing the
corrected measured flow at operating speed to design speed
with that of the expected flow derived from the characteristic
curves against the corrected total dynamic head at design
speed.
• Determine Pump efficiency as the ratio of power input to the
pump shaft to hydraulic power.
• Specific power consumption 58
 E Insulation Audit:
A. Walk through survey of Boiler, Turbine
and associated steam piping to identify the
damaged and Hot spot area.
B. Surface temperature measurement at
the damaged and Hot spot area by
infrared temperature indicator.
C. Estimation of heat loss in the hot spots
and damaged insulation area.

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 F Balance Of Plant
 (i) Compressed air system:
 Free Air Delivery i.e. Capacity evaluation of the
Plant and Instrument air compressors.
 Checking volumetric efficiency of compressors.
 Assessment of compressed air leakage quantity.
 Assessment of Energy performance of the air
compressors/ specific power consumption.
 Study of the compressed air network and
suggest suitable energy saving options.

60
(ii)Air conditioning system:
• Performance evaluation of AC Plant w.r.t net
cooling / refrigeration capacity along with heat
load of Air handling unit and energy
requirements at the operating conditions vis-à-
vis design condition to be determined.
(iii) Ash Plant
• Performance of ash Slurry pumps through power
measurement and flow measurement.
• Ash water ratio assessment and
recommendations for optimization in water and
power consumption.

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(iv) Cooling Tower Performance
• It shall include establishment of
• Liquid/Gas ratio
• Fan efficiency as the ratio of shaft power
developed and the work done by the fan
• Cooling Tower Effectiveness, approach and
range.
• Cooling capacity.

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 V Coal Handling Plant

 Input Power measurement of all the key

equipment of the CHP area like:
 Paddle feeders,
 Conveyors,
 Stacker & Re-claimer,
 Wagon Tipplers,
 Crushers,
 Establishment of specific energy performance
indicators.

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 METHODS / OBSERVATION FOR SAVINGS
ENERGY
1) Operation of machine at very low turbine I/L
parameters.
2) Operation of turbine at lower loads.
3) HP and IP turbine cylinder efficiencies are very
low.
4) Main steam and HRH inlet temperature to turbine
very low.
5) RH pressure drop high
6) High quantity of SH Spray.

64
 METHODS / OBSERVATION FOR SAVINGS
ENERGY
7) HP heater no. 5 out of service.
8) Turbine cycle not operating as per design scheme
i.e. Ejector and De-aerator pegging steam from
PRDS header as against normal source from de-
aerator & extraction steam respectively.
9) Passing of turbine cycle drain valves.
10) Make up quantity to cycle is very high which
indicates excessive system steam (heat) loss.
11) TTD & DCA of heaters high

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 METHODS / OBSERVATION FOR
SAVINGS ENERGY
12)Condenser air ingress and dirty tubes.
13)Under loading of motors
14)Excessive air leakage in compressed air
system
15)Faulty insulation
16)Drain valves passing
17)Air ingress to Boiler furnace
18)FAD of compressors low
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 E.A. OF A PLANT - EXAMPLE
Power Plant comprises of 31 Tph, Thermax make,
Bi‐drum, natural circulation, under bed, balanced
draft, atmospheric fluidisation bed combustion,
bottom supported, and membrane
wall construction type of a boiler.
Two sets of Triveni make turbo generator.
1st Turbine is of 4.4 Mw extraction cum
condensing type.
2nd Turbine is of 2.2Mw condensing Type and
other power plant auxiliary and power distribution
system.
67
 Scope of the audit study
The main objective of this exercise is to carry out :-
1) Specific energy consumption.
2) Analysis and make recommendations for reduction
in auxiliary power consumption .
3)Optimize specific fuel consumption .
4) achieve a reduction in recurring expenditure on
energy to
improve business viability by
5) plugging the waste energy and through
improvement in the operational and maintenance
practices of the facility.
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 Major areas covered under energy audit

Study of the
1) Power Plant Boiler and its auxiliaries,
2) Water pumping system,
3) Cooling towers,
4) Motors and
5) Electrical distribution system.

