ENERGY Conservation Consultancy By Ravindra M Datar Senergy Consultants (P) Ltd

Why Conserve?  Product need to be internationally competitive.  Cost raises but selling price stagnates.  Savings is surest way to increase profits.  10-25% saving can be realized in many industries; half of which with small investment.  10-25% saving can be realized in many industries; half of which with small investment.  The nation gains as  A new captive power plant take 4 years to construct; while benefits of savings can be enjoyed in 6 months.  The power plant costs Rs 50,000/- per kW, while savings costs are not even Rs 10,000/- per kW.

Senergy Synergybetween Our expertise on conservation of energy & Your experience & knowledge of process, operations, plant engineering, etc. To Save Energy

Senergy is An ISO company. An ISO company. In this field for more than 14 years. In this field for more than 14 years. Team of experts headed by a technocrat from IIT - Mumbai. Team of experts headed by a technocrat from IIT - Mumbai. A company with customer Base of 300 industries. A company with customer Base of 300 industries. Customer driven company with many repeat orders & orders form group companies. Customer driven company with many repeat orders & orders form group companies. Approved by MEDA & GEDA. Approved by MEDA & GEDA. Contributing Rs 50 crores/year, towards conservation of energy. Contributing Rs 50 crores/year, towards conservation of energy.

Senergy Provides Personalised services. Provides Personalised services. Conducts comprehensive & interactive studies. Conducts comprehensive & interactive studies. Gives practical & realistic recommendations. Gives practical & realistic recommendations. Provides services till actual realization of saving. Provides services till actual realization of saving. Can organize subsidies and soft loans. Can organize subsidies and soft loans. Take responsibility for turnkey implementation, on specific requests. Take responsibility for turnkey implementation, on specific requests.

Few of our clients Century Enka Ltd Century Enka Ltd Century Rayon Century Rayon Nanavati Hospital Nanavati Hospital Essel World Essel World EBG India Pvt Ltd EBG India Pvt Ltd JBF Industries Ltd JBF Industries Ltd Emco Ltd Emco Ltd PepsiCo India Ltd PepsiCo India Ltd ICI Ltd ICI Ltd Essel Propack Ltd Essel Propack Ltd M S E B M S E B Hindustan Lever Ltd Hindustan Lever Ltd Nicolas Piramal India Ltd Nicolas Piramal India Ltd Wyeth Lederle Ltd Wyeth Lederle Ltd Nirlon Ltd Nirlon Ltd GTC Industries Ltd GTC Industries Ltd Advani Oerlikon Ltd Advani Oerlikon Ltd Frigerio Conserva Allana Ltd Frigerio Conserva Allana Ltd Whirlpool of India Ltd Whirlpool of India Ltd Pidilite Industries Ltd Pidilite Industries Ltd Sumaira Group (Tanzania) Sumaira Group (Tanzania) Ceylon Glass Company Ltd Ceylon Glass Company Ltd

Senergy: Activities Energy Conservation Consultancy. Energy Conservation Consultancy. Promotion of Renewable Energy Sources. Promotion of Renewable Energy Sources. Turnkey consultancy for non-standard suggestions. Turnkey consultancy for non-standard suggestions. Consultancy for Process Audit & Yield Improvement. Consultancy for Process Audit & Yield Improvement. Consultancy for Proficient Plant Operations. Consultancy for Proficient Plant Operations.

Road Map: Energy Conservation Consultancy 1. Team formation 2. Overview of Process & Operations 3. Analysis of Specific Energy Consumption 4. Energy Accounting & Balancing 5. Energy Consumers / Converters 6. Distribution Systems 7. Utilization systems 8. Identification of potential saving areas 9. Implementation 10. Monitoring

TEAM Participation of all concerned. Participation of all concerned. Positive suggestions through various schemes. Positive suggestions through various schemes. Immediate & correct evaluation of suggestions. Immediate & correct evaluation of suggestions. Positive solutions for roadblocks / problem areas. Positive solutions for roadblocks / problem areas. Wider acceptance for recommendation. Wider acceptance for recommendation. Quick and effective implementation. Quick and effective implementation. Development of knowledge bank. Development of knowledge bank. Continual improvements. Continual improvements. Savings on sustainable basis. Savings on sustainable basis.

Overview of Process / Operations Brief description of activities, with emphasis of major consumers. Brief description of activities, with emphasis of major consumers. Process / Material flow diagram. Process / Material flow diagram. Utilization pattern for major consumers. Utilization pattern for major consumers. Co-relate the critical parameters at the point of generation & utilization Co-relate the critical parameters at the point of generation & utilization –Air pressure at compressor outlet / point of utilization –Suction pressure of refrigeration compressor / process temperature

Specific Energy Consumption Specific energy is the energy consumed per unit output. Analyze variations with respect to Analyze variations with respect to –Output –Seasonal variations –Yield Start the analysis at Macro-level then Proceed towards Micro-level

Example Specific Energy Consumption

Energy Accounting / Balance Prepare break up of consumption for each form of energy by Prepare break up of consumption for each form of energy by –Measuring energy consumption of individual equipment. –Noting down operating period. –Take data from various sub-meters Compare total consumption as estimated above with actual consumption to ascertain Compare total consumption as estimated above with actual consumption to ascertain –“Unaccounted” or “Miscellaneous” portion of the consumption Analyze consumption pattern (wrt time) Analyze consumption pattern (wrt time)

