4 sin ha

8/6/2019 4 Sin Ha

http://slidepdf.com/reader/full/4-sin-ha 1/34

BASELINE ENERGY AUDIT

&

METHODOLOGY OF DATA VERIFICATION

Venue : PAT WORKSHOP forTEXTILE - Sector , at Bhilwara

Date –

22nd February 2011

Presented By: R.B.SINHAENERGY AUDIT SERVICES, Faridabadmail <[email protected]>

Mob.: 09811229516

8/6/2019 4 Sin Ha


POTENTIAL FOR ENERGY SAVING

Several steps have already been undertaken in Textile Sector for the

improvement in Energy Saving. Still there is substantial potential forfurther more Energy Saving.

PAT framework includes the following elements:-

1. Methodology for setting Specific Energy consumption (SEC) foreach DC in the baseline year.

2. Methodology for setting the Target to reduce the Specific

Energy consumption (SEC) in the next 3 years. Target for reduction

in SEC would vary from D.C. to D.C.

8/6/2019 4 Sin Ha


3. The process to issue energy savings certificates (E.S. Certificates) to

those DCs, who achieve SEC lower than the specified value.

4. Trading of E.S. Certificates.

Example of SEC level in Spinning Mills

• CASE STUDY # 1

Data from an overseas spinning mill, having 4 units ,each Unit having25,000 to 28,000 of spindles.

Totally Air conditioned( by Chillers) throughout the year.

‘Specification Power consumption’ worked out in KWH per 100 kg.

8/6/2019 4 Sin Ha


Main Observations

1. Wide variation from month to month in each of 4 Plants – all managed by

the same team of Managers & Engineers, under the same compound.

2. Lot of variation in specific Energy Consumption is a Positive indication for

the substantial potential for Energy Saving.

CASE STUDY- 2

Sp. Power consumption in KWH per 100 kg. for several overseas units:-

1st Mill A1, A2, A3, A4

2nd Mill B1, B2

3rd Mill C1 & C2

All these Spinning Mills are very well managed and on theidentical lines as described in Case Study # 1.

8/6/2019 4 Sin Ha


Efficient Plants & Equipments

Totally Air Conditioned (Centrifugal Chillers) throughout the year.

• CONCLUSION

Specific Energy Consumption variation in so vast range, gives added

confidence for the success for Energy Saving.

8/6/2019 4 Sin Ha


TABLE # 1

SPECIFIC POWER CONSUMPTION, YEAR 1997MONTH PRODUCTION (Kg.) POWER CONSUMPTION KWH PER 100 KG.

P1 P2 P3 P4 TOTAL

PRODN.

(P1-P4)

TOTAL

POWER

CONSUMP. (P1-P4)

P1 P2 P3 P4 AVERAGE

(P1-P4)

JAN. 1076839 336115 250386 29937 1693277 6279280 345 335 390 - 371

FEB. 1028758 328404 240860 161934 1759956 6864710 349 331 419 - 390

MAR. 1161208 361063 266715 325683 2114669 8856430 374 360 405 656 419

APR. 1006532 311621 247210 339744 1905107 7907510 368 360 394 620 415

MAY. 1089086 355620 267622 430010 2142338 9094698 419 398 416 466 425

JUNE 1030119 355620 274426 463576 2123741 9146572 431 406 409 462 431

JULY 993831 348363 271251 502132 2115577 9000450 423 421 403 444 425

AUG. 996099 335208 274333 505307 2110947 8844620 415 427 394 435 419

SEPT. 1039191 331126 283952 509843 2164112 8858680 400 430 383 430 409

OCT. 1059603 325683 272158 494421 2151865 8876760 395 433 390 447 413

NOV. 1031480 329765 270797 496235 2128277 8662990 401 409 365 441 407

DEC. 982945 294384 269890 500318 2047537 8548083 409 445 385 436 417

1997 - - - - - - 393 385 402 472 407

1996 - - - - - - 410 357 392 - 395

1995 - - - - - - 405 366 388 - 393

8/6/2019 4 Sin Ha


TABLE # 2

SP. POWER CONSUMPTION

Comparison Several Overseas Spinninbg Mills

MONTH UNITS CONSUMED 100 KG.

