Deploying Energy Audit to Design Energy Conservation Policy for an Industry

Project Title

Deploying Energy Audit to Design Energy Conservation Policy for an Industry

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

One of the most important problems in developing countries like Pakistan is in the power sector. Pakistan has a total installed power generation capacity of over 40,000 MW as of 5 April, 2021 but the maximum capacity of transmission network is about 24,500 to 25,000 MW. Energy consumption of industries is approximately 26.3% of total energy consumption in Pakistan. Conservation of Energy will lead to lower billing costs for industry. The use of proposed system in Pakistani context is extremely beneficial to save energy and reduce electricity bills.Nowadays, electrical energy is a major concern because most of human activities are based on energy. Energy consumption rates around the world are increasing due to industrialization and increasing population. Pakistan primarily relies on foreign imported fossil fuels to fulfill its energy demand, and spends approximately 20% on crude oil imports. The energy input both electricity and fuel are essential parts of any manufacturing process and often form a significant part of the expenditure of the plant; thus any saving in energy directly adds to the profits of the industry. The cost of energy is escalating and will continue to do so in the near future due to high fuel costs. Every year, demand for electricity is increasing by 6-8 per cent, while up gradation of transmission network is not taken seriously. Due to this reason, the gap between demand and supply is constantly increasing. To reduce this gap, there are two alternative ways: one is to generate more electricity and upgrade transmission line, which requires huge investment, and the second is to efficiently conserve electricity. For making energy conservation and efficiency effective, Energy audit is basic tool. Auditing is the process to identify the wastages of energy without in any way affecting productivity and growth rate. In energy conservation and efficiency process, usually new investments are required such as replacement of old inefficient equipments to new one. So, energy conservation through Energy Audit can be a very useful way to save energy.

Project Objectives

• To reduce the gap between electricity demand and supply: The cost of energy is escalating and will continue to do so in the near future due to high fuel costs. Energy consumption of industries is approximately one third of total energy consumption in Pakistan. Demand of electricity is increasing every year and gap between demand and supply is constantly increasing.Hence our objective is to reduce this energy gap. One way to reduce this energy gap is to generate more electricity and the second is to efficiently conserve electricity.
• This work is addressing the three UN SDGs:

1. ‘‘Affordable and Clean Energy’’ which defines ‘‘Ensure access to affordable, reliable, sustainable and modern energy for all.’’
2. ‘‘Responsible Consumption and Production’’ which defines ‘‘Ensure sustainable consumption and production patterns.’’
3. ‘‘Climate Action’’ which defines ‘‘Take urgent actions to combat climate change and its impacts.’’

• As an energy Auditor, we expect 20% of energy savings of the total energy consumption in industry. It is possible to identify options to reduce overall cost of energy as well as pollution control. Energy saving directly adds to the profit of the industry and thus will help to meet the 7th of UN SDGs.

Project Implementation Method

Methodology
Energy Audit can be classified into the following two methods.
i) Preliminary Audit
ii) Detailed Audit

• Preliminary Energy Audit Methodology

Preliminary energy audit is a relatively quick exercise to:
(1) Identify energy consumption in industry
(2) Identify the scope for saving
(3) Identify the low cost development and savings
(4) Set a 'reference point'
(5) Identify areas for more detailed study and measurement

• Detailed Energy Audit Methodology

Detailed energy auditing is carried out in three phases: Phase I, II and III.
Phase I - Pre Audit Phase
Phase II - Audit Phase
Phase III - Post Audit Phase
1. Phase I -Pre Audit Phase Activities:
A structured methodology to carry out an energy audit is necessary for efficient working. An initial study of the industry should always be carried out, as the planning of the procedures necessary for an audit is most important. The main aims of this visit are: -
(1) To discuss with the industry’s senior management the aims of the energy audit.
(2) To discuss economic guidelines associated with the recommendations of the audit.
(3) Obtain site drawings where available - building layout, electricity bills etc.
(4) To finalize Energy Audit team
(5) To identify the main energy consuming areas
(6) To identify the instrumentation required for carrying out the audit
(7) To plan with time frame
2. Phase II- Detailed Energy Audit Activities:
Depending on the nature and complexity of the industry, a comprehensive audit can take from several weeks to several months to complete. The information to be collected during the detailed audit includes: -
(1) Energy consumption by type of energy, by major items of process equipment, by end-use
(2) Energy cost and tariff data
(3) Process flow diagrams
(4) Sources of energy supply (e.g. electricity from the grid or self-generation)
(5) Energy Management procedures and energy awareness training programs within the industry.
3. Phase III - Post Audit Phase:
The audit report should conclude with specific recommendations for detailed engineering studies and feasibility analysis. After successfully carried out energy audit, energy auditor should report to the top management for effective communication and implementation.