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 Energy Consumption and
Energy Generation of the Plant:

 The average daily power production is 1,30,000

units and monthly power production average is
39 lacs units. Out of which 33.87lacs of unit is
supplied to paper plant and
 4.84 lac units per month is the Auxiliary Power
Consumption.
 Break‐up of this auxiliary power is graphically
represented in following chart.

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71
Monthly Fuel Consumption, Steam & Power
Production and Supply position

72
Summary of Base Line Energy Consumption

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 Major Observations
• Boiler efficiency as per BIS standard 8753. The test
method employed is based on abbreviated efficiency by
loss method (or indirect method) tests, which neglects the
minor losses and heat credits.
• The Boiler efficiency is observed as 80.91% against the 83
±2% design efficiency.
• There is a margin of about 2‐3% improvement by various
measures, which are largely O&M related and R&M
related.
• About 1‐2% improvement is possible by various O&M
related aspects such as providing improved insulation at
furnace, APH, Economiser, manhole doors and by
providing internal lining of fire proof cement on furnace
doors.
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 Major Observations
 For further improvement in efficiency, R&M activities are required.
 Especially in the area of super heater so that design parameters of
super heated steam can be achieved; in this regard detail techno
economic and cost benefit analysis is being carried out in chapter on
turbines.
 Overall boiler water, CBD & Steam water quality & chemistry is
observed within the prescribed limit of OEM.
 However it was observed that parameters like O2, residual hydrazine,
metal contents like copper and iron and conductivity are not being
monitored on regular basis.
 CBD flow rate is observed in the range of 600‐900 Liters/hr at
temperature of 170 °C .
 There is scope for heat recovery through flash steam recovery
system.
 Observed loss due to moisture in fuel is 0.86 % which can be brought
down to a value of 0.20% detail is discussed in 3.8 sections.
75
 Water Pumping System

 Water pumping is vital energy consuming area in

the power plant.
 Major pumps which were studied in this report
are:
 Condensate Extraction pumps
 Boiler feed water pumps
 RO/DM water plant pumps
 Make‐up/transfer pump
 Cooling water circulation pumps
 Raw water pumps
76
 Observations – On Pumps
• Total approximate energy consumption of pumping
system = 10754 Kwh per day
• Total auxiliary power consumption per day = 16200Kwh
• Almost 2/3rd of the auxiliary power is consumed by
water pumping system.
• From the pump performance analysis based on the
actual operating parameters it is observed that :-
• Efficiency of 4.4MW condenser C.W. pumps less than
60% which is on lower side.
• There is no energy and flow meters installed for major
pumps in the power plant

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 Turbine

 The average heat rate of 4.4 MW turbine is

observed as 4700Kcal/KWH
 and for 2.2MW turbine is 2800Kcal/KWH with
turbine cycle efficiency of 18.3% and 30.2%
respectively.
 In absence of performance PGT data it is difficult
to identify deviation from that.
 It is also observed that steam generated in the
boiler is of specification 65kg/cm2 and
Temperature 445°C .
 against the design temperature of 490°C ±5°C.

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 Turbine

 An increase in inlet steam temperature, i.e., an increase in

superheat gives a steady improvement in cycle efficiency
and
 lowers the heat rate due to the increase in inlet temp and
 rising the inlet temperature also reduces the wetness of the
steam in later section of the turbine and improves internal
efficiency of the turbine.
 If the turbine inlet steam temperature is increased to 490°C
±5°C as per the design conditions then
 the heat energy input to the turbine will increase and
corresponding effect in cycle efficiency is @ 5.5% to 6.5%
 reduction in specific steam consumption and turbine
efficiency will improve by of 0.6% to 0.72%.