A1 A2 A3 A4 B1 B2 C1 C2

JAN. 345 335 390 - 297 354 327 431

FEB. 349 331 419 - 297 317 322 433

MAR. 374 360 405 656 294 298 320 431

APR. 368 360 394 620 283 290 317 426

MAY 419 398 416 466 287 281 322 435

JUNE 431 406 409 462 293 282 333 425

JULY 423 421 403 444 287 302 331 433

AUG. 415 427 394 435 284 308 333 436

SEPT. 400 430 383 430 283 385 332 436

OCT. 395 433 390 447 - - 276 386

NOV. 401 409 365 441 - - 280 379

DEC. 409 445 385 436 - - - -

AVG. 393 385 402 472 289 313 318 423

AVG.

COUNT

29.28 24.10 29.73 26.96 25.47 27.37 23.96 26.71

8/6/2019 4 Sin Ha


METHODOLOGY

A. Brief Description about the Plant

1. Present installed capacity and stages of capacity addition (if any).

2. Trend of capacity utilization (last 5 years).

3. Trend of monthly production & capacity utilization of last one year.

B. Review of Process Flow diagrams.

Entire Process should be divided into Sub – Systems for this study.

8/6/2019 4 Sin Ha


SPINNING MILLS

A.1 RINGH FRAMES Design Actual

(a) Count- wise Doff to Doff time

(b) Spindle Speed

(c) % Yarn breakage(d) Monthly Production

(e) R. F. Main Motor- Efficiency

Level

(f) Pnemofil Blowers

8/6/2019 4 Sin Ha


POST SPINNING

SPEED FRAMES Design Actual

(a) Monthly Production

(b) Speed Control

AUTO CONERS Design Actual

(a) Suction Blower – Speed

Control

(b) Draft - mm

8/6/2019 4 Sin Ha


TFO MACHINES

(a) TFO Motors - % & steps taken Design Actuals

For improving operating

Efficiency

(b) Monthly Production

(c)

8/6/2019 4 Sin Ha


HVAC- H. PLANTS

(a) Fan Efficiency for Design Actual

Supply Air Fans

Return Air Fans

(b) Technology for Rh - % control(c) Speed Control for these Fans

(d) Spray Water Pumps – control

system

8/6/2019 4 Sin Ha


WEAVING MILLS

(a) Monthly Production Design Actual

(b) Compressed Air requirement

(c) Pressure of Compressed Air

(d) Monthly Power consumption

in Air Compressors Units

Units per Kg

8/6/2019 4 Sin Ha


BOILERS & STEAM

(a) Monthly Steam generation Design Actual

(b) Evaporation ration

(c) Steam Pressure & Temp-

(d) Waste heat Recovery

(e) Steam Condensate Recovery

(f) Specific Steam Consumption

8/6/2019 4 Sin Ha


PROCESSING MACHINES

(a) System for Temperature control Design Actual

(b) System for Fan speed Control

for different Zones of Stenters,

Printing Machines etc(c) Major Pumps - Speed Control

TECHNOLOGY UPGRADATION

To study steps undertaken for all these areas – 3 years

8/6/2019 4 Sin Ha


8/6/2019 4 Sin Ha


C. ENERGY SCENARIO of the Plant

1. Different types of Energy sources being used and their %

contribution – for 3 years.Primary Energy (Solid Fuel, Liquid Fuel, Gaseous Fuel etc.)

Secondary Fuel (Electricity)

(a) Purchased from grid

(b) Self generation.

2. Establish the trend of the following for the last 3 years.

(a) % share of grid power to the total power.

(b) % share of self generated power.(c) % share of internally generated thermal Energy from waste

heat, co-generation or by product of total energy.

(d) f h f l f d

8/6/2019 4 Sin Ha


(d) % cost of Energy to that of total cost of production.

(e) % share of renewable Energy.

3. Trend of monthly production & Energy Consumption (Electrical &

Thermal) of the last one year.

