ME482

ENERGY CONSERVATION AND

MANAGEMENT

Text books:
 1. Callaghn, P.W. Design and Management for Energy Conservation, Pergamon Press,
Oxford,1981.
 2. Witte. L.C., P.S. Schmidt, D.R. Brown, Industrial Energy Management and
Utilisation, Hemisphere Publ, Washington, 1988.
 MODULE 1

Energy - Power – Past & Present scenario of World; National Energy consumption Data –
Environmental aspects associated with energy utilization –Energy Auditing: Need, Types,
Methodology and Barriers. Role of Energy Managers. Instruments for energy auditing
 ENERGY AND POWER
 Energy exists in many forms such as chemical energy,nuclear
energy,solar energy,mechanical energy, electrical energy,internal energy
in a body, thermal energy etc.
 Energy transformations are responsible for various activities
 Energy is the cause behind the motion of particles or objects or else in
simple words energy is the capability to perform work.
 Power
• Power is defined to be the rate at which work is performed, or the
derivative of work over time.
• In other words, power is a measure of how quickly work can be done.
The unit of power is the Watt = 1 Joule/ 1 second.
• Energy is central to sustainable development and poverty reduction efforts.

• It affects all aspects of development-social, economic, and environmental-

including livelihoods, access to water, agricultural productivity, health,
population levels, education, and gender related issues.

• Some of the common energy sources are coal, petroleum, natural

gas,(fossil fuels), nuclear fuels, and biomass .

• Of all these, the most widely used energy sources are the hydrocarbon
compounds or fossil fuels which account for more than 80% of global
primary energy consumption
• Depending on their sustainability, energy resources can be broadly
classified as either renewable (flowing water, wind, geothermal, solar,
hydrogen, biomass) or non-renewable (petroleum, coal, natural gas,
uranium).

• The non-renewable energy resources account for 82% of the world's

energy consumption (76%)from fossil fuel and 6% from nuclear power).

• while the remaining 18% comes from renewable energy sources such as
biomass (11%), hydropower (4.5%) and geothermal, windand solar energy
(2.5%).
• World energy consumption is the total energy used by the entire
human civilization. Typically measured per year.

• It involves all energy harnessed from every energy source applied

towards humanity's endeavours across every single industrial and
technological sector, across every country.

• It does not include energy from food, and the extent to which direct
biomass burning has been accounted for is poorly documented.

• Institutions such as the International Energy Agency (IEA), the U.S.

Energy Information Administration (EIA), and the European Environment
Agency (EEA) record and publish energy data periodically.
.
 Improved data and understanding of World Energy Consumption may
reveal systemic trends and patterns, which could help frame current
energy issues and encourage movement towards collectively useful
solutions.
 Environmental aspects associated with energy utilization
 Non renewable energy usage:

 A serious problem associated with the use of conventional crude oil or any
carbon-containing fossil fuel is that it releases CO2 into the atmosphere
thereby promoting climate change from global warming.

 Climate change undermines power and energy production by increasingly

depleting renewable and non-renewable sources, creating resources
scarcity and damage to infrastructure.

 It also undermines environmental dimensions by increasing sealevel rise,

extreme weather events and land degradation and pollution.
 Coal is an abundant energy resource that is burned mostly to
produce electricity and steel.
 Coal is mostly carbon but contains small amounts of sulfur,
which are released into the atmosphere as sulfur dioxide
when the coal burns.
 Sulfur dioxide combines with water and air and forms
sulfuric acid, which is the main component of acid rain.
 Acid rain can cause deforestation, affects aquatic life by
acidifying waterways.
 Burning coal also releases trace amounts of toxic mercury
and radioactive materials.
 Energy audit

 Energy AUDIT IS An official survey/study of the energy

consumption/processing/supply aspects related with an
organisation,system,process,plant, equipment(or a region/state/nation).
 The energy audit is carried out by the energy audit group headed by the
energy auditor.
 Energy auditing is the official method for identifying energy
consrvation opportunities and obtaining recommendations regarding
the further actions to be taken by line management for energy
conservation measures.
 Need for Energy Audit

The three top operating expenses are energy (both electrical and thermal),
labour and materials.

Energy Audit will help to understand about the ways energy and fuel
are used in any industry, and help in identifying the areas where waste
can occur and where scope for improvement exists.