Example Energy Accounting / Balancing Description%kWh/M Illumination30%5,40,000 Air conditioning 20%3,60,000 Computers7.5%1,35,000 Pumps12.5%2,25,000 Electrical Heating 2.5% 45,000 45,000 Residential & Commercial 15%2,70,000 Miscellaneous12.5%2,25,000 Total100%18,00,000

Energy Accounting DescriptionConsumption kWh% Residential & Commercial % Hostels % Pumping % Common Lighting % Departments % Total %

Average Power (kW) MonthOverall22 to 66 to 9 & 12 to 18 9 to 1218 to 22 Aug Sep Oct Nov Dec Jan Feb Mar Apr May

Energy Consumers / Converters Evaluate performance of major consumers to –Carry out energy balance for the entire system. –Check if the equipment operates at design capacity. –Estimate efficiency at design / operating capacity. –Compute specific energy consumption. –List the major losses and estimate their contribution. –Discuss & finalize ways to eliminate / minimize the losses and optimize the efficiency /output. –Evaluate possibility of enhancing useful output. –Check feasibility of using cheaper source of energy do the same work.

Basic Definitions Efficiency: Ratio of Energy utilized for useful work to the total energy supplied to the equipment. Ratio of to energy supplied less sum of all losses to the total energy supplied to the equipment. Ratio of to energy supplied less sum of all losses to the total energy supplied to the equipment. Capacity utilization: Ratio of the Actual output to the Rated output of the equipment. Specific energy consumption: Ratio of the total energy supplied to the equipment to the Actual output.

Specific Power Consumption – Shaft Power (kWh/TR) Evaporator Temp ( 0 C) Condenser Temperature ( O C)

Refrigeration Effect (TR) Evaporator Temp ( 0 C) Condenser Temperature ( O C)

Air Compressor PrSp PowerSp OutputPower BarkW/M 3 M 3 /kWkW

Distribution Systems Utilities like steam are generated at centralized place & distributed through out plant. Utilities like steam are generated at centralized place & distributed through out plant. Such distribution is always associated with drop in energy level. Such distribution is always associated with drop in energy level. Distribution losses are such losses expressed as fraction (or percent) of the initial energy. Distribution losses are such losses expressed as fraction (or percent) of the initial energy. Such losses can be in in more than one form like pressure drop, heat gain, leakages, etc. Such losses can be in in more than one form like pressure drop, heat gain, leakages, etc. Minimizing such losses is one of the simplest & surest way of conservation of energy. Minimizing such losses is one of the simplest & surest way of conservation of energy.

Example Distribution Systems Steam Insulation Insulation Leakages Leakages Pressure drop Pressure drop –Routing –Line size Trapping Trapping –Location –Size –Type

Utilization Systems Efficient utilization of utilities / energy is of prime importance. Efficient utilization of utilities / energy is of prime importance. Conduct energy balance for each form of energy. Conduct energy balance for each form of energy. Identify critical parameters for utilities. Identify critical parameters for utilities. Validate criticality of process / plant parameters. Validate criticality of process / plant parameters. Map process / plant requirement with generation for critical parameters. Map process / plant requirement with generation for critical parameters. Quantify waste streams and potential for energy recovery through the same. Quantify waste streams and potential for energy recovery through the same. Look for more economical source of energy. Look for more economical source of energy.

Plate Type Heat Exchanger Energy Recovery from Effluent Chilled Water Waste Ice 8.5 TPD Fresh Water 30 0 C 221m 3 /day Ch Water 11 0 C 25 0 C E T P Effluent 12 0 C 221m 3 /day 1250 TR / 221 M 3 /day 13 0 C Process Chilled Water System

Identification of Energy Saving Areas Analyze the deviations from norms / normal values. Analyze the deviations from norms / normal values. Identify reasons. Identify reasons. Work out corrective action. Work out corrective action. Discuss with TEAM to formulate Action Plan Discuss with TEAM to formulate Action Plan Make simple but complete fact sheet for each area. Make simple but complete fact sheet for each area. Categorize areas based on ease of implementation, investment, etc. Categorize areas based on ease of implementation, investment, etc.

Implementation Pick up low hanging fruits – it goes in a great way to boost up team moral and management support. Pick up low hanging fruits – it goes in a great way to boost up team moral and management support. Supervise actual implementation Supervise actual implementation Provide assistance during commissioning & trouble-shooting. Provide assistance during commissioning & trouble-shooting.

Monitoring Ensure that the Team is on the right path and at correct pace. Ensure that the Team is on the right path and at correct pace. Measure the actual savings and ensure realization on sustainable basis. Measure the actual savings and ensure realization on sustainable basis. Devise monitoring system for key energy consumers & prepare log / data sheets. Devise monitoring system for key energy consumers & prepare log / data sheets. Install mechanism for suggestion scheme with effective implementation. Install mechanism for suggestion scheme with effective implementation. Monitor specific energy consumption at macro as well as micro level. Monitor specific energy consumption at macro as well as micro level.

In Nutshell 1. Team formation 2. Overview of Process & Operations 3. Analysis of Specific Energy Consumption 4. Energy Accounting & Balancing 5. Energy Consumers / Converters 6. Distribution Systems 7. Utilization systems 8. Identification of potential saving areas 9. Implementation 10. Monitoring

ThankYou!