The boundary of a DC Gate-to-Gate (GtG) concept.

• The plant boundary would be selected such that the total energy

input and the above defined product output will be fully captured.

• Typically it is the entire plant excluding colony, residential complex

and transportation system.

• Similarly, mining operations in case of Iron & Steel, Aluminium and

Cement sector are not part of plant boundary.

• Once the plant boundary has been fixed, the same boundary should

be considered for entire PAT cycle.

• Ideally, plant boundary should not change during the entire cycle.

8/6/2019 4 Sin Ha


The SEC of an industry would be calculated based on Gate-

to-Gate concept with the following formula.

Total energy input to the plant boundary

SEC = --------------------------------------------------------

Quantity of the Product

While calculating the total energy input to the plant, all energy

sources would be converted to a single unit i.e. MTOE (metric ton of oil equivalent) using standard engineering conversion formulae:

• Electricity purchased from Grid: 1 kWh = 860 kcal.

• Solid fuel: Quantity (kg) * GCV (kcal/kg) kcal.

• Liquid fuel: Quantity (m3) * density (kg/m3) * GCV (kcal/kg) kcal.

• 1 MTOE = 107kcal.

8/6/2019 4 Sin Ha


In this calculation, the following would be considered :

•

All forms of energy (Electricity, Solid fuel, Liquid fuel, Gaseous fuel,by-products used as fuel etc.) which are actually consumed for

production of output should be considered.

• Energy consumed in colony and for outside transportation system

should not be accounted.

• Energy used through renewable energy sources should not be

accounted.

• Any energy consumed for major construction work would not be

accounted as this is not meant for producing the product. Quantity

of such energy should be separated out from total energyconsumption.

8/6/2019 4 Sin Ha


OUR PLAN

We would like to divide composite plants into three sub groups:-

(a) Spinning Mills(b) Weaving Mills

(c) Processing Plant

For Spinning Mills – We would like to collect the details of ‘Count-wise’

monthly production for the last one year.

Trend the Energy consumption in GtG concept of last 5 years

(2006-07 to 2010-11).

Establish the Sp. Energy Consumption in GtG concept.

8/6/2019 4 Sin Ha


CASE -I : All Energy Purchased and Consumed

Case II: Electricity Partially Generated by DG Sets other

8/6/2019 4 Sin Ha


Case-II: Electricity Partially Generated by DG Sets, other

Energy Purchased and consumed

Case – II : Electricity Generated by CPP other Energy

8/6/2019 4 Sin Ha


Case – II : Electricity Generated by CPP, other Energy

Purchased & Consumed Electricity partially sold to grid

DATA VERIFICATION

8/6/2019 4 Sin Ha


DATA VERIFICATION

Review of reported data of each DC – would be reviewed.

It is a friendly verification of the ‘reported – data’.

Most Important Factors1. Source of Data - documents, records, log books or Metering

or estimated - to be noted so that ‘same yard – stick’ is followed

while verifying the resultant saving after 3 years.

To analyse data with respect to production and standard performance

values etc.

Item Unit Source Of Data Frequency Of Data Records

Method Of DataRecords

Production

Purchased Electricity

Energy – others

8/6/2019 4 Sin Ha


F. OUR WORK PLAN

Based upon consideration experience in Textile Sector, our team would

study the entire plant on gate – to – gate concept, based on flow diagramssuch as:-

(i) Spinning Section

(ii) Post spinning – TFO & Auto Coners

(iii) Humidification Plants

(iv) Air Compressors

(v) Captive Power Plants

(vi) Boilers

(vii) Chillers (if available)

(viii) Cooling Towers

(ix) Lighting

GUIDELINES

8/6/2019 4 Sin Ha


GUIDELINES

(a) We shall cover around 85% of the total Energy Consumption.

(b) Performance Evaluation – Energy performance of the main Plants -Equipments / Utilities would be assessed w.r.t. to Technical

Specifications / design data, operational data, or site data etc.

(c) Measurements would be carried out wherever needed, specially to

quantify expected saving for any particular proposal.

