Energy Audit A Case Study of Pashupati Candle filter Udhyog And Country food Pvt.Ltd

Final Year Project Report Submitted To Thapathali Campus Department of Industrial Engineering
TRIBHUWAN UNIVERSITY
INSTITUTE OF ENGINEERING
THAPATHALI CAMPUS
Energy Audit
A Case Study of Pashupati Candle filter Udhyog And Country food Pvt.Ltd
Prepared By:
BidurGhimire
BikramBasnet
Bikram Dahal
Prakash Jamar Kattel
Samir BabuBhetwal
ShekharGhimire
Sarbin Shrestha
UddhavBasnet
Project Supervisor Er. BhismaPandit
25th May, 2014

Energy Audit
Final Year Project | 2014 1
Energy Audit Team
Bidur Ghimire
Bikram Basnet
Bikram Dahal
Prakash Jamar Kattel Samir Babu Bhetwal Shekhar Ghimire Sarbin Shrestha Uddhav Basnet
Energy audit
Optimization
Cost saving
Energy Audit
Project Supervisor Mr. BhishmaPandit Senior Energy Expert GIZ, EEC, FNCCI

Energy Audit
DECLARATION
We hereby declare that we carried out project work reported in this report in the Department of Industrial Engineering, Tribhuwan University, under the supervision of Er. Bhisma Pandit (senior energy expert). We solemnly declare that to the best of our knowledge, no part of this report has been submitted here or elsewhere in a previous application for award of a degree. All sources of knowledge used have been duly acknowledged.
Energy Audit Project Team
Bidur Ghimire ………………………..
Bikram Dahal ………………………..
Bikram Basnet ………………………..
Prakash Jamar Kattel ………………………..
Samir Babu Bhetwal ………………………..
Sarbin Shrestha ………………………..
Shekhar Ghimire ………………………..
Uddhav Basnet ………………………..

Energy Audit
WORDS FROM THE SUPERVISOR
I am very glad to work with final year industrial engineering students who have chosen “Energy Audit” as major project. Energy is growing issue in modern industries and optimum use of energy enhances efficiency, reduces the cost and energy consumption. The project is very important from the scenario of energy saving. At least some of industries will be aware about optimization of energy and that will be fruitful to effort project team has made.
The project was successfully completed under my supervision in Pashupati Filter Candle Udhyod (LPG Regulator Division), Ramkot, Kathmandu and Country food Pvt. ltd. The team has really made great effort under my guidance to search energy saving opportunities in the industry. The data collected and measures recommended are authentic and valuable as far as possible.
I would like to thank the project team for their excellent teamwork and best wishes for their success in future.
Thank you,
With regards
Er. Bhishma Pandit Project supervisor (Energy Audit project) Senior energy expert EEC, GIZ, FNCCI

Energy Audit
CERTIFICATE OF COMPLETION
To whom it may concern
This is to certify that final year industrial engineering project team specified below from Thapathali Campus has successfully completed “Energy Audit” project dated 7th – 12th February 2014 in Pasupati Candle Filter Udhyog (LPG Regulator Division). The project was carried under the supervision of Er. BhismaPandit (senior energy expert) . The following are the enthusiastic members of energy audit student project team.
BidurGhimire
BikramBasnet.
Bikram Dahal
Prakash Jamar Kattel
Samir BabuBhetwal
Sarbin Shrestha
ShekharGhimire
UddhavBasnet
The project team has created valuable output for industry and recommended effective measures to reduce energy cost and consumption. The team is spectacular with their work completion, dedication and has stunned us with their performance. On behalf of company, I would also like to admire their report and presentation.
I would like to thank the project team for their excellent teamwork and best wishes for their success in future.
……………………………………….
Sushil Kumar Agrawal
Managing director
Pasupati Candle Filter Udhyog.
Kathmandu

Energy Audit

Energy Audit
Letter of approval from Pashupati Filter Candle Udhyog

Energy Audit
ACKNOWLEDGEMENT
This project report couldn’t have been accomplished without the splendid support and cooperation of all those unnamed inspires who encouraged us during our project. This final year project report has been prepared and submitted as a part of industrial engineering program BIE (IV/I).
We wish to express our sincere gratitude to Thapathali Campus, particularly Department Of Industrial Engineering for providing us an opportunity for undertaking this project on “Energy Audit”. This project bears on imprint of many peoples. We have no words to express our gratitude for the facilitation and encouragement provided to us by Er. Bhisma Pandit and Er.Ram Sundar Kusi . We are extremely thankful for the support of Industrial Energy Management Project (IEMP). We sincerely thank Er. Sudan Neupane of Industrial Department for integral support to carry out the study and all other teachers for their valuable suggestions.
We also wish to express our gratitude to the officials and other staff members of Pashupati Filter and Candle Udhyog and Country Food Pvt.Ltd for their support and cooperation during the energy audit for retrieving the required information. Our special thanks to Sushil Kumar Agrawal, Pradip Regmi of Pashupati filter Candle Udhyog and Santosh Lal Shrestha, Meena Kumari Chidi of Country Food Pvt. Ltd for allowing us to perform audit in the factory.
We are thankful to our seniors, friends of Thapathali Engineering Campus for their smart support and inspiration. Where this report succeeds we share the credits where it errors we particular group accept the responsibility.

Energy Audit
EXECUTIVE SUMMARY
Energy itself is growing issue at present scenario and its effective management has growing scope in the field of industrialization. As Industrial Engineer, we must have sound knowledge of energy management, which would be integral part when we enter the field of our engineering. This is the main reason behind selection of “Energy Audit”. The project is supervised by Er. Bhisma Pandit(senior energy expert) and audit instrument support from Thapathali Campus and IEMP. The project is carried with permission in Pashupati Filter Candle Udhyog (LPG LPG Regulator Division)and Country foods Pvt.Ltd. Energy audit is the verification, monitoring and analysis of use of energy including submission of technical report containing recommendations for improving energy efficiency with cost benefit analysis and an action plan to reduce energy consumption. It is carried in three phases, preliminary audit, detail audit and post audit phase. With the authentic test procedure and instrument provided, we performed energy saving calculation and recommended various measures suitable for industries specifying financial investment and payback period. At the beginning, preliminary data was taken on energy share and financial saving was evaluated based on same data. After the energy audit performed under the supervision, we compiled report and presented in both industries. We discovered different areas of energy saving like excess air control in furnace, use of capacitor bank, condensate water recovery, DG loading etc. The project emerged to be successful both from technical and financial point of view. The financial saving from both industries is quite appreciable with the measures recommended by our project team. To attain objective of project wasn’t easy we had great challenge in industries confirmation and certain practical limitation. At last, the group team effort made it possible on time.

