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Detailed Energy Audit of Thermal Power Plant

This paper presents a model based on physical and structural industrial load control. Lighting is an important service for all industries. Depending on the type of industry, industrial lighting consumes 2 to 10% of total energy.
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Topics covered

  • Energy Audit Process,
  • Energy Research,
  • Walk-through Audit,
  • Energy Savings,
  • Energy Audit Implementation,
  • Energy Conservation,
  • Energy Testing,
  • Energy Audit Regulations,
  • Electricity Demand,
  • Air Compressors
100% found this document useful (2 votes)
326 views13 pages

Detailed Energy Audit of Thermal Power Plant

This paper presents a model based on physical and structural industrial load control. Lighting is an important service for all industries. Depending on the type of industry, industrial lighting consumes 2 to 10% of total energy.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Topics covered

  • Energy Audit Process,
  • Energy Research,
  • Walk-through Audit,
  • Energy Savings,
  • Energy Audit Implementation,
  • Energy Conservation,
  • Energy Testing,
  • Energy Audit Regulations,
  • Electricity Demand,
  • Air Compressors

10 V May 2022

https://doi.org/10.22214/ijraset.2022.42651
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue V May 2022- Available at www.ijraset.com

Detailed Energy Audit of Thermal Power Plant


Sudheer Chandra1, Tanu Rizvi2
1
M-Tech Scholar of Electrical Engineering, SSTC, Bhilai (C.G.), INDIA
2
Assistant Professor, Department of Electrical Engineering, SSTC, Bhilai (C.G.), INDIA

Abstract: This paper presents a model based on physical and structural industrial load control. Lighting is an important service
for all industries. Depending on the type of industry, industrial lighting consumes 2 to 10% of total energy. Innovation and
continuous improvements in the lighting industry have opened up considerable opportunities for energy efficiency in the area.
Lighting is a space that, during the design process, provides a wide range of energy efficiency by combining new & advance ener
gy-saving bulbs, lamps and gears, as well as high performance techniques. It only provides an indication of some of the options
a power auditor may consider when conducting an industry analysis. Energy conservation and exploration of new energy
options is an acceptable solution to meet the growing demand of industry in the future. The implementation of energy research
can improve equipment efficiency and thus reduce energy losses.
Keywords: Energy Audit, Energy efficiency, Power, Consumption, Industry

I. INTRODUCTION
Power availability is a critical factor in the country's economic progress. In today's world, energy is extremely valuable, and India
ranks third in the world in terms of overall energy consumption. By 2030, the country's power usage is predicted to exceed 4 trillion
units. Fossil fuels, particularly coal, dominate the country's electricity sector. The Indian government is working to enhance
renewable energy investment, with a goal of 175 GW capacity by 2022 [1]. As of 31 December 2021, In India, the total installed
capacity of electric power generating plants owned by various electric utilities was 393389.46MW. The following is a breakdown of
the share of various types of generating stations:
Thermal power plants - 235218.72MW Hydro power plants - 46512.22MW Nuclear power plants – 6780MW Renewable Energy
Source - 6780.0MW[3]
In fiscal year 2021, the industry sector consumed the most energy, accounting for 41% of total consumption in India. The domestic
sector came in second with 26% of the vote. Traction and railways, on the other hand, accounting for 1% of India's total electricity
consumption. [3] Energy conservation entails lowering energy usage without compromising quantity or quality. A comprehensive
energy management programme starts with energy conservation, which leads to proper equipment rating, the adoption of max-
efficiency technology, and a shift in habits that waste a lot of energy. [4] Problem rise in electrical equipment due to many factors
such as ageing of the device, ageing of the wires used, dust factor, humidity, and various factors, the quality and performance of this
electrical system is distorted [5]. As an outcome, electrical energy is lost and transformed to heat energy, lowering system efficiency
and increasing power consumption. It is possible to bring down losses by using the methodology energy audits, which aids in
determining the overall operation of the electrical system. If there are any leaks, they will be discovered and repaired. As a result,
the methodology energy auditing activity will aid in the long-term durability of electrical and electronic equipment [6].
Vandana global limited, Power plant industrial area phase-2, Siltara Raipur, Chhattisgarh, undertook an energy audit to determine
the power plant's energy usage and losses in the lighting sector. Energy Audit can include a variety of activities, depending on the
type of energy assessment and the objectives of the energy research center. The power test can start by looking at the electrical
account to see how much energy is used. The study was conducted by various researchers with a variety of methods to assess energy
consumption in [7], who said that by using the results of energy research they could strive to reduce their energy costs by reducing
costs. Energy auditing is needed to reduce energy debt and reduce energy losses. Governments should take steps to make periodic
inspections of industrial buildings compulsory. [8] Electricity is a very important factor in private and public health. Power testing is
a useful way to determine the energy consumption of a building and to determine the best solution. Regular power inspections will
expose energy consumption and waste, and help identify new energy saving opportunities. [9] Decreased energy consumption
indicates a decrease in carbon emissions. Power assessment is a powerful tool for identifying and evaluating a complete energy
management system. Energy Auditing is a compelling tool for isolating and evaluating a complete energy management system. This
approach can be important in an industry that is cost-effective and costs a few different benefits such as improved creativity, higher
profitability, better quality, and the most important fulfillment of the goal of saving energy in the world.