Energy Audit would give a positive orientation to the energy cost

reduction, preventive maintenance and quality control programmes
which are vital for production and utility activities
The primary objective of Energy Audit is to determine ways
to reduce energy consumption per unit of product output or
to lower operating costs.

provides a reference point for managing energy in the

organization.

provides the basis for planning a more effective use of

energy throughout the organization.
 Objectives of energy audit

 To understand the facility’s energetic behaviour

 To identify the excess of energy consumed
 To find out the motive of this excess
 To propose alternate solutions
 To justify them from technical and economical point of
view.
 To determine the ideal energy consumption profiles.
• Energy auditing recommends steps for reducing the energy
costs and improving the productivity without sacrificing
quality,standard of living/comforts and environmental balance.

• Energy audit recommends improvements in process, energy

conservation opportunities, and recycling of waste items.

• The energy audit forms the basis of understanding of present

system operation and serves as a benchmark for modifications
and decisions, in future.

• All efforts to conserve energy should start with an energy audit

of the structure,facilities and operation.
 Types of energy audits
 The energy audits are classified into three
categories:
 Simple walk-Through energy audit
 Intermediate / preliminary energy audit
 Comprehensive (Exhaustive) / detailed
Energy audit.
 Simple walk-through energy audit
 Walk through energy audit is the first, simple, rapid survey of
the plant/process.
 It is the least costly method and it identifies preliminary
energy savings.
 It is carried out by virtual inspection of the facility and is
completed in a limited period of time of 2 days.
 The audit team takes a round through the plant area with
attention focussed on the energy inputs, spots of wastage and
available energy conservation opportunities.
 Items for waste recycling opportunities are identified.
•The audit report submitted is accompanied by basic comments on
project/process feasibility.

•Walk through audit recommends whether further audit (preliminary or

detailed) is to be carried out or not.

Intermediate / preliminary energy audit

 Intermediate energy audit covers detailed survey, measurements and
system analysis than the walk-through energy audit.

 The energy consumption and energy losses are measured and

quantified.economics of energy efficiencies is analyzed.

 The energy analysis is carried out for 70% of energy usage.

 The intermediate EA aims at the following information:
 Identification and quantification of energy usage
 Economic evaluation of energy usage
 Economic Analysis of energy usage and proposed energy conservation measures.
 Identification of capital intensive energy conservation opportunities (ECOs
requiring major additional investments).

 In intermediate energy audit the energy cost in 3 years including the

current year is compared and the energy consumption in (kcal) per unit of
production is calculated.

 The preliminary audit recommends whether a detailed energy audit is

required or not.
 Comprehensive energy audit/ detailed energy
audit
 It is a thorough and extensive energy audit that analyses and quantifies the
amount of energy consumption in each sub system of the plant
(eg:lighting,heating and ventilation, boiler plant etc) and compares the same
with the target energy consumption.

 The energy survey is done with proper measuring and detection equipments.

 The complete energy analysis is carried out accounting for 95% of energy
used.

 It account for the total energy utilised in plants. It involves detailed

engineering for options to reduce energy consumption and also reduce cost.

 The duration of such studies is generally from 1 to 10 weeks.

The energy balance is calculated and the energy consumption index is
computed and compared against the energy consumption index of similar
industries.

The comprehensive energy audit report includes

 i) Energy conservation opportunities (ECOs)

 (ii) Energy conservation measures (ECMs)

 (iii) Projected investments for ECMs.

 (iv) Projected annual savings of ECMs and pay-back period.

 (v) Feasibility studies for retrofitting/modification work.

The comprehensive audit is quite exhaustive, and it is
convenient to split it into following sub parts:
1. Overall system audit:
 This accounts for energy leakage/loss through the total
sys-tem to the atmosphere. The energy conservation
measures to eliminate such leak-ages/loss are recommended.
 2.Functional audit:
 It surveys the quantity of energy used for each function.
 It identifies the energy conservation measures in operation
and maintenance of each main plant and its subsystems such
as heating systems, ventilation and air conditioning systems
air distribution systems etc and suggests ECOs.
3. Utility Audit:
• It surveys the quantity of energy required for each utility or support
services in an industry.
 It identifies yearly/monthly/daily consumption of commercial
second-ary energy (electricity/petroleum products/fuel etc.) and
suggests ECOs.

4. Process audit:
 It surveys the quantity of energy required for each process.
 It recommends major changes in the process requiring retro-fitting.