79
 Cooling Tower

 CT ‐1 range found to be 7.9 and CT‐2 range found to be

11.6 against design of 8
 CT‐ 1&2 approach found to be 10.73 and 8.8 against
design 4 indicates, poor heat transfer.
 CT‐1 &2, effectiveness found to be 42.40% and 56.86%
against design 66.66%, which indicates poor heat
transfer in CT.
 Power measurements indicate under loading on CT fan
motors and power factor is in the range of 0.52 to 0.74.
 This is poor.
 In Cooling Tower ‐1, Fly ash & other foreign particles are
present in reasonable quantity at most of the places like
lowers, frills etc.
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 C.W. Water Chemistry
 Quality of makeup water is very good, here the scaling
chances in the system are very less but corrosion is
taking place aggressively specially in MS pipelines.
 At some places in cooling water piping system corrosion
observed due to which water leakage/seepage is existing.
 The corrosion in the system is suspected due to improper
functioning of corrosion inhibitor treatment.
 As PH in circulating water is around 8.5, Zn as corrosion
inhibitor will not work perfectly at higher PH.
 Zinc will precipitate at higher PH & not inhibit the surfaces
perfectly.
 Alkalinity in the makeup water is very less; treatment
philosophy must be designed to take care of low alkalinity
system to control corrosion. 81
 Electrical system and motors

 There is no sub metering of the transformers and major equipment.

 The cumulative transformation capacity is 8500 KVA for 4.30 MW
(5625 KVA) Alternator.
 The earthing pits for transformer are not adequately spaced.
 The overall power factor of the plant is being maintained at above
0.93 lagging, but
 the p. f. of some of the individual feeders is below the satisfactory
level.
 The motors of Main elevator 1&2, Reject elevator 1, Ash Handling
Motor, and all cooling tower fans are operating at less than 60% of
loading.
 The average total voltage harmonic distortion is 6.45%.
 The average total current harmonic distortion is 9.3%.
 The variation between the terminal voltage and specified voltage is
under 5% which is a healthy sign.
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Summary of recommendations and
energy saving measures:
• Boilers
• Carry out modification and retrofit in super heater section
of Boiler to achieve design parameter of main steam
temperature of 490°C ±5°C. This will result in saving of
8 tons of coal per day.
• And will reduce loading on Boiler by almost 1.8TPH,
• And improvement in boiler insulation will result in
efficiency gain of 1% in boiler.
• The tentative investment for this work will be
approximately INR 25,00,000/‐ and simple payback
period of 58days.

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 Energy Management System,
Energy Auditing and their
implementation techniques for
power industries. Energy
Saving methods with typical
examples and exercises for power
stations

84
• Energy and Fuel saving by installing Flash steam recovery
system for Boiler Continuous Blow down, (CBD) the
tentative saving of fuel through this measure should be
53580 Kgs of coal and,
• Tentative investment for installing this system will be of INR
4,50,000/‐ and simple payback period of 557days.
• About 1‐2% improvement in boiler efficiency is possible
providing improved insulation and re-insulation of damaged
areas around APH, Economiser, manhole doors, and at
various other ducting points need to be redone.
• By providing internal lining of fire proof cement on furnace
doors, cost of this work is already taken in account in first
point.
• The tentative saving from this step will be saving of 500
MT per annum of coal consumption on account of improved
boiler efficiency even if only 1% gain in boiler efficiency is
achieved. Resulting into monetary saving of INR
27,50,000/‐.
85
 Reducing moisture in coal
• Loss due to moisture in fuel is 0.86 % which can be
brought down to a value of 0.20% by employing method
for fuel moisture removal through piping a portion of
flue gases at stack temperature on to the hooded
conveyor of coal feed suing nozzles.
• Tentative investment for the duct and pipe work should
be INR 3,00,000/‐
• Overall boiler efficiency gain of 0.66% will result in
annual saving of
• INR. 19,15,465/‐.
• Hence a simple payback period of 2 months.

86
 Water Pumping System

 By replacing cooling water circulating pumps with the

energy efficient pumps will give recurring energy saving
of 190,895 units per annum if motor is also replaced by
energy efficient class of Motors.
 And 113,880 units if only pump is replaced and existing
motors are utilised.
 Payback period for proposed replacement of pumps in
case‐1 is 87days and in case ‐2 is 146 days.
 Installation of Flow and Energy meters for all major
power consuming pumps and observe flow and power
pattern on regular basis (Shift and Daily basis).
 So that pumps having deviation in specific power
consumption can be identified by plant operation team.
87
 Cooling Tower

• For energy savings and better air flow consider replacement of

Aluminium alloy C.T. fan blades, with energy efficient FRP
hollow fan blade.
• Estimated saving on account of each set of blades replaced will
of 52560 Kwh in case ‐1 when both Fan and motor are replaced.
• And 26280 Kwh in case ‐ 2 when only fan blades are replaced
with utilizing same motor.
• The investment for each set of blades is of INR 85,000/ ‐ and
simple payback period on account of saving through reduced
recurring energy consumption, for each set of fan blades
replaced is 4months in case ‐1 when FRP Hollow Fan blades
are installed with new high efficiency motor
• And 8 months in case‐2 if only new set of FRP Hollow Fan
blades are installed with existing motor.

