ENERGY AUDITING

1. FUNDED BY THE EUROPEAN COMMISSION Sustainable and Cleaner Production in the ManufacturingIndustries of Pakistan SCI-Pak Mar 2009- Feb 2012 ENERGY AUDITING

2. Introduction Energy auditing is attractive due to - Present day by day increase in energy price - Energy bills consume large part of the income - Energy cost is the substantial part of the production cost Benefits - Energy cost reduction (10-30%) - Reduction in environmental pollution

3. Introduction The Energy Audit is one of the first tasks to be performed in the accomplishment of an effective energy cost reduction program. An energy audit consists of: - Detailed examination of how a facility uses energy - Calculation of what the facility pays for that energy - Identification of energy wastage areas - Recommendations for changes in operating practices or energy consuming equipment that will cost effectively save money on energy bills

4. Introduction Energy audit can also be called: Energy Survey Energy Analysis “Audit” has a negative connotation, so it can be avoided by calling above names. The energy audit is a positive experience with significant benefits to the business or individual, and the term “audit” should be avoided if it clearly produces a negative image in the mind of particular business or individual.

5. Types of Energy Audits - Industrial Audits - Commercial Audits - Residential Audits

6. Basic Components of an Energy Audit Following are the basic steps of an energy audit: - Collection of information about the facility’s operation and about its past record of utility bills or energy consumption (Water, electricity, gas, diesel etc) - Analysis of utility consumption data to get a picture of how the facility uses or wastes energy. This step helps auditor to prioritize the areas of his examination during energy survey. - Identification of energy efficiency measures or technologies - Evaluation of these measures to determine their benefits and their cost effectiveness. Economic comparison is made to rank the various measures - Action plan is created where certain energy efficiency measures are selected for implementation

7. Auditor's Toolbox It is essential that the auditor should measure certain parameters to ascertain energy consumption or wastages. The amount of equipment needed depends on the type of energy consuming equipment used at the facility and on the range of potential energy efficiency measures that might be considered. Common Tools for Energy Audit Following are the common tools used during energy audit:

8. Common Tools for Energy Audit Following are the common tools used during energy audit: - Measuring tape - Light meter - Thermometer (Common digital and Infrared) - Energy analyzer (Volt, watt, ampere, power factor, harmonics) - Combustion analyzer - Air flow measurement devices (Anemometer) - Hygrometer (Humidity measurement) - Vibration analysis gear - Safety equipment (helmet, goggles, dust masks, safety shoes, gloves etc) - Thermal image camera - Ultrasonic water flow meter

9. Preparation for the Audit - Collection of preliminary data of the facility (Annual production & energy data, physical and operational information - Analysis of the data (identify audit focus areas) - Analysis of monthly bills for gas and electricity and monthly consumption of diesel, coal etc (Amount and cost analysis)

10. Preparation for the Audit This data should then be put into tabular and graphical form to see what kind of patterns or problems appear from the tables or graphs. Any anomaly in the pattern of energy uses raises the possibility for some significant energy or cost savings by identifying and controlling that anomalous behavior. Sometimes an anomaly on the graph or in the table reflects an error in billing, but generally the deviation shows that some activity is going on that has been not noticed, or is not completely understood by the customer.

11. Electricity Vs ProductionGas Vs Electricity GenerationGraphical Presentation

12. Rate Structure To fully understand the cost of energy, the auditor must determine the rate structure under which that energy use is billed. Energy bill comprises of various items (taxes, penalties etc) that vary from month to month. Few customers or businesses really understand the various rate structures that control the cost of the energy they consume. Auditor can help here because the customer must know the basis for the costs in order to control them successfully. Example of an electricity bill Click

13. Physical and Operational Data for the Facility The auditor must gather information on factors likely to affect energy use in the facility. Geographic location, facility layout, operating hours and equipment can all influence energy use. Geographic Location Geographic location of the facility should be noted. Facility Layout Thefacility layout or plan should be obtained, and reviewed to determine the facility size, floor plan, and construction features such as wall and roof material and insulation levels. These plans should be updated not the old ones. Operating Hours Operating hours of the facility should also be obtained. Is there only a single shift? Are there two shifts? Three? Knowing the operating hours in advance allows some determination as to whether some

14. Physical and Operational Data for the Facility Loads could be shifted to off peak times. Adding a second shift can often be cost effective from an energy cost view, since the demand charge can then be spread over a greater amount of kWh. Equipment List Finally auditor should get an equipment list for the facility and review it before conducting the audit. All large pieces of energy consuming equipment such as heaters, air conditioners, water heaters and specific process related equipment should be identified. This list, together with data on operational uses of the equipment allows a good understanding of the major energy consuming tasks or equipment at the facility. As a general rule, the largest energy and cost activities should be examined first to see what savings could be achieved. The greater effort should be devoted to the energy efficiency measures which show greatest savings, and the least effort to those with the smallest savings potential. Geographic location of the facility should be noted. Facility Layout Thefacility layout or plan should be obtained, and reviewed to determine the facility size, floor plan, and construction features such as wall and roof material and insulation levels. These plans should be updated not the old ones. Operating Hours Operating hours of the facility should also be obtained. Is there only a single shift? Are there two shifts? Three? Knowing the operating hours in advance allows some determination as to whether some