Energy Audit
TABLE OF CONTENTS
DECLARATION ………………………………………………………………………………...2
WORDS FROM SUPERVISOR………………………………………………………..…….…..3
CERTIFICATE OF COMPLETION ………………………………………………….…….…4-5
CERTIFICATE OF APPROVAL……………………………………………………….….……..6
ACKNOWLEDGEMENT…….………………………………………………………………….7
EXECUTIVE SUMMARY…………………………………………………………………..…..8
LIST OF TABLES…………………………………………………………………………..…..11
LIST OF CHARTS………………………………………………………………………………12
ABBREVIATION………………………………………………………………………………..13
NOTE……………………………………………………………………………………………14
1 INTRODUCTION ................................................................................................................ 14
2 POTENTIAL OF ENERGY AUDIT IN NEPAL:................................................................ 16
3 OBJECTIVE ......................................................................................................................... 18
4 LIMITATIONS ..................................................................................................................... 19 5 LITERATURE REVIEW: .................................................................................................... 20 5.1 Existing technology ........................................................................................................ 20 5.2 Swot analysis .................................................................................................................. 23 5.3 Existing policy: .............................................................................................................. 23 5.4 Related Organizations: ................................................................................................... 24
5.5 International vs. National ............................................................................................... 24
6 METHODOLOGY: .............................................................................................................. 25

Energy Audit
7 CASE STUDY: A) PASHUPATI FILTER CANDLE UDHYOG (LPG LPG REGULATOR DIVISION) ................................................................................................................................... 33
7.1 Overview Of Industry..................................................................................................... 33
7.2 Distribution Of Energy Sources ..................................................................................... 34
7.3 Energy Scenario ............................................................................................................. 35
7.4 Energy Audit And Savings ............................................................................................. 38
8 CASE STUDY (B) COUNTRY FOOD PVT.LTD. ............................................................. 49
8.1 Overview Of Industry..................................................................................................... 49
8.2 Energy Audit And Savings ............................................................................................. 50
8.3 Other energy saving opportunity that could not be quantified ....................................... 59
8.4 Energy saving opportunity in future .............................................................................. 59
9 FINDINGS AND ANALYSIS ............................................................................................. 60
10 CONCLUSION ..................................................................................................................... 61
11 RECOMMENDATION ........................................................................................................ 62
12 REFERENCES ..................................................................................................................... 63
APPENDIX…………………………………………………………………………………..63-68

Energy Audit
LIST OF TABLES
Table 5.1: Energy Audit Instrument ............................................................................................ 20
Table 6.1: Plan of action of Energy Audit ................................................................................... 30
Table 7.1: Overview of Industry .................................................................................................. 33
Table 7.2: Distribution of Electrical Energy ................................................................................ 34
Table 7.3: Distribution of Diesel consumption ............................................................................ 34
Table 7.4: Distribution of LPG Consumption .............................................................................. 35
Table 7.5: list of energy sources .................................................................................................. 35
Table 7.6: Energy ratio evaluation ............................................................................................... 36
Table 7.7: Quantification of loss and savings .............................................................................. 39
Table 7.8: Investment and Payback for Compressor Leakage Maintenance ............................... 40
Table 7.9: Investment and payback for the insulation cap ........................................................... 42
Table 7.10: melted metal and diesel consumed by melting furnace ............................................ 43
Table 7.11: Showing Diesel Consumed and Piece Manufactured ............................................... 44
Table 7.12: Savings in lighting system ........................................................................................ 48
Table 8.1: Overview of Industry .................................................................................................. 49
Table 8.2: Electricity tariff depending on time of day ................................................................. 50

Energy Audit
LIST OF CHART
Chart 2.1: Energy consumption scenario of Nepalese Industries ............................................................ 17
Chart 7.1:Distribution of expenses in energy sources (for year 069/070) ............................................... 33
Chart 7.2: Consumption of Diesel and Electricity .................................................................................. 37
Chart 7 3: Cost of diesel with respect to monthly turnover..................................................................... 37

Energy Audit
ABERRATION
kJ : Kilo Joule
Kg : Kilogram
kW : Kilo Watt
kVA : Kilo Volt Ampere
kVAR : Kilo Volt Ampere (Reactive)
kWh : Kilo Watt Hour
Kg/hr : Kilogram per Hour
Kcal : Kilo Calorie
M3/min: Cubic meter per minute
FAD:- Free Air Delivery
Tph: Ton Per Hours
LPG:- Liquified Petroleum Gas
F/A : From and At
GoN: Government of Nepal
FNCCI : Federation of Nepalese Chamber of Commerce and Industries
NEEP : Nepal Energy Efficiency Program
CNI : Chambers of Nepalese Industries
GiZ : Deutsche Gessellschaft fur Internationale Zusammenarbeit
VFD:- Variable frequency drive

Energy Audit
1 INTRODUCTION
1.1 DEFINITION
Energy audit is defined as the verification, monitoring and analysis of use of energy including submission of technical report containing recommendations for improving energy efficiency with cost benefit analysis and an action plan to reduce energy consumption.
Need for energy audit:
 Three top operating expenses are energy (both electrical and thermal), labor and materials.
 Energy would emerge as a top ranker for cost reduction
 primary objective of Energy Audit is to determine ways to reduce energy consumption per unit of product output or to lower operating costs
 Energy Audit provides a “ bench-mark” (Reference point) for managing energy in the organization
Type of energy audit
The type of Energy Audit to be performed depends on:
 Function and type of organization
 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.
1. Preliminary Audit
2. Detailed Audit

Energy Audit
1. Preliminary Audit
Preliminary energy audit is a relatively quick exercise to:
 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
2. Detailed Energy Audit
A comprehensive audit provides a detailed energy project implementation plan for a water distribution and water treatment facility, since it evaluates all major energy using systems.
This type of audit offers the most accurate estimate of energy savings and cost. It considers the interactive effects of all projects, accounts for the energy use of all major equipment’s (Like pumps, electrical motors, transformers, electrical system lighting etc. and includes detailed energy cost saving calculations and project cost.
In a comprehensive audit, one of the key elements is the energy balance. This is based on an inventory of energy using systems, assumptions of current operating conditions and calculations of energy use. This estimated use is than compared to utility bill charges.

Energy Audit
2 POTENTIAL OF ENERGY AUDIT IN NEPAL: Nepalese industries offer a huge potential to cut production cost by using energy more efficiently. The energy makes the machine to operate and form the product/service that industry is willing to give its customer. Nepalese industry still lack in energy awareness and it is necessary to quantify energy saved equivalent to money saved because it is what attracts the management and motivates to take step to save energy. Energy audit had emerged in Nepal only 4-5 years ago so it is still beyond the approach of many industries in Nepal that haven’t realized how fruitful it is to them. It is necessary to motivate the industries as it has increased production with the increase of energy consumption. We always have problem of limited resources and energy available is limited and should be optimized in consumption. A drop of petroleum product saved per day also results in higher saving when calculated in long term. The saving of fuel counts a lot from environment and financial point of view. The more the energy is consumed the more saving opportunities can be discovered. We can see large amount of potential in Nepal for energy audit as it is just in growing phase and energy is consumed in large amount.

Energy Audit
Chart 2.1: Energy consumption scenario of Nepalese Industries
Industrial energy consumption by fuel type in percentage 2008/2009 (source: DOI 2009/10;DCSI 2009/10) total final energy consumption 13.4 MGJ
coal, 58.7
electricity, 23.2
agri residue, 10
fuel wood, 5.4
HS Diesel, 1.8
other petroleum, 0.9
kerosene, 0.8
L diesel, 0.1
coal
electricity
agri residue
fuel wood
HS Diesel
other petroleum
kerosene
L diesel

Energy Audit
3 OBJECTIVE
3.1 MAIN OBJECTIVE
 To perform the Energy Audit in different industries.
3.2 SPECIFIC OBJECTIVE
 To reduce energy cost through energy conservation and planning
 Estimate of the proportion of costs and opportunities for businesses to reduce costs for each area of energy use;
 Identify priority conservation; - assessment of the energy saving potential in selected areas;
 Examination of energy efficiency performed or planned in the company of innovation;
 Development of effective measures for the implementation of the identified potential energy savings;
 Development of proposals for the organization of the energy management system in the enterprise;
 Making energy efficiency programs during the energy audit.