88
• Cooling tower fills needs to be checked for fill
chocking and poor water distribution. Equal and
• uniform water flow to each cell to be ensured for
proper distribution of water as this will improve
• effectiveness of Cooling Tower. Improved CT
performance will allow to stop one CT fan during cold
• weather conditions.
• Monitor approach, effectiveness and cooling capacity
for continuous optimisation efforts, as per seasonal
variations as well as load side variations.

89
 Electrical system and Motors

 The earthing pits provided for transformer are also not

adequately spaced.
 This causes the earthing currents to either keep
circulating in the system or is injected into the ground at
various stages thus increasing heat losses.
 Due to this a major amount of energy which is produced
is not recorded in
 the meters and a low efficiency is recorded.
 The proper earthing also enhances the protection relays
to function as per the design parameters and will
improve system safety and reliability.

90
 Electrical system and Motors

 The installed capacitors need to be tested and relocated

and some new capacitors need to added in the system so
that the plant transmission and distribution losses are
reduced.
 The expected annual savings from this measure should be
approximately INR 36,44,160/‐.
 The tentative investment required for purchase of
capacitors of 750Kvar is INR 3,59,950/‐ and simple
payback period of 1.2 months.
 12 motors are recommended to be changed with proper
rating of energy efficient motors as suggested in following
table:

91
92
 Investment & Payback

The capital investment required for

replacing the above mentioned motors is
INR 6,77,700/‐
The cumulative tentative annual saving in
energy is 68,1,959 KWH
The cumulative monetary saving should
be INR 34, 09,797/‐
The cumulative simple payback period is 3
months.
93
Summary Recommendations

94
INTRODUCTION TO ENERGY AUDIT AND
METHODOLOGY
 Audit Objective and purpose of Energy Audit
 The main objective is to carry out specific energy
consumption analysis.
 and make recommendations for reduction in auxiliary
power, optimize specific fuel consumption.
 and to achieve a reduction in recurring expenditure on
energy to improve business viability by plugging the
waste energy
 and through improvement in the operational and
maintenance practices of the facility.

95
 Scope of Work
• The aim and scope of audit is to quantify the fuel and
energy consumption of the facility.
• It further aims to identify the loss avenues in the
systems
• and establish total and specific steam generation,
• boiler efficiency monitoring,
• load balancing,
• run‐ability optimization and achieving best possible fuel
to steam ratio.
• The audit will thus cover parameter detection of:

96
 Parameters Detection of :--
 1. Feed water inlet flow.
 2. Blow Down flow estimation (If possible).
 3. Inlet air temperature.
 4. Temperature of exhaust to stack.
 5. Feed water quality.
 6. Cycle of concentration
 7. Variance in phase loading of motors ACB’s and
Transformer
 8. Operation of motors
 9. Losses due to poor capacitor behaviour or installation
faults.
 10. Load curves.

97
 Expected End Result of E.A.
 The completion of audit will achieve identification
of all types of boiler losses
 and possible ECOs (Energy Conservation
Opportunities).
 It will highlight the efficiency improvement
possibilities in motors,
 capacitors
 and voltage variations.