We used Detailed Energy Audit Methodology for implementation of this project. Process of Detailed Energy Audit is described earlier.

Benefits of the Project

• Gap between energy demand and suply will be reduced: The cost of energy is escalating and will continue to do so in the near future due to high fuel costs. Energy consumption of industries is approximately one third of total energy consumption in Pakistan. Demand of electricity is increasing every year and gap between demand and supply is constantly increasing.Hence our objective is to reduce this energy gap. One way to reduce this energy gap is to generate more electricity and the second is to efficiently conserve electricity.
• Conserve energy without effecting production will directly add to profit of Industry.
• Lower Billing Cost: Energy consumption of industries is approximately 26.3% of total energy consumption in Pakistan. Conservation of Energy will lead to lower billing costs for industry.
• Low cost production: As the billing cost of Industry decreases, product they making will be low cost and they can give different discount offers to customers to atract them towards themselves.
• Lower Crude Oil imports: Pakistan primarily relies on foreign imported fossil fuels to fulfill its energy demand, and spends approximately 20% on crude oil imports.
• ‘‘Affordable and Clean Energy’’ which defines ‘‘Ensure access to affordable, reliable, sustainable and modern energy for all.’’
• ‘‘Responsible Consumption and Production’’ which defines ‘‘Ensure sustainable consumption and production patterns.’’
• ‘‘Climate Action’’ which defines ‘‘Take urgent actions to combat climate change and its impacts.’’

Technical Details of Final Deliverable

Test Bench:

This test bench exist on following components.

1. Energy Analyser Meter (ePrecision X3000).
2. Current Transformer (FICO, Class 0.5, 30/6A)
3. Caliboration of CTs with Energy Analyser Meter

Energy Analyser Meter (ePrecision X3000):

e Precision X3000 is a powerful multifunction power meter with modular design, which can be
applied for monitoring and controlling of the electrical system. e Precision X3000 can measure and
analyze real time data, such as U, I, P, Q, S, COS?, F, kWh, kVAr, etc. e Precision X3000 has the
following functions: RS-485 communication port, 2 energy pulse output (include active energy and
reactive energy), Max/min data record, and SOE event record. e Precision X3000 can extend
functions by choosing the external optional modules: harmonic analysis, 8 remote signals on/off mode,
programmable 4 analog outputs (0~5V or 4~20mA optional), data storage, Profibus Com. protocol,
Ethernet communication functions. The multi-tariff function allows the user to measure energy in any
interval (the min. interval is 30min.), which can read the sum, sharp, peak, valley, flat energy data in
30 days, and measure 2nd to 63rd harmonics in statistics.
All our instruments fulfill all important requirements and regulations concerning electromagnetic
compatibility and safety isolation (IEC61000, IEC1010 standard and EN61010 standard). The devices
have been developed, manufactured and tested in accordance with Quality Assurance System ISO
9001.

Current Transformer (FICO, Class 0.5, 30/6A):

It is a type of transformer that is used to measure alternating current (AC).It is made by FICO company. Its rating is 5VA. Its accuracy class is 0.5, which means that its error of measurement of current is 5%.

Along these also the caliboration was required. The caliboration was required for CTs to maych their current according to the Energy Analyser Meter.

Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther Industries Energy Core Technology Internet of Things (IoT)Other Technologies Big Data, Clean TechSustainable Development Goals Affordable and Clean Energy, Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Sustainable Cities and Communities, Responsible Consumption and Production, Climate ActionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	23385
ePrecision X3000 energy analyser meter	Equipment	1	18450	18450
Current transformers	Equipment	3	600	1800
Connectors	Equipment	12	60	720
Thinnels	Equipment	12	20	240
7/29 wire	Equipment	15	55	825
Test Bench	Miscellaneous	1	1350	1350