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 1836
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue V May 2022- Available at www.ijraset.com

A. Energy Audit
An energy audit examines a building's energy usage in order to determine the elements that contribute to increased energy
consumption. The information acquired during the inspection serves as the foundation for the suggestions made to reduce energy
expenditures. An energy audit entails a complete walkthrough inspection by a qualified energy auditor, who will then offer a report
detailing their findings as well as proposals for energy efficiency improvements. [10]
An energy audit allows us to better understand how electricity is used in the industry and to find out locations wherever energy is
wasted and where there is opportunities for improvement. An energy audit must meet the following criteria: [11, 12]
1) Calculated, current energy consumption data
2) A complete analysis of the energy consumption profile
3) Instead of a simple payback period, include a life-cycle cost.

B. Need of Energy Audit


The demand for electricity is increasing every day. More energy sources will be required to meet this requirement. Fossil fuels
produce both energy and pollution, both of which are damaging to humans. [13]. Pollution testing and emission calculators are
available online and are used to measure pollution levels and environmental emissions. Strength testing will decrease the
environmental effect directly or indirectly [14]. The functions of energy research are,
1) an energy audit can lower electricity utilization,
2) an energy audit can lower the electricity bill and keep the cash
3) an energy audit can enhance the comfort degree
4) an energy audit can lessen the carbon emission
5) an energy audit can limit useless waste and pollution
Energy testing is a major and important step money. It may seem that organizational power research provides a point of reference
for controlling energy use and provides a better system of vital energy use in the organization. [15]

C. Types of Energy Audit


Energy auditing is the most effective way to reduce energy debt and usage in the commercial and non-commercial industries [16].
The type of strength test that must be performed is determined as
1) how much penetration and depth required for the final examination
2) used industry: its function and type
3) the size of the audit and the required amount achieved.
There can be three types of energy audits [17], and they are walk-through energy audits, target energy audits, and detailed energy
audits.

D. Walk through Energy Audit


Audit your energy usage. It's also known as a preliminary audit because it's a primitive surveying audit in which the auditor only verifies an
organization's energy usage. No substantial steps for energy usage will be made in this type of energy audit. It's the first step in the auditing
process, as well as the simplest and least expensive. And it's focused on the regions that use the most energy. [18]. The walk-through
energy audit takes less time to complete than spam.
The auditor will locate the energy usage area and compile a comprehensive list of energy-saving strategies [19].
The certified energy manager, certified auditor, or professional engineer is in charge of the walkthrough audit. For finding anEnergy
saving strategy, walkthrough energy audit details are insufficient. The auditor can operate with greater precision and profitability in
less time. The auditor obtains all of the information of an organization from this sort of energy audit, which are then used in a
detailed energy audit [20, 21]. The walkthrough energy audit's will include: -
1) Determining energy use in an organization.
2) Determine the amount of energy consumed in a company.
3) A brief interview with the organization's point of contact.
4) During this form of auditing, the only primary problem area will be addressed.
5) To determine the most likely (and easiest) solutions to cut consumption and enhance efficiency metrics [22].
6) To discover improvements and cost cutting opportunities (special/low-cost).