98
 Methodology for E.A.
 Monitoring of energy related parameters of various equipment
using sophisticated and portable energy audit instruments.
 Online measurement of operating data with various
instruments.
 Collection of details regarding electricity consumption in the
past, maximum demand and power factor.
 Discussion with concerned officials to take note of energy
conservation activities already undertaken, if any.
 Critical analysis of data collected during field visit.
 Identification of opportunities having possible energy
conservation potential and quantification of energy losses.
 Identification of suitable measures for reducing energy
consumption.
 Preparation of financial analysis for recommended measures.
99
 Details of the Instruments used

 Following major instruments were used during the field

study and data collection
 1. Power and Harmonics Analyser
 2. Ultrasonic Flow Analyser
 3. Contact type and non‐contact type infrared temperature
sensors
 4. Anemometer
 5. Lux meter
 6. Oxygen Probe and Flue gas analyser
 7. Distance meter
 8. Contact type digital tachometer

100
 Description of the Plant

• Magnum Ventures Ltd. is a Paper Plant.

• The Power Plant has following major Plant and Apparatus:
• Boiler: Thermax make, Bi‐drum, natural circulation, under bed,
balanced draft, atmospheric , fluidised bed , bottom supported,
and membrane wall construction type of a boiler.
• This boiler is normally operated @ 35‐37 Tph.
• Turbine: Two sets of turbo generator both of Triveni make. 1st
Turbine is of 4.4 Mw, extraction cum condensing type and
• 2nd Turbine is of 2.2Mw condensing Type.
• Cooling Tower: 2 Nos of Paharpur make 1200 m3/hr flow rate,
induced draft, cross flow type of cooling towers.
• Coal handling system: Power Plant receives coal through road
and coal is stored in yard. The process flow diagram is
represented as under: 101
C.H.P. Schematic

102
Energy Consumption Profile and Energy
Management System

103
Energy Management Action Plan

104
105
 Operational efficiency of the boiler

 Boiler Efficiency calculated by Loss Method as per BIS

standard 8753. The major losses covered are:
 Heat loss due to dry flue gas losses.
 Heat loss due to moisture in fuel
 Heat loss due to moisture in air.
 Heat loss due to hydrogen in fuel
 Heat loss due to un‐burnt carbon in fly ash and bottom ash.
 Heat loss due to radiation to be assumed depending on
emissivity of surface
 Unaccounted losses as declared by the boiler supplier

106
 Turbine Efficiency evaluation

• Heat Rate calculation by standard formula.

+ -
HEAT
RATE =

107
 Impact of inlet steam temperature on
operating conditions and cycle efficiency

108
Effect of Steam inlet pressure on Steam
Consumption and Efficiency

109
Effect of Steam inlet temperature

110
Effect of exhaust pressure/ vacuum

111
 Conclusion:

Cost benefit analysis for suggested modification to achieve

desired steam temperature.

112
CONDENSER COOLING-
Cooling tower specifications

113
Cooling Tower Performance

114
 Important Parameters of Cooling Tower
 Range ‐ is the difference between the cooling tower water
inlet and outlet temperature.
 Approach ‐ is the difference between the cooling tower outlet
cold water temperature and ambient wet bulb temperature.
 Although, both range and approach should be monitored, the
'Approach' is a better indicator of cooling tower performance.
 Cooling tower effectiveness (in percentage)‐ is the ratio of
range, to the ideal range, i.e., difference between cooling
water inlet temperature and ambient wet bulb temperature.
 Cooling capacity ‐ is the heat rejected in K.Cal/hr , given as
product of mass flow rate of water, specific heat and
temperature difference.
 i.e. Q x Sp.Heat x Δ T.
115
Cooling tower operating Data
and efficiency calculations

116
Water Chemistry of Cooling Tower
Make‐up and Circulating Water

Make-Up Circulating
Parameters
Water Water
pH 7 8.5
P-Alkalinity Nil 14
M-Alkalinity 12 70
Chlorides 54 504
TDS 102 1217
Total Hardness 8 40
117
 Observations:
 Cooling tower # 1 has lower effectiveness compared to
Cooling Tower #2.
 CT # 1 range is 7.9 and CT‐2 range is 11.6 against design of 8.
 CT‐ 1&2 approach is 10.73 and 8.8 against design 4 ;indicates,
low ambient temp and poor heat transfer.
 CT‐1 &2, effectiveness is 42.40% and 56.86% against design
66.66%. Which indicates poor heat transfer in CT
 Power measurement indicate under loading on CT fan motors
and power factor is in the range of 0.52 to 0.74. This is poor.
 In Cooling Tower ‐1, Fly ash & other foreign particles are
present in large quantity at most of the places like louvers,
frills etc.

