Electrical Audit

Energy audit: Definition and Types
Energy audit is a systematic study or survey to identify how energy is being used in a building or plant, and identifies energy savings opportunities. Using proper audit methods and equipment, an energy audit provides the energy manager with essential information on how much, where and how energy is used within an organization (factory or building).
This will indicate the performance at the overall plant or process level. The energy manager can compare these performances against past and future levels for a proper energy management. The main part of the energy audit report is energy savings proposals comprising of technical and economic analysis of projects. Looking at the final output, an energy audit can also be defined as a systematic search for energy conservation opportunities.
This information can be transformed into energy savings projects. It will facilitate the energy manager to draw up an action plan listing the projects in order of priority. He will then present it to the organization's management for approval. Providing tangible data enables the management to be at a better position to appreciate and decide on energy efficiency projects. Adopting this activity as a routine or part of the organization's culture gives life to energy management, and controlling the energy use by energy audit is what we refer to as Energy Management by Facts
Stages of Energy Audit
Energy audit stages

Energy audit can be categorized into two types, namely walk-through or preliminary and detail audit.
Walk-through or preliminary audit

Walk-through or preliminary audit comprises one day or half-day visit to a plant and the output is a simple report based on observation and historical data provided during the visit. The findings will be a general comment based on rule-of-thumbs, energy best practices or the manufacturer's data.
Preliminary Energy Survey

Quick overview of energy use patterns Provides guidance for energy accounting
system
Provides personnel with perspectives of
processes and equipment

Identify energy intensive processes and equipment Identify energy inefficiency ,if any Set the stage for detailed energy survey
Detail audit
Detail audit is carried out for the energy savings proposal recommended in walk-through or preliminary audit. It will provide technical solution options and economic analysis for the factory management to decide project implementation or priority. A feasibility study will be required to determine the viability of each option.
Detailed Energy Survey

Detailed evaluation of energy use pattern
By processes and equipment Measurement of energy use parameters Review of equipment operating characteristics Evaluation of efficiencies Identify DSM options and measures Recommendation for implementation
Inputs and Outputs of Energy audit
ELECTRICAL ENERGY AUDIT

Areas covered under Electrical audit are 1. Electrical System : Electrical Distribution system (substation & feeders study) PF Improvement study Capacitor performance Transformer optimization Cable sizing & loss reduction Motor loading survey Lighting system Electrical heating & melting furnaces Electric ovens
2. Mechanical System : Fans & Blowers Exhaust & ventilation System Pumps and pumping System Compressed air System Air Conditioning & Refrigeration System Cooling Tower System
THERMAL ENERGY AUDIT

Areas covered under Electrical audit are Steam Generation Boilers Steam Audit and Conversation Steam Trap Survey Condensate Recovery System Insulation Survey Energy and Material Balance for Unit operation Heat Exchanger Waste Heat Recovery System
WATER AUDIT & CONSERVATION Industry has recognized 'Water Audit' as a important tool for water resource management Water Audit study is a qualitative and quantitative analysis of water consumption to identify means of reuse and recycling of water. This study includes segregation of effluent streams and schemes for effectively treating them to enable byproduct recovery. Water Audits encourage social responsibility by identifying wasteful use, enables estimation of the saving potential they not only promote water conservation but also deliver cost savings, but also companies to safeguard public health and property, improve external relations and reduce legal liability.
Benefits of energy audit

There is a lot of potential for energy savings from energy audits.. Technical solutions proposed in the energy audits show massive potential for energy savings in every subsector with an average of almost ten percent of the energy usage. However, this can only materialize through replication at other factories within the respective sub-sector.
Benefits of an industrial energy audit include:

Energy savings Avoiding power factor penalties and environmental compliance costs Quality improvements Productivity improvements Reduced maintenance Fewer breakdowns Better safety and protection A process for repeatable improvements
Process VS. Equipment

Equipment efficiency improvement : Process efficiency improvement Max. 5% : 15% to 30%
Conclusion Focus on Processes
Energy intensive processes and equipment