Energy Audit
4 LIMITATIONS
 Inadequate availability of test equipment for the various tests to be performed in the industries. Also, available equipment’s are of lower performance.
 Less availability of factual data from the industries as they have no proper records.
 Difficult to manage time of inspection and testing as per the production schedule.
 Forecasted energy saving may alter according to the change in production system and volume
 Some data which cannot be measured and quantified are assumed and considered theoretically.
 Costing related to recommended change and parts replacement are according to current market price which may vary accordingly.
 Some quantification were beyond our knowledge and approach

Energy Audit
5 LITERATURE REVIEW: 5.1 EXISTING TECHNOLOGY Energy performance assessment consists of several instruments that facilitate the energy audit in simple way. Energy audit has flourished in construction and building at international level but it is still in progressive phase at Nepal. The concept of energy audit is increasing in Nepal in past few years. The concept of energy audit not only confined within the energy saving but also simultaneously helps in establishment of safe working environment within the industries. The measures which assists in energy saving will also helps in safety management of machines, equipment, materials and method of work to be performed Table 5.1: Energy Audit Instrument
Energy Audit Instrument with image
Description
1.Flue Gas Analyzer:
Used for optimizing the combustion efficiency by measuring/monitoring the oxygen and CO levels in flue gas of boilers, furnaces etc. and calculation of CO2 percentage in excess air level and efficiency.
2.Luxmeter
Used for measurement of illumination level. Illumination levels are measured with a lux meter. It consists of a photo cell which senses the light output, converts to electrical impulses which are calibrated as lux

Energy Audit
3.Tachometer:
In any audit exercise, speed measurements are
critical as they may change with frequency, belt
slip and loading. A simple tachometer is a contact
type instrument which can be used where direct
access is possible.
4. Fyrite kit:
A hand bellow pump draws the flue gas sample
into the solution inside the fyrite. A chemical
reaction changes the liquid volume revealing the
amount of gas. A separate fyrite can be used for
O2 andCO2 measurement.
5. Anemometers
Anemometers are used to measure airflow and
volume at registers and in ducts. Vane
anemometers measure airflow independent of the
air density making them ideal for many
applications where measurement without the need
for corrections is desired. Hot Wire anemometers
are used for low velocity measurements and
require corrections for high accuracy
measurements. Hot wires are ideal for airflow
measurements at fume hoods and other low flow
applications.

Energy Audit
6.Infrared thermometer
A non-contact or infrared thermometer allows the measurement of temperature without physical contact between the thermometer and the objects of which temperature is determined.
7. Ultrasonic Leak detector Ultrasonic leak detector is used to detect leaks of compressed air and other gases which are normally not possible to detect with human ear. 8. Clamp meter Clamp-on meter or power analyzer are used to measure main electrical parameters such as KVA, KW, PF, Hertz, KVAr, Amps, and volts. Some of these instruments also measure harmonics. Instant measurements can be taken with hand- held meters, while more advanced ones facilitates cumulative readings with print out as specified intervals. These are very useful instruments for measuring above parameters in a wire without having to make any live electrical connections

Energy Audit
5.2 SWOT ANALYSIS Strength  Habitual with industrial environment  Emerging topic in present scenario  Familiar with production activities Weakness  Equipment limitation  Lack of authentic data for baseline  It isn't mandatory (strategic issue) Opportunity  Career development  Energy and cost savings  Personal relationship with industrial personnel Threat  Minor miscalculation may lead to false output  Rejection of energy audit performance due to confidential information of company 5.3 EXISTING POLICY: There is limited policy made by the Government of Nepal for the energy audit and it’sManagement to be done in the industrial sector. But there is a government project namely “Industrial Energy Management Project” (IEMP) which is doing energy audit for the industries and also providing some trainings and seminars to the Energy related professionals and industrial workers. Beside energy being the major problem in the country, wastage of energy in the industrial sector is major problem. The GoN had no strong and effective policy regardaing the energy management in Nepalese industries. Energy audits are not mandatory in Nepalese industries.

Energy Audit
5.4 RELATED ORGANIZATIONS:
The Energy Efficiency Centre (EEC) under FNCCI is the implementing partner of NEEP component-3. EEC is a not for profit autonomous body which aims to provide energy efficiency services to the Nepalese industrial sector. Other organizations like IEMP and CNI are working in industrial and commercial sectors to manage energy consumption with proper utilization and management through Energy Auditing.
5.5 INTERNATIONAL VS. NATIONAL
 Energy audit is just at growing phase
 Lack of energy auditors in Nepal
 Energy audit isn’t mandatory and there is no legal provision.
 Lack of complex energy audit instrument.
 Limited organization uplifting and encouraging about energy efficiency.
 At international level we can even find energy audit in buildings and construction.

Energy Audit
6 METHODOLOGY:
6.1 SITE VISITS
 M/S Pashupati Filter candle Udhyog (LPG LPG Regulator Division) and M/S Country Food Pvt.Ltd was visited daily for a week and consulted with the technician and plant managers to get the relevant help regarding our project work and to get details about the processes and technical factors in the respective industries.
 Energy efficiency centre (EEC) office in FNCCI building, Teku was visited frequently for grasping the experts’ opinion regarding the project matters
 Industrial Energy Management Project (IEMP) office at Tripureshwor was visited for grasping the experts’ opinion regarding the project matters and support of energy audit equipment.
6.2 DATA COLLECTION
 Base line data were collected from respective industries’ record book.
 The power consumed by various machineries and equipment were recorded with respect to time and loading. The instrument used to measure the power is clamp on meter.
 The temperature on the surface of furnace, boiler body and steam pipeline were recorded by using the infrared thermometer.
 The air intake from the FD in the boiler was recorded using the Anemometer.
 Overall inspection of the plant machineries, safety approach, and the work flow was inspected visually and recorded.
6.3 ANALYSIS
 The collected data were analyzed and saving opportunities were suggested.
 The suggestion for the energy saving were made as per the technical and financial feasibility

Energy Audit
 Over all industrial process were analyzed from the prospective of safety and the relevant suggestion were made to improve the safe practice and occupational health within the industries.

Energy Audit
6.4 TEST PERFORMED
Boiler Efficiency test:
Boiler efficiency can be calculated by two methods namely direct and indirect method. We applied direct method for the calculation of boiler efficiency. The percentage output in the form of steam with respect to fuel input is calculated as efficiency.
Efficiency (h) = 푄1∗(ℎ2−ℎ1) 푄2∗퐺퐶푉 표푓 푓푢푒푙 * 100 %
Where,
Q1 = Quantity of steam generated per hour
Q2 = Quantity of fuel consumed per hour
h1 = Enthalpy of inlet feed water
h2 = Enthalpy of steam generated
GCV = Gross Calorific value
Furnace Efficiency test:
We applied direct method for the calculation of furnace efficiency. The amount of metal melted is weighted and the fuel consumed is measured. The efficiency is calculated by following formula
Efficiency (h) = 푚퐶푝(푡2−푡1)+푚푙 푄∗퐺퐶푉 표푓 푓푢푒푙 * 100 %

Energy Audit
Where,
M = mass of metal melted (kg/hr)
Cp = specific heat capacity of metal (KJ/kg-hr)
T1 = initial temperature of metal (0C)
T2 = melting temperature of metal (0C)
L = latent heat of melting of metal (KJ/kg)
Q = Quantity of fuel consumed (Kg/hr)
GCV = Gross Calorific Value. (KJ/kg)
Excess air test
The air intake in the boiler through FD was measured. The instrument used to measure the flow of air was anemometer. The percentage intake of air via FD with respect to the theoretical air requirement of the fuel is calculated as excess air quantity.
Excess air quantity: 푄1 푄2 * 100%
Q1: Quantity of air inlet via FD (kg/hr)
Q2: Quantity of theoretical air required for combustion of fuel (kg/hr)
Q1 is calculated by measuring the inlet velocity of the air via FD and the diameter of FD opening. The air inlet is obstructed by the damper.
Q1: 푣푒푙표푐푖푡푦 표푓 푎푖푟 ∗ 푎푟푒푎 표푓 푐푟표푠푠 푠푒푐푡푖표푖푛 표푓 퐹퐷 ∗ % 표푓 푢푛푑푎푚푝푒푑 푎푖푟 푖푛푙푒푡 푠푝푒푐푖푓푖푐 푔푟푎푣푖푡푦 표푓 푎푖푟
In case of theoretical air requirement, the amount of actual air required will be about 20- 25% more than the theoretical air requirement. The theoretical air requirement for various fuels is listed in appendix.