118
 Makeup water quality is very good, here the scaling
chances in the system are very less but corrosion is
taking place aggressively specially in MS pipelines.
 At some places in cooling water piping system
corrosion observed due to which water
leakage/seepage is existing.
 As metal used in the cooling system are MS &
Admiralty Brass so corrosion due to Chloride is not
possible as it attacks only SS metal.
 Also the Chloride level in circulating water is not very
high for any trouble, with such metals (MS &AB)
system may be run up-to 2000ppm chloride level in
the circulating water.
119
 Conclusion and recommendation
 For energy savings and better air flow consider
replacement of Aluminium alloy fan blades, with
energy efficient FRP hollow fan blade.
 Cooling tower fills needs to be checked for fill
chocking and poor water distribution. Equal and
uniform water flow to each cell to be ensured for
proper distribution of water.
 This will improve effectiveness of CT. Improved
CT performance will allow to stop one CT fan
during cold weather conditions.
 Periodically clean plugged cooling tower nozzle.
120
 Conclusion and recommendation
 Monitor approach, effectiveness and cooling capacity for
continuous optimisation efforts, as per seasonal variations
as well as load side variations.
 A good chemical treatment with proper monitoring of the
system will overcome all the
 water related problems in the system.
 Corrosion rack must be installed on monthly basis to check
corrosion rate (mpy) in the system.
 Also Fly ash & other foreign particles adding
microbiological load to the cooling system , a side stream
filter may be installed to remove suspended particles from
cooling towers along with proper bio‐dispersant dosing.

121
Cost benefit analysis with proposed modification of
cooling tower fans blade material

122
ELECTRICAL SYSTEM -Transformers

123
 OBSERVATION & RECOMMENDATION -
Transformers
 1. There is no sub metering of the transformers.
 2. The cumulative transformation capacity is 8500 KVA for 4300 MW
(5625 KVA) Alternator.
 3. The earthing pits are not adequately spaced.
 1. Recommended to install a sub meter on each of the transformer
for monitoring the loading of the transformer.
 2. The earthing pits provided are also not adequately spaced. This
causes the earthing currents to either keep circulating in the system
or is injected into the ground at various stages thus increasing heat
losses. Due to this a major amount of energy which is produced is
not recorded in the meters and a low efficiency is recorded.
 3. The proper earthing also enhances the protection relays to
function as per the design parameters and will improve system
safety and reliability.

124
 POWER FACTOR ANALYSIS

• Overall pf is 0.93 which is good. But pf of some feeders is very

low.

125
 OBSERVATION

 1. The installed power factor compensating

capacitors through ensures an overall good PF,
 since they are concentrated in few panels therefore
the lagging currents are circulated in the whole
distribution and transmission system.
 Transmission losses of plant are the losses occurring
in main transformers, H.T. Cables, Switch Gear etc. =
3 % (Of total yearly Consumption).
 Distribution losses of plant are the losses occurring in
main L.T. Cables, L.T. Switch Gear, L.T. Bus ‐Bar etc. = 7
% (Of total yearly Consumption)
126
 LOADING PATTERNS OF MOTORS
 The motors are designed to run at maximum efficiency
when they are loaded more than 60%.
 The power factor of the motors also decreases
drastically when the motor is under loaded.
 Similarly, in the over loaded condition the efficiency,
power factor, heating i.e. overall performance of the
motor decreases.
 Therefore, it is necessary to evaluate the motor
performance.
 This helps in improving the efficiency and
 Helps in the right selection of the motor capacity.

127
Loading Pattern of Motors

128
List of motors
operating at less than 60% loading

129
 RECOMMENDATION-Motors
• Following motors should be replaced with lower capacity
motors.

130
131
 Motor Replacement (Poor Efficiency)

• Following motors should be replaced with high efficiency

motors.