Examples of processes
Electrical furnace
Examples of equipment
Electrical motor Pump Fan
Rolling mills
Gas furnace Steam generation Feed water system Condensate return system
Heater (gas,..,electric)
Dryer (steam/electric) Motor / generator Compressor Light bulb
Steam distribution system

Electrlyzer
Energy conservation opportunities

Electrical
Reduce demand by load management
Electrical / thermal
Reduce consumption by improving energy use efficiency (reducing losses ,utilizing waste heat ,etc..)
Examples of conservation opportunities - processes

1.Electric furnace
- Automation of energy supply control - Substitute electricity by thermal energy ( mazout/solar/gas ) - Reduce radiation losses
2. Steam generation system - Combustion efficiency improvement - Waste heat recovery from flue gases
- Heat loss reduction from boiler surfaces

- Reduce leakage 3. Condensate return system 4. Steam distribution system - Pipe insulation - Steam traps - Steam leaks
Examples of conservation opportunities equipment

1. Gas/air compression system
pre-cooling the gas/air

2. High efficiency motors
3. High efficiency lamps

4. High efficiency pump/fan 5. Change electric dryer and heater to oil/gas fuel 6. Replace motor/generator set with silicon controlled rectifier (SCR)
Demand Side Management (DSM)
Energy Audit / step by step
Analyze utility bills
Case study
Basic data of the company
1- General description of company and products. 2- Electrical distribution system. 3- Energy price. 4- Energy factor and environmental pollution. 5- Electrical loads of company.
1- General description of company and products:

Company A lies in Kilo XX Alexandria desert road. The company operates 24 hours with 3 shifts a day for 300 days/ year. The company produces dry batteries.
2- Electrical distribution system:

Electric power network of A Company is supplied by two transformers 500 KVA, 11/ 0.4 kV. Also, there is two standby generators 400 kVA per each. Figure (1) shows the single line diagram for the electric distribution network.
Table (2)
Meter Contracted No. power 366 1350 KW Max. demand 2007 863 kW Power factor 2007 0.9
Figure (2) shows the monthly development of electric consumption for company loads during 2006 and 2007.
3- Energy price:
According to appendix (2)
4- Energy factor and environmental pollution.

0.2196 kg fuel /kWh 3.082 kg CO2/ kg fuel 0.677 kg CO2 /kWh
5- Electrical loads of company:

The following tables represent loads and its rating
Item
motor Heaters Water pump Exhaust fan Cooker assistant
Description No. X rating

1 X 3HP 28 X 3000 W 1 X 0.25 HP 1 X 0.75 HP 2 X 1 HP + 4 X 0.75 HP
Power (HP)
3 112.6 0.25 0.75 5 121.6 0.75 7.3 2 1 11.05
Total power for this process Conveyor belt heater Exhaust fan Conveyor belt 3 X 0.25 HP 1 X 10 Ampere + 1 X 15 Ampere 2 X 1 HP 1 X 1 HP
Total power for this process
lighting loads:
Type No. of lamps X rating 40 X 304 40 X 84 Total power (kW) 12.16 3.36
Location ABC 1 ABC 2
120 cm. fluorescent lamp 120 cm. fluorescent lamp

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Energy audit: Definition and Types

Stages of Energy Audit

Energy audit stages

Walk-through or preliminary audit

Preliminary Energy Survey

processes and equipment

Detailed Energy Survey

Inputs and Outputs of Energy audit

ELECTRICAL ENERGY AUDIT

THERMAL ENERGY AUDIT

Benefits of energy audit

Benefits of an industrial energy audit include:

Process VS. Equipment

Conclusion Focus on Processes

Energy intensive processes and equipment

Steam distribution system

Energy conservation opportunities

Examples of conservation opportunities - processes

- Heat loss reduction from boiler surfaces

Examples of conservation opportunities equipment

pre-cooling the gas/air

3. High efficiency lamps

Demand Side Management (DSM)

Energy Audit / step by step

Analyze utility bills

1- General description of company and products:

2- Electrical distribution system:

4- Energy factor and environmental pollution.

5- Electrical loads of company:

Description No. X rating

Total power for this process

Location ABC 1 ABC 2

120 cm. fluorescent lamp 120 cm. fluorescent lamp

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