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 1837
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue V May 2022- Available at www.ijraset.com

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 1838
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue V May 2022- Available at www.ijraset.com

Table -1
Schedule of energy audit phase-1
S.No. Analysis Observation and Result
inspection

1. Plan & organized a walkthrough Done


audit of plant with plant
Manager

2. Conduct a Awareness program Done


with department

3. Organize a survey and Done


monitoring

4. An analysis of Power Done


Consumption

5. Finding and developing energy


efficiency opportunities Done
6. Choosing the instruments that See
will be utilised in an energy Table
Audit

7. Inspection and report to upper See


Management Table

Table-3 Instruments used for Audit


S.No Electrical Measuring Instrument

1. Lux Meter

2. Power Analyser

3. Synergy Meter

4. Pitot Tube & Manometer

5. Contact/Infrared Thermometer

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 1839
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue V May 2022- Available at www.ijraset.com

2) Phase -2 Audit Phase


a) Energy Saving Of Lighting System
Several areas are found during the industry audit as spots where savings are effectively guaranteed. After determining the right
places, a lighting count is required. The following are the most popular ways to save energy on lighting systems
 Infrared read Coating halogens replace halogens (spotlights).
 Light Emitting Diode(LED). have taken the place of HPSV lights
 Let natural lighting helps.
 Upgrade HVAC system.
 Metal halides are used to replace halogens (flood type).
 LED tube light can replace fluorescent tube light.
 Magnetic ballasts are being replaced with electronic ballasts.

b) Led Lights In Place Of Old/Defective Lights

Saving Calculation After Replacement of 70W, 150W,250W and 400W HPSV Lights with 35W,50W,100W
and 150W LED Lights in Ferro Alloy Unit

Sr. Particulars UoM Old Scenario New Scenario Difference


No. (HPSV Lights) (LED Lights)

(i) (ii) iii (i-ii)


Power Consumption of 300Lights
1 kWh 48.80 21.00 27.80

2 Operation minutes Per Day Hours 14 14 0.00


Total Power Consumption Per day
3 KWh 683.20 294.00 389.20

4 Annual Running Days Days 365 365 0.00

5 Annual power Consumption KWh 249368 107310 142058

Pure Variable Cost (PVC)Avg.


6 ₹/kWh 4.5 4.5

7 Total effective PVC Per Yr. ₹. 11,22,156 4,82,895


Profit (i)-(ii) (PVC Reduced or
8 ₹. 6,39,261
Throughput Increased )

Investment Amount of 300LED


9 ₹. 4,00,000
Lights

10 Return on Investment (ROI) % 160%

11 Pay Back Period Month 7.51

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 1840
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
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G. Bill Analysis
1) Before Replacement
Power consumption by 300 Bulb in 1 hours =48.80kWhPower consumption by 300 Bulb in 1 day =48.80X14
=683.20kWh
Power consumption by 300 Bulb in 365 days= 249368kWh

Fig -Comparison of cost of power Consumption between HPSV lamps and Light emitting diodes

Cost of electricity@ ₹4.5/Units= ₹ 11,22,156/-

2) After Replacement
Power consumption by 300 Bulb in 1 hours =21kWh Power consumption by 300 Bulb in 1 day =21X14
=389.20kWh
Power consumption by 300 Bulb in 365 days= 142058kWh Cost of electricity@ ₹4.5/Units=₹ 4,82,895/-

Fig -Comparison of Consumption of Power between HPSV lamps and Light emitting diodes

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International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
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II. ENERGY SAVING ON AIR COMPRESSORS


A. FAD Test for Compressors (Conveying Air)

FAD Test for Compressors (Conveying Air)


Sr. Compressor UOM Formula Comp(7) Comp(8) Comp(1) Comp(2) Comp(4)
No. Identification
Rated Parameters
CHICA G O
ELGI ELGI ELGI PNEUM
1 Make Name plate (EE13 2-8) (E160-8) ELGI (EE13 2-8) ATIC
(E160-8) (SS215P
-7)
kg/c m 2
2 Rated Design Pressure Name plate 7.14 7 7 7.14 7