15. Safety Considerations Safety is a critical part of any energy audit. The auditor or the auditing team should be thoroughly briefed on safety equipment and procedures, and should never place themselves in a position where they could injure themselves or other people at the facility. Adequate safety equipment should be worn at all appropriate times. Auditors should be extremely careful making any measurements on electrical systems, or on high temperature devices such ass boilers, heaters, cookers etc. Electrical gloves should be worn as appropriate. Auditor should be careful when examining any operating piece of equipment, especially those with open drive shafts, belts or gears, or any form of rotating machinery. The equipment operator or supervisor should be notified that the auditor is going to look at that piece of equipment and might need to get information from some part of the devices. The auditor should never approach the equipment without operator.

16. Conducting the Audit Visit Once the information on energy bills, facility equipment and facility operation has been obtained, the audit equipment can be gathered up, and the actual visit to the facility can be made. Introductory Meeting The audit person or team should meet with the facility manager and the maintenance supervisor and briefly discuss the purpose of the audit and indicate the kind of information that is to be obtained during the visit to the facility.

17. Conducting the Audit Visit Walk Through Tour A walk through tour of the facility or plant tour should be conducted by the facility/plant manager, and should be arranged so the auditor or audit team can see the major operational and equipment features of the facility. The main purpose of the walk through tour is to obtain general information. More specific information should be obtained from the maintenance and operational people after the tour. This tour is essential to have the feel of the facility. Audit Interviews Getting the correct information on facility equipment and operation is important if the audit is going to be most successful in identifying ways to save money on energy bills. The company philosophy towards investments, the impetus behind requesting the audit, and the expectations from the audit can be determined by interviewing the general manager, chief operating officer, or other executives.

18. Conducting the Audit Visit The facility manager or plant manager is one person that should have access to much of the operational data on the facility, and a file of data on facility equipment. The finance officer can provide any necessary financial records (e.g., utility bills for electricity and gas, expenditures for maintenance and repair, etc.) The auditor must also interview the floor supervisors and equipment operators to understand the process problems. Line or area supervisors usually have the best information on times their equipment is used. The maintenance supervisor is often the primary person to talk to about types of lighting, sizes of motors, sizes of air conditioners and space heaters, and electrical loads of specialized process equipment. Finally , the maintenance staff must be interviewed to find the equipment and performance problems. Auditor should write down these people’s names, job functions and telephone numbers, since it is frequently necessary to get information after survey.

19. Conducting the Audit Visit Getting Detailed Data Following the facility or plant tour, the auditor or audit team should acquire the detailed data on facility equipment and operation that will lead to identifying the significant energy conservation opportunities that may be appropriate for this facility.

20. Conducting the Audit Visit Preliminary Identification of Energy Conservation Opportunities As the audit is being conducted, the auditor should take notes on potential energy conservation opportunities that are evident. Identifying opportunities requires a good knowledge of the available energy efficiency technologies that can accomplish the same job with less energy and less cost. Identifying any potential opportunity during the walk through will make it easier later on to analyze the data and to determine the final opportunities recommendations.

21. Post Audit Analysis Following the audit visit to the facility, the data collected should be examined, organized and reviewed for completeness. Any missing data item should be obtained from the facility personnel or from a re-visit to the facility. The preliminary energy conservation opportunities identified during the audit visit should now be reviewed, and actual analysis of the equipment or operational change should be conducted. This involves determining the costs and benefits of the potential opportunities, and making a judgment on the cost effectiveness of the potential opportunities. Cost effectiveness involves a judgment decision that is viewed differently by different people and different companies. Often simple payback period is used to measure cost effectiveness, and most facilities want payback of not more than two years or less.

22. Energy Audit Report The next step in the energy audit process is to prepare a report which details the final results and recommendations. The length and detail of this report will vary depending on the type of facility audited. Energy Audit Report Format Executive Summary A brief summary of recommendations and cost savings Table of Contents Introduction Purpose of the energy audit Facility Description Product or service, and material flow, size, construction, facility layout and hours of operation, equipment list with specification

23. Energy Audit Report Energy Bill Analysis Utility rate structures, tables and graphs of energy consumptions and costs, discussion of energy costs and energy bills Energy Conservation Opportunities Listing of potential energy conservation opportunities, cost and savings analysis, economic evaluation Action Plan Recommended opportunities and an implementation schedule, designation of an energy monitor and ongoing program Conclusion Additional comments not otherwise covered Reference: Energy Management Handbook, Sixth Edition by Wayne C. Turner, 2007

24. CASE STUDY Energy Audit of ABC Textile Industry

25. Case Study Introduction of the Industry Medium sized textile processing industry. Woven grey fabric is processed to produce dyed and printed finished fabric. Production started in 1987. Involved in local and export business (indirectly through clients). Planning to shift their business from local to export. Member industry of APTPMA. Mill operates 300 days a year (24 hours, three shifts). Total 150 workers. Energy Sources Electricity: GESCO is the main source of electricity. Standby diesel fuel based generator of 550kVA. Its running frequency is 5-6 hours a day and it consumes 70-80 liters diesel per hour. Annual electricity consumption from generator = 540,000 kWh from GESCO = 1,798,400 kWh

26. Case Study Production Vs Electricity Not consistent. Average consumption of electricity per meter is 0.14 kWh. Jul (0.18 kWh), Mar (0.21 kWh)-Low production, high electricity consumption. Oct (0.09 kWh)-High production, low electricity consumption.