5. Transportation audit:
 It surveys the quantity of energy required for all types of transportation
systems such as cars, trucks, forlifts and other material handling
equipments in an industry.
 It also identifies the ECO’S in such systems.
 The data collected from the above mentioned types of comprehensive
audits are analyzed to develop a energy consumption profile that
covers all the end-use applications of energy.

 Observation of end use of energy consumption reveals various ECOs

Methodology of energy audit (detailed energy

audit)
There are ten steps for conducting Detailed Energy Audit
 Instuments for energy Audit

To obtain the best information for a successful energy cost control program,
the auditor must make some measurements during the audit visit. The amount
of equipment needed depends on the type of energy- consuming equipment
used at the facility, and on the range of potential EMOs that might be
considered.Tools commonly needed for energy audits include the following.

Tape measures —The most basic measuring device is the tape measure. A 25-
foot tape measure and a 100-foot tape measure are used to check the
dimensions of the walls, ceilings, doors, and windows, and the distances
between pieces of equipment for purposes such as determining the length of a
pipe for transferring waste heat from one piece of equipment to another.
 Lightmeter / LUX Meter - This instrument is used to measure
illumination levels in facilities. A light-meter allows direct analysis of
lighting systems and compares it with recommended light levels
specified by the Illuminating Engineering Society . Many areas in
buildings and plants may be significantly over-lighted. measuring this
excess illumination allows the auditor to recommend a reduction in
lighting levels through lamp removal or by replacing inefficient lamps
with high efficiency lamps.

 Thermometers—thermometers are used to measure temperature in

offices and other worker areas. It is also used to measure the
temperature of operating equipment. Knowing process temperatures
allows the auditor to determine process equipment efficiencies, and
also to identify waste heat sources for potential heat recovery
programs.
 Voltmeter —A voltmeter is used for determining operating voltages on
electrical equipment, and is also used when the nameplate of a piece of
equipment has worn off or is unreadable or missing.

Wattmeter/Power Factor Meter —A portable wattmeter/power factor

meter is used for determining the power consumption, power factor and load
factors of motors and other inductive devices. This meter typically has a
clamp-on feature which allows an easy and safe connection to the current-
carrying conductor, and has probes for voltage connections.

Combustion Analyzer —Combustion analyzers are devices which estimate

the combustion efficiency of furnaces, boilers, or other fossil fuel burning
machines. Digital combustion analysis equipment performs the
measurements and reads out combustion efficiency in percent. These
instruments are very reliable, easy to use, and inexpensive.
 Airflow Measurement Devices- Measures air flow from heating, air
conditioning or ventilating ducts, or from other sources of air flow.
Typical airflow measuring devices include a velometer, an
anemometer, or an airflow hood.

 Smoke Generator -A smoke generator is used in residences, offices

and other buildings to find air infiltration and leakage around doors,
windows, ducts and other structural features. however the chemical
“smoke” produced by this device may be hazardous, and breathing
protection masks must be used while operating this device.
Infrared Cameras - these are equipments that are used to find overheated
electrical wires, connections, neutrals, circuit breakers, transformers,
motors and other pieces of electrical equipment. They can also be used to fi
nd wet insulation, missing insulation, roof leaks, and cold spots. Thus,
infrared cameras are excellent tools for both safety related diagnostics and
energy savings diagnostics.

Ultrasonic Leak Detector —these are electronic ultrasonic receivers that

are tuned very precisely to the frequency of the hissing sound of an air leak.
These devices are extremely sensitive to the noise of even a small air leak.
The detectors can screen out background noise and pick up the sound of an
air leak.When equipped with an optional probe attachment, some
ultrasonicreceivers can also be used to test steam traps.

 .
Safety Equipment —The use of safety equipment is a vital precaution for
any energy auditor. A good pair of safety glasses is an absolute necessity for
almost any audit visit.
Hearing protectors may also be required on audit visits to noisy plants or in
areas where high horsepower motors are used to drive fans and pumps.
Electrically insulated gloves should also be used if electrical measurements
will be taken, and insulated gloves should be used for working around boilers
and heaters.
Breathing protection masks may also be needed when hazardous fumes are
present from processes or materials used.
Steel-toe and steel-shank safety shoes may be needed on audits of plants
where heavy, hot, sharp or hazardous materials are being used.
ASSIGNMENT 1

Explain The Barriers Of Energy Audit

Explain The Concept Of
Transformers, Capacitors, Ht And Lt Supply

SUBMISSION DATE MARCH 7th