3 Rated FAD CFM Catalogue 965 1003 1003 965 1000


Compressor Rated Power kW Catalogue 167 180.6 180.6 167 180.6
consumption @ rated
4 parameters

5 Specific Energy KW/ CF Calculated 0.173 0.180 0.180 0.173 0.181


Consumption(SE C) M
6 Projected Compressor kW Calculated 94.9 93.1 90.0 72.7 66.6
Power
FAD Test for Compressors (Conveying Air)
Sr. Compressor UOM Formula Comp(7) Comp(8) Comp(1) Comp(2) Comp(4)
No. Identification
Rated Parameters
consumption @
Operating Pressure
7 Projected Specific Energy KW/ CF Calculated 0.10 0.09 0.09 0.08 0.07
Consumption (SE M
C) @ Operating Pressure

Measured Parameters
8 Load Pressure bar Measured 4.5 4.6 4.5 4.5 4.5
9 Unload Pressure bar Measured 5.0 5.1 5.0 5 5
10 Operating Pressure bar Measured 4.9 4.5 4.4
4.1 3.6
11 Compressor Air ◦C Measured 44.9 50.3 66.7
Discharge Temperature 46 40.1
(Tr)
12 Ambient Temperature (T a ) ◦C Measured 30.0 30.0 30.0
30 30
13 Power kW Measured 149.6 151.7 152.3 148.3
147.27
8
14 Atmospheric Pressure kg/c m 2 Standard 1.026 1.026 1.026
1.026 1.026
15 Measured FreeAir Delivery ft 3/mi Measured 1306 1269 1137 1080 1022
(FAD) n (cfm)
16 Specific Energy kW/c fm Power / FAD 0.11 0.12 0.13 0.14 0.14
Consumption(SE C)
17 Difference in SEC @ kW/c fm SEC -0.02 -0.03 -0.04 -0.06 -0.08
Operating Pressure Difference (Sr.
No. 7 - 16)

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International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
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B. Observations
1) Actual air flow is more than the rated FAD indicates excessive clearance in air endof thecompressor which indicates
the deterioration of compressor.
2) The Compressor Discharge air Temperature is on a Slightly Higher side. Higher thetemperature,higher will be
power consumption.
3) Even though Actual Specific energy consumption is less than the rated, it is onhigher side when
compared to the projected SEC at operating pressure.

C. Recommendations
1) SEC of all Compressors is on higher side which indicates the higher powerconsumption.Hence,
recommend to do proper maintenance
2) Clean suction filters on weekly basis to avoid extra energy consumption. Change alltheconsumables as per the
schedule.
3) Due to opening of doors, dust accumulated in compressor area & causes morepowerconsumption. Keep all the
doors closed.

D. Notable / Remarkable Po i n t s for E ner gy Savi ngs


1) Every 4 ° C increase in inlet air temperature leads in a 1% increase in energy consumption to achieve similar output.
2) 250 mmWc pressure drop in suction filter increases power consumption by 2 %
3) Manometer / differential pressure gauge should be installed across the suction filter for easily identification of dut y
suction.

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 1843
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue V May 2022- Available at www.ijraset.com

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 1844
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue V May 2022- Available at www.ijraset.com

III. CONCLUSIONS
"Energy saved is energy generated," says a famous quote. This shows that, in addition to increasing generation capacity at a higher
price, an energy audit is required to conserve electricity at a considerably lower cost. Because the demand for electricity is always
on the increasing, power companies are under pressure to expand capacity to fulfil the demand.
Because industries are thelargest electricity consumers, the authors conducted a case study of an industrial unit to achieve this goal.
The information presented in this paper demonstrates how we can save electricity by making improvements to the system and
making it more energy efficient. The government needs to make an energy audit compulsory for each industrial facility in the
country.

IV. ACKNOWLEDGMENT
The author is grateful to M/s Vandana Global ltd’ Siltara Phase-II Raipur CG, for giving chance to conduct an energy audit. I am
particularly grateful to Ramnaresh Choubey, assistant manager {energy audit} that help me to write this paper.

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ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue V May 2022- Available at www.ijraset.com

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