Energy Audit
FAD test:
This test is performed as a performance assessment test in the compressed air system.
FAD = (P2-P1)/Po * (V/T)
Where,
P2 = final pressurekg/cm²
P1 = initial pressurekg/cm²
Po = atmospheric pressure in kg/cm²
T =time taken to build P2 pressure in minutes
V = volume of compressor cylinder

Energy Audit
6.5 PLAN OF ACTIONS Table 6.1: Plan of action of Energy Audit
Step
Plan of action
Purpose/Results
1
Phase I-Pre Audit Phase
 Plan and organize
 Walk through audit
 Informal interview with energy manager, production/plant manager
 Resource planning, establish/organize an energy audit team
 Organize instruments and time frame
 Macro data collection (suitable to type of industry)
 Familiarization of process/plant activities
 First hand observation and assessment of current level operation and practices
2
 Conduct of brief meeting/awareness programmed with all divisional heads and person concerned (2- 3hrs).
 Building up cooperation
 Issue questionnaire for each department
 Orientation, awareness creation
3
Phase II-Audit Phase
 Primary data gathering, process flow diagram and energy utility diagram
 Historic data analysis, baseline data collection
 Prepare flow charts
 All service utilities system diagram (example: single power distribution diagram, water, compressed air and steam distribution)
 Design, operating data and schedule of operation
 Annual energy bills and energy consumption pattern (refer manual, log

Energy Audit
sheet, name plate, interview)
4
 Conduct survey and monitoring.
 Measurements :Motor survey, insulation, and lighting survey with portable instruments for collection of more and accurate data. Confirm and compare operating data with design data
5
 Conduct of detail trials/experiments for selected energy guzzles.
 Trials/Experiments:
 24 hours power monitoring (MD, PF, kwh etc)
 Load variations trends in pumps, fans compressor etc
 Boiler/Efficiency trials for (4-8 hours)
 Furnace efficiency trials
6
 Analysis of energy use
 Energy and material balance
 Energy loss/waste analysis
7
 Identification and development of energy conservation (ENCON) opportunities
 Energy and material balance and energy loss/waste analysis
 Identification and consolidation on ENCON measures
 Conceive, develop, and refine ideas
 Review the previous ideas suggested by unit personal
 Review the previous ideas suggested by energy audit if any
 Use brainstorming and value analysis techniques
 Contact vendors for new/efficient technology

Energy Audit
8
 Cost benefits analysis
 Assess technical feasibility, economic viability and prioritization of ENCON option for implementation
 Select the most promising projects
 Prioritize by low, medium, long term measures
9
 Reporting and presentation to the top management
 Documentation, report presentation to the top management
10
Phase III-Post Audit Phase
 Implementation and follow up
Assist And implement ENCON recommendation measures and monitor and performance
 Action plan, schedule for implementation
 Follow up and periodic review

Energy Audit
7 CASE STUDY: A) PASHUPATI FILTER CANDLE UDHYOG (LPG LPG REGULATOR DIVISION)
7.1 OVERVIEW OF INDUSTRY Table 7.1: Overview of Industry
Name
Pashupati Filter Candle Udhyog
Location
Dadapauwa, Ramkot
Type
Small Scale Industries
Standards achieved
NS, ISO- 9001/2008
Products
LPG regulators
Filter candle
Brands
Indo LPG regulator
Mauria LPG regulator
Hari International
No of workers
20-25
Energy required
Electricity
thermal
compressed Air
Distribution of energy
Chart 7.1:Distribution of expenses in energy sources (for year 069/070)
diesel , 75%
LPG, 5%
Coal, 9%
electricity, 11%

Energy Audit
7.2 DISTRIBUTION OF ENERGY SOURCES
7.2.1 Electrical Energy Table 7.2: Distribution of Electrical Energy
Major Utilities
Compressor
Die casting with aluminum melting furnace
Drilling Machines
Drying Furnace
lighting
Approved demand
30 kW
No of units consumed
12769
Demand charge (for 30 kVA fixed demand)
12*3000
Rs 36000
Cost of energy
@ Rs 8 per kWh
Rs 102152
Total electrical energy charge
Rs. 138152
7.2.2 Diesel Consumption Table 7.3: Distribution of Diesel consumption
Major uses
Diesel Generating Set
Aluminum melting furnace
DG capacity
62 kVA
Furnace capacity
100kg/hr
Diesel consumption in litre
8800
Cost of diesel
@ Rs 103 per litre
Rs. 906400

Energy Audit
7.2.3 LPG Consumption Table 7.4: Distribution of LPG Consumption
Major uses
1. LPG furnace
2. LPG geyser
Furnace capacity
1000 piece /lot
Geyser capacity
100 ltr/hr
LPG consumption (kg)
987.6
Cost of LPG
@107.3 per kg
105969.5
7.3 ENERGY SCENARIO Table 7.5: list of energy sources
Fuels
Kcal/Kg
Unit (kg)
Total Kcal
kWh
Total Cost(Rs)
Diesel
10000
7480.00
74800000.0
86976.74
906576.00
Coal
4000
505.00
20260000.0
23558.14
65845.00
LPG
11800
987.60
11653680.0
13550.79
105969.48
Electricity
(kWh) 12769.0
10981357.2
12769.00
134701.00
Total Energy
117695037.2
136854.70
1213091.48

Energy Audit
7.3.1 Energy Consumption Table 7.6: Energy ratio evaluation
Particulars
Quantity
Total energy consumed (kWh)
136854.70
Total cost of energy
Rs.1213091.48
Annual turnover of 069/70 in pieces
141933.00
Annual turnover of 069/70
Rs.23285714.00
Cost of Energy per piece
Rs.8.546
% of energy cost over annual turn over
5.2%

Energy Audit
Chart 7.2: Consumption of Diesel and Electricity
Chart 7 3: Cost of diesel with respect to monthly turnover
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
shrawan
bhadra
aswin
kartik
mangshir
poush
magh
falgun
chaitra
baisakh
jestha
ashar
2069
2070
cost of diesel
electricity bill
0
20
40
60
80
100
120
140
160
0
500
1000
1500
2000
2500
3000
3500
shrawan
bhadra
aswin
kartik
mangshir
poush
magh
falgun
chaitra
baisakh
jestha
ashar
2069
2070
Total turnover
Cost of diesel
Turnover in ,000
cost of diesel in ,000

Energy Audit
7.4 ENERGY AUDIT AND SAVINGS
7.4.1 Air Compressors:
During our trial, we find significant loss of compressed air on the pipeline as well as in the compressor itself. We perform free air delivery test (FAD) and leakage test on compressor to quantify the losses. From our trial and testing, we came to following conclusion
Significant savings can be made by tracking the losses of compressed air in pipeline
Loss of pressure in cylinder, if compressor is standby which can be eliminated to have significant saving
Efficiency of compressor can be increased by decreasing the room temperature of compressor room in summer days.
Losses of compressed air in pipeline and savings:
FAD test
P2 = 1.097 kg/ cm²,
Po =12 kg/cm²,
V = 420lit= 0.42m³,
T =6.06 min
FAD = (P2-P1)/Po * (V/T)
= (12-1.0197)/1.0197 *(0.42/6.1)
=0.7414 m³/min
(Where P2=final pressure, P1= initial pressure, Po= atmospheric pressure in kg/cm² T=time taken to build P2 pressure in min
Similarly for another compressor V=350 lit, T=8.41 min; FAD=0.448 m³/min