132
 Motor Replacement – Cost & Pay back period.

The total investment to replace the above

mentioned motors is Rs. 6, 77,700
The cumulative annual saving in energy is
6,81,959 KWH
The cumulative monetary saving is
Rs. 34, 09,797
The cumulative simple pay back period is
3 months

133
 Harmonic Measurement of Main feeders

OBSERVATION
1. The average total voltage harmonic distortion is 6.45%.
2. The average total current harmonic distortion is 9.3%.
134
 Harmonics Measurement of Motors

1. The average total voltage harmonic distortion is 5.34%.

2. The average total current harmonic distortion is 13.59%.135
 POWER SUPPLY QUALITY
• The BIS standard specifies that a motor should
be capable of delivering its rated output with a
voltage variation of 6%.

• The continuous voltage variation causes motors

to heat up and thus triggering the deterioration
of insulation.

• The Power Factor, Slip and torque of the motor

is also affected by the voltage variation.

136
Power supply quality and Voltage Variation

137
 What is Harmonics:-
 While designing any A.C. machine, it is assumed that voltage
and current wave from at the output terminals of A. C.
machines is sinusoidal and consists of only one frequency
which is called fundamental frequency or 1st harmonics.
 and such sinusoidal wave from does not contain harmonics of
other frequencies.
 Due to non linear system load such as thyristorised control,
variable frequency drive and D. C. motor, harmonics are
generated in the supply system, and hence original
sinusoidal wave form is disturbed and wave form becomes
complex and non sinusoidal in nature generating 2nd, 3rd, 4th
and so on frequencies of the fundamental frequency.
 The above phenomenon is shown in the below given diagram
138
 Harmonic Wave Form
• The complex wave form is made up of various harmonics as
shown below: -

139
 ILL Effects of Harmonics
 The effects of current harmonics:‐
1. Increased heating of winding.
2. Inductive interference with communication
circuits.
3. Increased iron losses.
 The effects of voltage harmonics:-
a) Increased heating of winding.
b). Capacitive interference with communication
circuits.
c). Production of large resonant voltages.

140
 How Harmonics are formed
• Major Causes of Harmonics
• Devices that draw non‐sinusoidal currents when a sinusoidal
voltage is applied
• create harmonics. Some of these devices are listed below:
• Electronic Switching Power Converters
• 1. Computers, UPS, Solid‐state rectifiers.
• 2. Electronic process control equipment.
• 3. Electronic Lightning Ballasts.
• 4. Reduced voltage motor controllers.
• Arcing Devices
• 1. Discharge lighting.
• 2. Arc furnaces, welding equipment.

141
 How Harmonics are formed
Ferromagnetic devices.
1. Transformers operating near saturation level.
2. Magnetic ballasts.
3. Induction heating equipment chokes.
Appliances
1. TV sets air conditioners, washing machines, and
microwave ovens.
2. Fax machines, photocopiers, and printers.

142
 Problems created by Harmonics
Higher RMS current and voltage in the system are caused by harmonic
currents, which can result in any of the problems listed below:
1. Blinking of Incandescent Lights‐ Transformer Saturation.
2. Capacitor Failure‐ Harmonic Resonance.
3. Circuit Breakers Tripping‐ Inductive Heating and Overload.
4. Electronic Equipment Shutting down‐ Voltage Distortion.
5. Flickering of Fluorescent lights‐ Transformer Saturation.
6. Fuses Blowing for no apparent reason‐ Inductive heating and Overload.
7. Motor Failures (overheating) – Voltage Drop.
8. Conductor Failure‐ Inductive heating.
9. Neutral conductor and terminal failures – Additive Triplen currents.
10. Electromagnetic Load Failures – Inductive heating.
11. Overheating of Metal Enclosures‐ Inductive heating.
12. Power Interference on voice communication‐ harmonic noise.
13. Transformer failures‐ Inductive Heating.
143
 Overcoming Harmonics
 Tuned Harmonics filters consisting of a capacitor
bank and reactor in series are designed and
adopted for suppressing harmonics .
 These Filters provide low impedance path for
harmonic component.
 The harmonic filters connected suitably near the
equipment generating harmonics help to reduce
THD to acceptable limits.