7. Investigate the All Possible Energy Efficiency Improvement Option.

a. Waste Heat Recovery Options

(i) Source

(ii) Comment on Feasibility

(iii) Quantum of Possible Extracted Energy.

8/6/2019 4 Sin Ha


b. Co-Generation Option

i. Comment on Feasibility

ii. Approximate Thermal & Electricity Energy Output.

c. Fuel Switch Options

d. Retrofit Options

e. Use of Energy Efficient Equipment

i. Energy efficient drives, pumps, fans, compressors,

lighting system etc.

ii. Variable Frequency Drives / Variable Speed Drives.

iii. Any other.

f. O & M Practices

i. Waste minimization (Reuse, Recycle, Resizing)

ii. Control Mechanism

iii. Data Monitoring & Accounting

8/6/2019 4 Sin Ha


g. Cost-Benefit option in all possible options.

i. Simple Pay Back Period

8. Review the Past Energy Efficiency improvement Strategies

(Last 3 years)

*Technology Upgradation / Process Modification / O&M Practice/ Retrofit/ Others

SUB-PROCESS

ACTIONTAKEN

CATEGORY* YEAR OFIMPLEMENTATION

RESULTEDSAVING

INVESTMENTDONE

8/6/2019 4 Sin Ha


9. Review the Future Energy Efficiency Improvement Strategy

(Discuss with Plant Management to get the future energy

efficiency improvement strategies)a. Specific Projects to be undertaken.

b. Investment Plan

c. Human Resource Planning in Energy Management

d. Any Target fixed by management as per their policy.

10. Prepare the Audit Report with following Structure / Format.

a. Acknowledgement

b. Study Team Membersc. Executive Summary

Sl Recommendations Annual Approx Simple Pay- Remarks

8/6/2019 4 Sin Ha


Sl.No.

Recommendations AnnualPotentialSaving

Approx.Investment

Simple Pay-back Period

Remarks

d. Introduction

e. Methodology Adopted

f. Instruments Used for Energy Audit.

g. Brief Description about the plant (process Flow Diagram)h. Energy Scenario & Usage pattern

i. Description about Sub-Process

j. Identifying ENCON options

k. Description about Past ENCON activities.l. Description about future ENCON strategy.m. Conclusion & Critical Comment.

KEY ENABLERS

8/6/2019 4 Sin Ha


KEY ENABLERS

• Technical diary of the plant (Design data)

• Performance data & specifications of various equipment

• Three annual reports and MIS reports etc.

• Free access to UCB data, onsite data, Lab data (Coal/ ash

analysis, water quality, % O2 values etc.)

• Access to past ENERGY AUDIT REPORTS of the plant

• Full time association of Energy Manager of the plant and

suitable O&M functionary.

8/6/2019 4 Sin Ha


KEY ENABLERS (CONT.)

•

All information will be kept confidential, by us.

• The study will commence only after all the formalities are

completed with EESL.

8/6/2019 4 Sin Ha


TEXTILES UNITS TO BE COVERED BY US

S.NO NAME OF THE INDUSTRY LOCATION REMARKS

1. KANCHAN PROCESSORS PVT. LTD. AJMER ROAD,BHILWARA 09829045888

2. MAHARAJA SHREE VMAID MILLS LTD. JODHPUR ROAD, PALI,

RAJASTHAN

3. MORDI TEXTILES & PROCESSORS LTD. UDAIPUR ROAD,

BANSWARA,

0296411297

4. NAHAR INDUTRIAL ENTERPRISES LTD. BHIWADI (Raj.)

5. NITIN SPINNES LTD. CHITTAUR ROAD,

BHILWARA

6. ORIENT SYNTEX BHIWADI 09785423667

7. POOJA SPINTEX (P) LTD. INDUSTRIAL AREA,

BHIWADI

8. RAJASTHAN TEXTILES MILLS Bhawani Mandi

9. RELIANCE CHEMOTEX INDUSTRIES

LTD.

CHITTAR ROAD,

BHILWARA

41846, 41135

4 sin ha

Documents