Energy Audit
Leakage test
(For 420 lit receiver volume capacity compressor)
Time taken for load (T) =2.17 min,
Time on unload (t) =12.25min ,
Q=compressor capacity in m³/min=0.7414m³/min
Leakage % = (T/ T+t)*100
= 15%,
Leakage quantity = (T/ T+t)*Q=0.11m³/minute
Table 7.7: Quantification of loss and savings Description Value FAD 0.7414m³/min Load(rated) 7.5 kw leakage qty 0.11m³/min specific power consumption 0.1686 kwhr/m³ energy lost due to leakage 8.902 kwhr/day annual leakage 2492.56 unit cost of leakage annual Rs. 34,272.7 Savings 60 % of leakage Rs. 20,563.62

Energy Audit
Compressed Air Losses Due to Plant Shutdown
The cylinder of the compressor must hold the pressure with the maximum decrease of pressure not more than 5%, if compressor is not connected with the supply. The significant decrease in pressure indicates the leakage in valve of compressor or joints of cylinder. Such leakage in compressed air facility increases with time if not accounted. During our trial over 7.5 kW compressors with cylinder capacity 420 liter, we found that the pressure in the cylinder drops to ‘0’ in the morning even if it was maintained in 9 kg/cm2 before shut down.
Quantification of loss and savings
Time to raise pressure to 9 kg/cm2 = 7.65 min (0.1275 hrs)
Leakage in terms of kWh/day = 0.1275 x 7.5 = 0.95625 kWh
No. of days of operation = 280 days
Annual leakage in kWh = 280 x 0.95625 = 267.75 kWh/year
Average cost per unit (Rs/kWh) = Rs. 13.75/kWh
Annual savings = Rs 3681.5625
Investment and payback Table 7.8: Investment and Payback for Compressor Leakage Maintenance
S.N
Particulars
Investment
Simple payback
1
Change valve
2000-4000
0.54-1.08 yrs
2
Regular monitoring
-
-

Energy Audit
Energy loss due to the location of Air Compressor:
The efficiency of the compressor highly depends upon the temperature of the inlet air. The efficiency of the compressor decrease with the rise in room temperature of compressor room. Higher the temperature more the work compressor needs to do to compress the air hence more power is consumed. It is that for every rise in 40C in room temperature the efficiency decreases by 1-2% for the single stage and 2-3 % for double stage compressor.
Details of compressor room
No. of compressor = 3
Height of roof = less than 10 feet
Roof type = zinc coated plates
No. of windows = 1
Temperature in winter days = 20-25 0C
Temperature in summer days = 30-35 0C
We can increase the efficiency of the compressors by decreasing the room temperature of the compressor room during summer days. We can maintain the room temperature to 20- 25 0C, during summer days simply by covering the roof externally or internally.
Losses quantification and Savings
Decrease in temperature = 100C
Increase in efficiency = 5%
No. of months = 6 months
Units saved = 126.35 units

Energy Audit
Annual savings = Rs. 1705.725 (from 1 compressor)
Overall saving from 3 compressors = Rs. 4000. (Approx.)
Investment and payback Table 7.9: Investment and payback for the insulation cap
S.N
Particulars
Investment
Simple payback
1
Internal covering from plywood
5000
1.25 yrs
2
External covering jute sacks and straw
2000
6 months

Energy Audit
7.4.2 Furnace:
Increasing air flow
Initially flame of the fuel burnt was observed and it was very yellowish which is not appropriate. It was due to less air supply then requirement so fuel was not completely giving its full usable energy so additional air was required. For that, the adjustment was done to supply more air and the corresponding fuel consumption and its output work were noted as below and the efficiencies before and after is mentioned. Table 7.10: melted metal and diesel consumed by melting furnace
Furnace
Melted amount
Melting Stock Weight
S.N
Day
Kg
diesel(ltr)
No. of Stock Pieces
1
1 (without adjustment)
439.8(M1)
35
1402
2
2 (with air adjustment)
528(M2)
34
1640
Initial temperature of alloy brick (T1) = 250c
Final temperature of melted alloy (T2) = 3200c
Specific heat capacity of alloy Cp = 417 J/Kg/K
Latent heat of fusion of alloy La = 110 KJ/Kg/K
Efficiency of furnace without adjustment (as it is condition)
Heat used (output) Q1 = M1 x Cp x (T2-T1) +M1 x La
= 439.8 x 417 x (320-25) +439.8 x 110 x 1000
=101929807.2 J
Heat input(Q2) = (oil ltrs x sp. Gravity) x GCV x 4.2 x 1000 J

Energy Audit
=1249500000 J
Efficiency = (Output (Q1)/Input (Q2)) x 100%
= 8.16%
Efficiency of furnace with air adjustment
Heat used (output) (Q1) = 123031920 J
Heat input (Q2) = 1213800000 J
Therefore efficiency = 10.136%
Table 7.11: Showing Diesel Consumed and Piece Manufactured
Manufactured pieces
Diesel consumed (liters)
Diesel consumed per piece
1402 (day 1)
35
0.02496 ltr/pcs
1640 (day 2)
34
0.02073 ltr/pcs
Savings after adjustment of air
Avg. annual production = 141933 pcs.
Saving per pcs of production = 0.02496-0.02073 ltr/piece
Annual savings = 0.00423 x 141933
= 600.37659 ltr
=Rs. 61,838.788
Savings due to stocks Pre-heating=
Alloy bars can be preheated by the flue gas and its temperature can be increased before melting in the furnace. By doing so, significant amount of fuel can be saved.

Energy Audit
Pre heating can be done by using stand of iron bars placed in the flue gas-escaping vent. For this simple mechanical structure can be used, its investment and savings are as below.
Initial temperature of alloy to be melted = 25 0C
Temperature can be maintained after pre-heat = 800C (minimum)
Specific heat capacity of alloy = 417 j/kg0C
Gross Calorific Value of Diesel = 10000 kcal/litre
= 8500 kcal/kg
Metal melting to per piece ratio= (wt melted/ piece manufactured) = 0.315
Forecasted wt of annum = 141933 x 0.315
= 44708.895 kg
Heat energy saved = [44708.895 x 417 x (80-25)]
= 1025398507 J = 1025398.5 kJ = 2444142.5016 kcal
Savings = Heat energy saved / (GCV of diesel x efficiency of furnace)
= 2444142.5016/ (10000 x 0.10136)
= 283.37 litres
Rate of fuel (diesel) = Rs 103/litre
Savings in Rupees = Rs. 29187.37832
Investment required=
Approximately for iron bar structure = Rs. 10,000
Simple Payback period = 0.34 yrs

Energy Audit
Saving due to covering Furnace during idle hours:
Initial temperature of melting vessel = 700C (without cap, in the beginning of the day)
Alloy residue temperature = 700C (without cap, in the beginning of the day)
Weight of vessel = 180 Kg (cast iron)
Weight of alloy in vessel = 10-15 Kg
Temp can be maintained after insulation = 2000C
Heat saving per day = 180 x 460 x (200-70) + 12.5 x 417 x (200-70)
= 11441625 J
Saving in term of oil (ltr) = heat saving per day/ GCV of oil* efficiency
= 3.16 ltr/Day
Annual saving = 3.16 x 280
= 884.8 liters
In amount = Rs. 91134.4
Saving in half hr break time
Oil saved in that half hr = 0.4 ltr per day
= 280 x 0.4
= 112 ltr
= 112 x 103
= Rs. 11536
Total saving = Rs 102670.4