144
 Motor Efficiency Test (No Load Method)

• Motor Specifications
• Rated power = 7.5 kW/10 HP
• Voltage = 415 Volt
• Current = 17 Amps
• Speed = 935 RPM
• Connection = Delta
• No load test Data
• Voltage, V = 424 Volts
• Current, I = 5.9 Amps
• Frequency, F = 50 Hz
• Stator phase resistance at 20 °C = 2.5 Ohms
• No load power, Pnl = 156 Watts

145
Stator Resistance at 120 deg.C.

146
Motor ή

147
 Economics of Motor Efficiency
 This clearly shows that Old and many times rewind
Motors have very low efficiency as compared to new
Energy efficient Motor.
 New Energy Efficient Motors have efficiency up to 95%.
 Avoid the use of old rewound motors or motor with stated
efficiency of less than 90% in future.
 Above motors have total measured running load as 463.75
KW and average efficiency of 83.6%.
 Replacement of motors can bring the efficiency of 95% on
running load thus improving efficiency by 11.4% and
subsequently reducing the load by 52.86 KW.
 This will result in savings of 52.86 x 20 hrs per day x 30
days = 31716 KWH per month = 31716 x 4.19 = INR
1,32,890 per month
148
Power Flow & Losses in Induction Motor.

149
Motor Characteristics

150
 Electrical Distribution Correction
Measures to improve power quality and reduce electrical losses
1. Maintain voltage level close to nameplate level, with a maximum
deviation of 5% (at 5% under voltage, copper loss increases by
10%).
2. Minimize phase imbalance within a tolerance of 1%.
Deviation of phase voltage will result in increased winding temp.
3. Maintain high power factor to reduce distribution losses.
4. Avoid excessive harmonic content in the power supply system,
Increased harmonic content will increase motor temperature.
5. Use oversize distribution cable in the new installation to reduce
copper losses.
This will also help in reducing voltage drop during starting and
running and minimizing the motor losses.
151
 Motor Efficiency Improvement
1.If motor is running at partial load then convert motor
from delta to star connection. This will improve motor
efficiency.
2. Replace rewound induction motor (with reduced
efficiency) with new energy efficient motor.
3. If process demands oversized motor then use of VFD
may be explored to save energy. This is also applicable
in case of varying load duty cycle motor application.
4. Control the motor temperature.
5. This will reduce copper losses and increase motor
life.
152
 Better System Matching

Measures available are:

1. Use an on/off control system using timer, PLCs,
etc. to provide motor power only when required.
2. Size the motor to avoid inefficient low load
operation.
3. Motor should run at 65% to 95% of its
nameplate rating to get maximum efficiency.

153
 Driven Load and Process Optimization
Measures available to optimize the process and its
operation are:
1. Change or reconfigure the process or application so
that less input power is required.
2. Downsize the over sized pumps, fans, compressors or
other driven loads if possible.
3. Install more efficient mechanical subsystems.
4.Check that coupling, gearbox fan or pump must be
energy efficient.

154
 Miscellaneous Measures to Improve Motor Efficiency

1. Proper lubrication : will minimize wear on moving parts.

Lubrication must be on a regular schedule to ensure wear is
avoided. Once it occurs, no lubricant can undo it. It is crucial that the
correct lubricant is applied in the right quantities.
2. Correct shaft alignment: It ensures smooth, efficient transmission
of power from the motor to the load. Incorrect alignment puts strain
on bearings and shafts, shortening their lives and reducing system
efficiency. Shafts should be parallel and directly in line with each
other. It is necessary to use precision instruments to achieve this.
Shaft alignment is an important part of installation and should be
checked at regular intervals.
3. Proper alignment: Belts and pulleys must be properly aligned and
tensioned when they are installed, and regularly inspected to ensure
alignment and tension stay within tolerances.
155
Abnormal wear patterns on belts indicate specific
problems that may require correction.
Loose bests may squeal and will slip on the pulleys,
generating heat.
Correctly tensioned pulleys run cool.
Excess tension strains bearings and shafts,
shortening their lives.
4. Painting of motor: Avoid painting motor housing
because paint acts as insulation, increasing operating
temperatures and shortening the lives of motors.
One coat of paint has little effect, but paint build-up
accumulated over years may have a significant effect.

156
IT IS FINALLY OVER
THANKS

157