Energy Audit and Case Study on Milk Plant

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ENERGY AUDITDarshan Vithani ,Pranav Pathak
ME-CSE

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Energy Audit
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,

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Energy Audit
AIM OF ENERGY AUDIT
to minimize costs for energy
to minimize operational costs
to minimize costs for repairs
and reconstruction
increase quality of environment that
contributes to increased work productivity

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Energy Audit
AIM OF ENERGY AUDIT
to minimize costs for energy
to minimize operational costs
to minimize costs for repairs
and reconstruction
increase quality of environment that
contributes to increased work productivity

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Energy Audit
TYPE OF ENERGY AUDIT
 The type of Energy Audit to be performed depends on:
- Function and type of industry
- Depth to which final audit is needed, and
- Potential and magnitude of cost reduction desired
 Thus Energy Audit can be classified into the following two
types.
i) Preliminary Audit
ii) Detailed Audit

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Energy Audit
PRELIMINARY ENERGY AUDIT METHODOLOGY
 Establish energy consumption in the organization
 Estimate the scope for saving
 Identify the most likely (and the easiest areas for attention
 Identify immediate (especially no-/low-cost) improvements/
savings
 Set a ‘reference point’
 Identify areas for more detailed study/measurement
 Preliminary energy audit uses existing, or easily obtained
data

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Energy Audit
DETAILED ENERGY AUDIT METHODOLOGY
 It is offers most accurate estimate of energy savings and cost
 This is based on an inventory of energy using systems,
assumptions of current operating conditions and calculations
of energy use.
 Detailed energy auditing is carried out in three phases: Phase
I, II and III.
Phase I - Pre Audit Phase
Phase II - Audit Phase
Phase III - Post Audit Phase

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Energy Audit
Steps For DETAILED ENERGY AUDIT METHODOLOGY

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Energy Audit
Steps For DETAILED ENERGY AUDIT METHODOLOGY

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Energy Audit
Steps For DETAILED ENERGY AUDIT METHODOLOGY

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Energy Audit
Steps For DETAILED ENERGY AUDIT METHODOLOGY

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Energy Audit
Steps For DETAILED ENERGY AUDIT METHODOLOGY

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Energy Audit
Steps For DETAILED ENERGY AUDIT METHODOLOGY

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Energy Audit
AREAS OF ENERGY AUDIT
Subject of energy consumption analysis are 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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Energy Audit
AREAS OF ENERGY AUDIT
• 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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Energy Audit
ENERGY AUDIT METHODOLOGY
 Pre-audit presentation.
 Collection of data / information.
 Measurements and monitoring with instruments.
 Computation and in-depth analysis.
 Post-audit presentation to discuss the Energy Conservation
Opportunities identified by the audit team.

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Energy Audit
INSTRUMENTS USED
 Flue Gas Analyzer
 Power Analyzer, Tachometer
 Ultrasonic Flow Meter
 Trap Man (For Steam Trap Survey)
 Raytech Gun & Digital Thermometer (Non-contact and Contact type
both)
 Anemometer, pH/TDS/Conductivity meter
 LUX Meter, Digital Manometer

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EnergyAuditatMotherDairy
(MilkPlant)
Case Study

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Energy Audit
BASE LINE DATA
Product Bulk Processed Milk (Toned, Double Toned
& Full Cream)
Capacity of the plant 8 Lac liters of Milk per day
Annual Fuel / Energy Consumption PNG: 17,76,000 SCM
Worth: Rs 3.7 Crores
Electricity: 134.6 Lac kVAh
Worth: Rs 6.68 Crores
Annual Energy Bill Rs 10.38 Crores
Compressed Air generation 180 cfm
Steam Consumption 65,000 kg/month for Milk Plant
15,000 kg/month for Ice Cream Plant

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Energy Audit
Summary of Savings Identified & Realized
(Year 2003 & 2004)
 Major recommendations implemented:
1. Boiler fuel switched over to PNG from LDO
2. Steam supplied to ICP from this boiler
3. Improvement of Power Factor from 0.9 to 0.996
4. New air compressor installed lowering SEC
5. Installation of Auto Blow Down system for Boiler
Total Savings projected by
PCRA
Electricity: 21,43,360 kVAh Worth: Rs 78.24 Lac
LDO: 184.31 KL Worth: 85.8 Lac
Total Savings Realised till
date
Electricity: 5,21,017 kVAh Worth: Rs 19.02 Lac
LDO: 130.06 KL Worth: Rs 60.55 Lac
% Savings Realised of total
energy consumption
Electricity: 3.7%
LDO: 20.3%

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Energy Audit
Summary of Savings Identified
(Year 2005)
Total savings identified Electricity: 7,17,004 kVAh
PNG: 1,36,042 SCM
Worth: Rs 59.18 Lac
No cost savings with immediate
payback
Electricity: 95,308 kVAh
Worth: Rs 4.1 Lac
Low cost savings with payback < 1
year
Electricity: 5,41,796 kVAh
Worth: Rs 23.3 Lac
High cost savings with payback
between 1-2 years
Electricity: 79,900 kVAh
Worth: Rs 3.44 Lac
Gas: 1,36,042 SCM
Worth: Rs 28.34 Lac
% savings identified of total energy
consumption
Electricity: 5.32%
Gas: 7.66%

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Energy Audit
BOILERS
Observations:
1. Condensate recovery is not being done.
2. Feed water temperature presently is 50C.
Recommendations:
1. Recover condensate to raise feed water temperature to upto 85C
2. Install de-aerator head on feed water tank and recover condensate.
3. Install steam operated condensate recovery pump
Savings Estimated / year Investment Payback Period
Rs 28.34 Lac Rs 25 Lac 11 Months

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Energy Audit
Air Compressors
Observations:
1. Air leakage are about 26%.
Recommendations:
1. Plugging of air leakages
Savings Estimated / year Investment Payback Period
Rs 4.0 Lac Nominal Immediate

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Energy Audit
Illumination
Observations:
1. HPMV lamps are used for street lighting.
2. 36 Watt Tube lights with copper chokes are used.
Recommendations:
1. Replace HPMV lamps by HPSV lamps
2. Replace 36 Watt Tube lights with T-5 28 Watt with electronic choke in
a phased manner.
Savings Estimated / year Investment Payback Period
Rs 3.34 Lac Rs 4.0 Lac 16 Months

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Energy Audit
Conclusion
The gaps may exist in design & actual operations for large complexes due
to integration of :
 Steam thermal systems.
 Electrical systems
 Process systems (Motive/ Thermal loads) due to variation in
efficiencies/ actual requirements
 Continuous monitoring and analysis of integrated systems is essential
for improvements.
 Energy Audits will identify such gaps.
 Implementation of recommendations will result into considerable
energy savings.

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Thank YouDarshan Vithani ,Pranav Pathak
ME-CSE