Energy Audit
Investment and payback
Area of furnace cap = 5857.53 cm²
Type of insulation = Glass fibre
Cost of insulation = 5000-6000 per sq. Meter
Overall cost of insulation and installation = 6,000 max.
Simple payback period= less than a month
7.4.3 Performance Evaluation of DG set:
Diesel generator sets of 62.5 KVA provide the backup in case of power failure.
In general, diesel set accounts for 20% of total electrical energy used. During our trial, it was found that loading was only 33%.
According to manufacture Manual
At 33% loading, DG generates 2.5 kWh/litre
At 70-80% loading, DG generates 3.5 kWh/litre
Considering 15kwh energy is consumed per hour for 3 hours a day,
Average saving per day =5.14litres
Saving per Year = 1440 liter of diesel
Savings in amount = 1.48 lakhs
Investment and payback
Cost of new generator = 7 lakh
Payback period = 4.72 years

Energy Audit
7.4.4 Savings due to Lighting Systems:
Nine bulbs were used as light indicator, which is operated 24 hrs a day each of 20 watt, which is unwanted, and instead 3-4 watt diode or CFL can be used as indicator. Table 7.12: Savings in lighting system
Bulbs
9 each 20 watts
Operation
24hrs each day
Cost per unit
Rs 13.75
Total kWh saved
1182.5
Total saving
Rs. 16260.75

Energy Audit
8 CASE STUDY (B) COUNTRY FOOD PVT.LTD.
8.1 OVERVIEW OF INDUSTRY Table 8.1: Overview of Industry
Name
Country Food Pvt.Ltd
Location
Chittapol-1. Bhaktapur
Type
Small Scale Industries
Products
Fresh milk
Butter
Brands
Nova
No of workers.
10-15
Energy Required
Electricity
Thermal

Energy Audit
8.2 ENERGY AUDIT AND SAVINGS
8.2.1 Plant Energy Systems
Electrical Energy and Load management Practices=
The approved maximum demand of the plant is 160 kVA. The dairy receives electric power from Nepal Electricity Authority, through a 160 kVA transformer at 11 kV and stepped down to 415.
The monthly demand charges as charged by Nepal Electricity Authority is at the rate of .230/KVA. The minimum billable demand is 50 % of approved demand of 160 KVA. The energy tariff depends on the time of the day and currently, is as follows Table 8.2: Electricity tariff depending on time of day
Period
./kWh
Peak time (6 PM to 11 PM)-R1
8.75
Off peak time (11 PM to 6 AM)-R2
4.30
Other time (6 AM to 6 PM)-R3
7.10
A Diesel generator sets of 125 KVA each, provide the backup in case of power failure.
Maximum Demand variation and Charges:
The billing demand charged by NEA is seen to be 80 kVA though the actual demand recorded is less. This is because the contract maximum demand of the plant is 160 kVA and NEA charges demand charge for 50 % of the contract maximum demand or actual demand recorded in the Energy meter (whichever is higher).

Energy Audit
Current scenario
Current approved demand =160 KvA Current minimum charge =80 Kva Current maximum demand =71 Kva So company is paying 9Kva extra charge.
Cost per Kva =Rs. 230
Extra Cost paid =9*230*12 =Rs. 24840 per year
Recommendation
Reduce demand charge to 100Kva.
Process
An official Letter from company to NEA.
 Approved demand can be changed by just sending letter if future demand increases.

Energy Audit
Power Factor Variation
The power factor at tail end of various loads as measured, is from 0.7 to 0.9.It is appreciated that the plant has installed capacitor bank with automatic power factor control to ensure achieving a power factor of 0.95 to optimize maximum demand and charges thereof.
Used of capacitor bank if demand is reduce
Current maximum demand = 71 Kva
Current power factor = 0.8
Proposed power factor = 0.95
Current power =56 Kw
Capacitor required =56*(tanᴓ1-tanᴓ2)
=23.45 Kva
= 25 Kva
Cost =25*1000
=Rs. 25000
Proposed maximum demand = 59 Kva
Saving = 12*230*12
=Rs. 33120
Payback period = 0.75 years

Energy Audit
Thermal Energy System
Boiler Detail
Type of boiler = husk pac boiler
Capacity = 1000 kg F/A at 1000C
Fuel used for boiler = wood (low grade, pine wood bark)
GCV of fuel used = 3200 kcal/kg
No of hours running = 6 – 8 Hours Per day (depending upon requirement)
Efficiency calculation of boiler
By direct method
Type of boiler = Wood Fired
Quantity of Steam (Dry) generated = 0.133 TPH = 133.33 kg/hr.
Steam pressure (gauze/temp) = 8 kg/cm2 at 1500C
Quantity of wood consumed = 0.07 TPH = 70 kg/hr.
Enthalpy of steam at 8 kg/cm2 @ 1500C =2516 KJ/kg
Enthalpy of inlet fed water at atmospheric pressure at 200C = 84 kJ /kg
Efficiency (h) = { 1000 * 0.1333 * (2516 – 84)}/ {0.07 * 1000 *3200 * 4.2}
= 34.45 %
Evaporation Ratio = 133.33/70
= 1.9

Energy Audit
Efficiency of boiler is found to be extremely low, so as the evaporation ratio. This is because the boiler is operated with low loading. Lower the loading lower will be the efficiency. The boiler is operated with approximately 20% loading. Besides loading efficiency of boiler can be increased by quantifying and minimizing the losses some which are discussed in this report
Excess Air calculation For Boiler:
Air is pushed via FD in the boiler. From our observation, we found that the boiler is operated automatically. The running and rest time of boiler depends upon the pressure of supply line. If the pressure of supply line is high, that is the steam in supply line in not being used the boiler remains in rest condition during this state no air is blown by the FD. From our inspection and the demand requirement we concluded that the run time is 2/3 of total operating hours..
For 1 hour operating time
We have, Run time = 40 minutes
Rest time = 20 minutes
Average speed of air = 3.825 m/sec
Diameter of FD = 38 cm (0.38m)
Volume of inlet air = 3.825 * (p * 0.382)/ 4 *0.70
= 0.303 m3/sec
(Note= 70 % of air is allowed to pass through the FD by damping phenomena)
For an hour of operating time, we have air inlet as
=40 * 60 * 0.303
= 728.78 m3/hr.

Energy Audit
= 607.31 kg/hr.(Specific gravity of air is 1.2 kg/m3)
Wood consumed in an hour = 70 kg (average)
Theoretical air requirement for low grade wood= 6.5 kg/kg of wood
Total theoretical air required in an hour= 455 kg
Excess air % = (607.31/455) %
= 133.4 %
Savings from air adjustment
We know we can’t get good burn without some excess air. In case of low grade wood the practically required air to burn is somewhat 20% - 25% excess than the theoretical air requirement. So the actual air requirement be;
Actual air requirement= 455 + 0.25 * 455 = 568.75 kg/hr.
Excess air supplied =(607 – 568.75) = 38.25 kg/hr.
Heat loss from excess air =mcpdt
= 38.25*1 * (200-25)
= 6693.75 kj/hr.
Amount of fuel saved =heat loss by excess air / gcv of wood
= 6693.75 / (3200 * 0.3445)
= 6.07 kg of wood/hr.
= Rs. 42.5 / hr.
= Rs. 340/day (considering 8 hour daily boiler operation)

Energy Audit
= Rs. 102000/ year (considering 300 days of operation annually)
Condensate Recovery System
Steam condensate carrying lot of heat energy from the pasteurization process which is flowing out in the drainage can be recovered for the proper utilization and energy saving. Heat carrying condensate, can be pumped into the feed water tank in the boiler to save successive amount of heat energy. Calculations from the data taken during audit, condensate and its recovery with cost of system to be applied with its payback are calculated as below:
Condensate can be obtained = 300lts. /day
Milk processed = 2500lts. /day
Temperature of condensate = 85-90˚C
Temperature of feed water =25˚C
Total heat recovered from condensate
= 300*1*(87.5-25)
= 18750kcal/day
Total wood saved after recovery in boiler
= Total heat recovered/ GVC of wood*Efficiency of boiler
= 18750/3200*0.3445
= 17kg/day