27. Case Study Natural Gas Source: SNGPL It is consumed in: - Steam boilers (3) - Therm oil heater (1) - Singeing machine (1) - Stenters (3) Annual consumption of natural gas is 3,938,449 m3. Not consistent. Average consumption of electricity per meter is 0.14 kWh. Jul (0.18 kWh), Mar (0.21 kWh)-Low production, high electricity consumption. Oct (0.09 kWh)-High production, low electricity consumption.

28. Case Study Production Vs Natural Gas Not consistent. Average consumption of gas per meter is 0.25 m3. Nov (0.33 m3), Mar (0.37 m3), gas consumption is higher. May (0.19 m3), quite low.

29. Case Study Monitoring Only one main gas meter to measure overall gas consumption. No separate meters to monitor gas consumption in boilers, singeing machine, therm oil heater and stenters. Steam Direct and indirect use. Annual steam consumption is 27,000 tons. No water and steam flow meters. SB= Standby

30. Case Study Annual Energy purchase Cost wise natural gas is 70% and electricity 30%

31. Case Study Specific Utility Consumption Annual production= 2,269,478 kg

32. Case Study Specific Energy Consumption Energy contribution= 94% natural gas CO2= 1.8 kg/m3 gas, 0.206 kg/kWh

33. Case Study Electrical Energy Issues - Improperly maintained electric panels - Loose connections - Voltage drops - Low power factor at motors Oversized motors

34. Case Study Electrical Energy Issues - Old inefficient motors - Motors burning issue - Frequent rewinding of motors - No preventive maintenance 40W tube lights with conventional magnetic ballast

35. Case Study Compressed Air System Issues - Some pressure gauges are out of order. Pressure setting is not optimum. - Air leakages - No moisture removal from receiver tanks - No suction filters or dirty filters. No proper ventilation

36. Case Study Thermal Energy Issues Water Quality Hard water with high TDS is used as boiler feed water - Energy loss through therm oil heater stack

37. Case Study Thermal Energy Issues Energy loss through bare steam pipelines - Energy loss of Rs. 0.4 million/yr

38. Case Study Thermal Energy Issues - Wastage of steam condensate (Rs. 0.58 million/yr) - Hot wastewater wastage at 70-80oC from soapers and jiggers (Rs. 3.36 millions/yr) - Wastage of warm water from comfit (14 m3/d, Rs. 82,000/yr) - Uncontrolled heating of process baths (jiggers, soapers and mercerization machines)- Temperature is maintained 10oC (Rs. 1.5 millions/yr) - Energy loss from steam leakage (near drum dryers, calenders, comfit, jiggers, mercerization, steam ager, stenters, jets)- Rs. 2.59 millions/yr - Scaling of jets and kier heat exchangers - Steam pressure drops (150 to 120 psig), Rs. 50,000/yr) - Wastage of energy from fixed singeing burners (Rs. 0.108 million/yr)

39. Case Study Thermal Energy Issues - Energy loss through flash steam (Rs. 0.21 millions/yr) - Malfunctioning of steam traps Recommendations - Properly maintained electrical distribution system (connection, distribution of load) - Monitoring of motors loads and replacement of oversized motors - Installation of energy efficient motors - Preventive maintenance plan - Replacement of T12 tube lights with T8 and T5 (Rs. 97,000 to 291,000 respectively)

40. Case Study Recommendations - Efficient compressed air system (pressure monitoring and its adjustment, leakage control, removal of moisture, placement of suction and line filters, proper ventilation, centralized compressed air system, replacement of piston compressors by screw compressors) - Treatment of process and boiler feed water - Economizer at therm oil heater stack - Insulation of pipelines - Monitoring and control of process baths temperature - Recovery of steam condensate - Heat recovery from hot wastewater (heat exchangers) - De-scaling of jets and kier heat exchangers - Steam leakage control - Reuse of warm clean water

41. Case Study Recommendations - Adjustable singeing burners - Recovery of flash steam - Upkeep of steam traps

42. Case Study Recommendations Workers training Use of soft water Water shut off valves on water hoses Monitoring and record keeping of water, energy and chemicals Proper chemical storage and safe chemical handling Recycling of mercerization washes in scouring process Reuse of cooling water Reuse of steam condensate Countercurrent washing at mercerization machine Water conservation at jigger dyeing Substitution of sodium hypochlorite with hydrogen peroxide Wastewater treatment plant Noise control Occupational health and safety measures