Energy Audit
= 17*30*12 kg/year
= 6120 kg/year
Total energy source saved in amount
= 6120*7
=Rs.42840 per year
Setup required for condensate recovery
 Pipes with proper insulation
 Pump
 Installation and transportation cost
Estimated cost for the condensate recovery system setup =Rs. 50,000 (approx.)
Payback period = Investment required/savings
= 50,000/42,840
= 1.17 years.
Losses from Steam Trap Quantification
We know during the flow of steam in supply pipe, some of the steam loss heat to the tube surface and form condensate. Such condensate formed cannot be further supplied but are needed to be separated from the steam. The steam trap performs the function to separate steam and condensate so that only steam is supplies further. Steam trap releases the condensate through pipeline connected. During our observation, we found some steam leakage from the pipeline connected to steam trap. That means the steam trap is not functioning properly. The losses due to improper functioning of steam tram can be quantified as below.
Plume length of steam= 0.5 meter

Energy Audit
Losses of steam per hr= 6 kg (approx.) from graph in appendix
Kg of wood saved = 3.15 kg/hr.
Saving in rupees = 22.1/ hr.
= Rs. 176.84/ day (considering 8 hour daily boiler operation)
= Rs. 53052.63/ year (considering 300 days of operation annually)

Energy Audit
8.3 OTHER ENERGY SAVING OPPORTUNITY THAT COULD NOT BE QUANTIFIED
 Air curtain not functioning and losses due to opening of cold storage.
 Ammonia leakage, steam leakage in different areas. (like in steam trap, pipes, valve sides etc.)
 Front side boiler insulation saving.
 COP improvement of refrigeration system.
 Regenerative efficiency calculation and method of improvement for proper savings.
8.4 ENERGY SAVING OPPORTUNITY IN FUTURE
 Use of refrigeration system at off hour. ( During the night time when the electricity demand charge is low refrigeration at optimum cooling can be done to be used in the day)
 Separate cooling space for butter and milk in the cold storage so as to create different low temperature required.
 High quantity of steam condensate can be recovered when capacity of production will be increased.
 Desuperheater at ammonia compressor discharge.
 VFD(variable frequency drive) in chiller motor and other motor.

Energy Audit
9 FINDINGS AND ANALYSIS
The following are the areas we explored and found the energy saving opportunities in related field with the financial analysis listed in the given table:
S.N
Saving opportunities
Fuel saved
Total amount saved/ year
Investment
Payback
period
1
Boiler excess air saving
14568 kg wood/year
Rs. 102000/ year
nil
2
Condensate Recovery System
`
5100 kg wood
Rs.42840 per year
Rs. 50,000
1.17 yr
3
Losses from Steam Trap Quantification
945 kg wood
Rs. 53052.63/ year
nil
4
Use of capacitor bank
Rs. 33120
Rs. 25000
.75 yr
5
Reducing demand (kva)
Rs. 24840
nil
6
Furnace air control
600.37 ltr diesel
Rs. 61,838.788
nil
7
Furnace stock preheating
283.37 ltrs
Rs. 29187.37832
Rs. 10,000
0.34yr
8
Furnace insulation cap
884.8 liters
Rs 102670.4
Rs 6000
Less than month
9
DG set
1440 liter of diesel
1.48 lakhs
7 lakh
4.72yr
10
Lighting system
1182.5 kwh
Rs. 16260.75
nil
Other findings
 DG efficiency depends upon loading
 Boiler efficiency depends upon loading

Energy Audit
10 CONCLUSION
Almost all industries from small, medium to large scale uses energy and this energy cost carries high percentage of factory overhead. In case of energy management process, they are not doing suitable methods of procedure and utilization, this result heavy energy cost due to losses. With the possibility of energy efficiency practices and technology, it is possible to cut down energy cost significantly in the industries without altering the productivity. Safe working environment can be obtain within the industry through the process of energy auditing as it involves various measures to improve efficiency of the machines and equipment which also maintain the safe operation of the machineries and equipments.
Proper methodology of operation, effective utilization, management and improvement of energy related works can produce massive savings. But there are several constrains for energy auditing in industries which significantly affects in auditing works. With proper policy from governmental sector for the energy, auditing some percentage of energy crises going within country can be minimized.

Energy Audit
11 RECOMMENDATION
 There is need of proper energy management policy from the Governmental sector.
 Proper operational process, maintenance and safety manual must be created for the energy consuming machineries.
 Adequate technological advancement for the proper utilization and saving of energy.
 Appropriate education and skill development trainings must be given for the energy related workers and industrialist.

Energy Audit
12 REFERENCES
 “Guide to Energy Management”, Fourth Edition, by Barney L. Capehart PhD, CEM; Wayne C. Turner PhD, PE, CME; William J. Kenedy PhD, PE. ISBN 0-203-91129-6 master e-book
 “Energy Management handbook”, Wayne C. Turner, Steve Doty
 “A research paper on energy efficiency of industrial utilities”, Er. Pratap Jung Rai
 Energy efficiency centre/energy efficiency module, Neplease context
 Bureau of energy efficiency, 2004
 “Guide Book For National Certification Examination For Energy Managers And Energy Auditors”, Bureau of Energy Efficiency (A Statutory Body under Ministry of Power, Government of India) 4 Floor, Sewa Bhawan, R. K.Puram, New Delhi
 www.bee-india.nic.in
 www.nea.org.np
 www.BSKtechnology.com
 www.mitchellinstrument.com

Energy Audit
APPENDIX1
List of various fuels and their respective calorific values.
Fuel
ufFuels
Approx heating value Kcal/Kg
Natural State
Dry state A BIOMASS
1
Wood
1500
3500
2
Cattle dung
1000
3700
3
Bagasse
2200
4400
4
Wheat and rice straw
2400
2500
5
Cane trash, rice husk, leaves and vegetable wastes
3000
3000
6
Coconut husks, dry grass and crop residues
3500
3500
7
Groundnut shells
4000
4000
8
Coffee and oil palm husks
4200
4200
9
Cotton husks
4400
4400
10
Peat
6500
6500 B FOSSIL FUELS
1
Coal
4000- 7000
2
Coke
6500
3
Charcoal
7000
4
Carbon
8000
5
Fuel oil
9800
6
Kerosene and diesel
10000
7
Petrol
10800
8
Paraffin
10500
9
Natural gas
8600
10
Coal gas
4000
11
Electrical (Kcal(KW)
860
12
Bio gas(Kcal/cu mtr) (12 kg of dung produces 1 cu. Mtr gas)
4700- 6000
Source : www. Engineeringtoolbox.com/fuels-higher- calorific-values

Energy Audit
APPENDIX 2
Composition of Various Fuels
Wood Compositon:
4785 KCal/Kg
Carbon
%
45.6
Hydrogen
%
3.96
Sulphur
%
0.07
Oxygen
%
37.45
Moisture
%
9.33
Ash
%
3.14
N
%
0.45
Diesel Compositon:
Carbon
%
87.3
Hydrogen
%
12.6
Sulphur
%
0.22
Oxygen
%
0.04
sg
0.86
Ash
%
0.01
N
%
0.006
Coal Compositon:
Carbon
%
44.03
Hydrogen
%
3.1
Sulphur
%
0.32
Oxygen
%
4.77
Moisture
%
3.84
Ash
%
43.12
N
%
0.82
Source: FNCCI, Energy project.

Energy Audit
APPENDIX3
Graph showing amount of steam loss with respect ot plume length leakage
Source:www.innovatechnica.com

Energy Audit
APPENDIX4
Steam table
T P vl vlg vg ul ulg ug hl hlg hg sl slg sg 0C kPa m3/kg m3/kg m3/kg kJ/kg kJ/kg kJ/kg kJ/kg kJ/kg kJ/kg kJ/kg.K kJ/kg.K kJ/kg.K 5 0.8726 0.001000 147.02 147.02 21.020 2360.4 2381.4 21.021 2488.7 2509.7 0.07626 8.9473 9.0236 10 1.2281 0.001000 106.32 106.32 41.986 2346.3 2388.3 41.988 2476.9 2518.9 0.1510 8.7476 8.8986 15 1.7056 0.001001 77.896 77.897 62.915 2332.3 2395.2 62.917 2465.1 2528.0 0.2242 8.5550 8.7792 20 2.3388 0.001002 57.777 57.778 83.833 2318.2 2402.0 83.835 2453.4 2537.2 0.2962 8.3689 8.6651 25 3.1690 0.001003 43.356 43.357 104.75 2304.1 2408.9 104.75 2441.6 2546.3 0.3670 8.1888 8.5558 30 4.2455 0.001004 32.895 32.896 125.67 2290.0 2415.7 125.67 2429.6 2555.3 0.4365 8.0148 8.4513 35 5.6267 0.001006 25.219 25.220 146.58 2275.9 2422.5 146.59 2417.8 2564.4 0.5050 7.8461 8.3511 40 7.3814 0.001008 19.527 19.528 167.50 2261.7 2429.2 167.50 2405.9 2573.4 0.5723 7.6827 8.2550 45 9.5898 0.001010 15.262 15.263 188.41 2247.5 2435.9 188.42 2393.9 2582.3 0.6385 7.5244 8.1629 50 12.344 0.001012 12.036 12.037 209.31 2233.3 2442.6 209.33 2381.9 2591.2 0.7037 7.3708 8.0745 55 15.752 0.001015 9.5716 9.5726 230.22 2219.0 2449.2 230.24 2369.8 2600.0 0.7679 7.2217 7.9896 60 19.932 0.001017 7.6733 7.6743 251.13 2204.7 2455.8 251.15 2357.7 2608.8 0.8312 7.0768 7.9080 65 25.022 0.001020 6.1986 6.1996 272.05 2190.3 2462.4 272.08 2345.4 2617.5 0.8935 6.9360 7.8295 70 31.176 0.001023 5.0437 5.0447 292.98 2175.8 2468.8 293.01 2333.1 2626.1 0.9549 6.7991 7.7540 75 38.563 0.001026 4.1323 4.1333 313.92 2161.3 2475.2 313.96 2320.6 2634.6 1.0155 6.6658 7.6813 80 47.373 0.001029 3.4078 3.4088 334.88 2146.7 2481.6 334.93 2308.2 2643.1 1.0753 6.5359 7.6112 85 57.815 0.001032 2.8279 2.8289 355.86 2132.0 2487.9 355.92 2295.5 2651.4 1.1343 6.4093 7.5436 90 70.117 0.001036 2.3607 2.3617 376.86 2117.1 2494.0 376.93 2282.7 2659.6 1.1925 6.2859 7.4784 95 84.529 0.001040 1.9818 1.9828 397.89 2102.2 2500.1 397.98 2269.7 2667.7 1.2501 6.1653 7.4154 100 101.32 0.001043 1.6726 1.6736 418.96 2087.1 2506.1 419.06 2256.6 2675.7 1.3069 6.0476 7.3545 105 120.79 0.001047 1.4190 1.4200 440.05 2072.1 2512.1 440.18 2243.4 2683.6 1.3630 5.9326 7.2956 110 143.24 0.001052 1.2095 1.2106 461.19 2056.7 2517.9 461.34 2230.0 2691.3 1.4186 5.8200 7.2386 115 169.02 0.001056 1.0359 1.0370 482.36 2041.1 2523.5 482.54 2216.3 2698.8 1.4735 5.7098 7.1833 120 198.48 0.001060 0.8911 0.8922 503.57 2025.5 2529.1 503.78 2202.4 2706.2 1.5278 5.6019 7.1297 125 232.01 0.001065 0.7698 0.7709 524.82 2009.7 2534.5 525.07 2188.3 2713.4 1.5815 5.4962 7.0777 130 270.02 0.001070 0.6676 0.6687 546.12 1993.7 2539.8 546.41 2174.0 2720.4 1.6346 5.3926 7.0272 135 312.93 0.001075 0.5813 0.5824 567.46 1977.5 2545.0 567.80 2159.4 2727.2 1.6873 5.2907 6.9780 140 361.19 0.001080 0.5079 0.5090 588.85 1961.2 2550.0 589.24 2144.6 2733.8 1.7394 5.1908 6.9302 145 415.29 0.001085 0.4453 0.4464 610.30 1944.5 2554.8 610.75 2129.4 2740.2 1.7910 5.0926 6.8836 150 475.72 0.001090 0.3918 0.3929 631.80 1927.7 2559.5 632.32 2114.1 2746.4 1.8421 4.9960 6.8381 155 542.99 0.001096 0.3457 0.3468 653.35 1910.7 2564.0 653.95 2098.4 2752.3 1.8927 4.9010 6.7937 160 617.66 0.001102 0.3060 0.3071 674.97 1893.3 2568.3 675.65 2082.3 2758.0 1.9429 4.8074 6.7503 165 700.29 0.001108 0.2716 0.2727 696.65 1875.7 2572.4 697.43 2065.9 2763.3 1.9927 4.7151 6.7078 170 791.47 0.001114 0.2417 0.2428 718.40 1857.9 2576.3 719.28 2049.2 2768.5 2.0421 4.6241 6.6662 175 891.80 0.001121 0.2157 0.2168 740.22 1839.7 2579.9 741.22 2032.1 2773.3 2.0910 4.5344 6.6254 180 1001.9 0.001127 0.1929 0.1940 762.12 1821.3 2583.4 763.25 2014.6 2777.8 2.1397 4.4456 6.5853 185 1122.5 0.001134 0.1730 0.1741 784.10 1802.5 2586.6 785.37 1996.6 2782.0 2.1879 4.3580 6.5459 190 1254.2 0.001141 0.1554 0.1565 806.17 1783.4 2589.6 807.60 1978.2 2785.8 2.2358 4.2713 6.5071 195 1397.6 0.001149 0.1399 0.1410 828.33 1764.0 2592.3 829.93 1959.5 2789.4 2.2834 4.1855 6.4689 200 1553.6 0.001156 0.1261 0.1273 850.58 1744.1 2594.7 852.38 1940.1 2792.5 2.3308 4.1004 6.4312

Energy Audit
APPENDIX 5
Cost of diesel: Rs. 100
Cost of electricity for Pashupati Regulator Factory: Rs.13.68
Cost of wood: Rs. 7/Kg
All saving are calculated per Annual basis.
All formula are taken from “Guide Book For National Certification Examination For Energy Managers And Energy Auditors”, Bureau of Energy Efficiency (A Statutory Body under Ministry of Power, Government of India) 4 Floor, Sewa Bhawan, R. K.Puram, New Delhi
www.bee-india.nic.in

Energy Audit

Energy Audit A Case Study of Pashupati Candle filter Udhyog And Country food Pvt.Ltd

Recomendados

Recomendados

Mais conteúdo relacionado

Mais procurados

Mais procurados (19)

Destaque

Destaque (20)

Semelhante a Energy Audit A Case Study of Pashupati Candle filter Udhyog And Country food Pvt.Ltd

Semelhante a Energy Audit A Case Study of Pashupati Candle filter Udhyog And Country food Pvt.Ltd (20)

Último

Último (20)

Energy Audit A Case Study of Pashupati Candle filter Udhyog And Country food Pvt.Ltd