Imperial Journal of Interdisciplinary Research (IJIR)
Vol-2, Issue-12, 2016
ISSN: 2454-1362, http://www.onlinejournal.in
Study of Energy Conservation
Opportunities in Plant Utilities.
Avinash Kumar Ray¹, Dr D.Buddhi² & Mr Hari Kumar Singh³
1
Master of technology in Energy Engineering
2,3
Gyan Vihar School of Engineering and Technology, Jaipur
Abstract: As we know that the energy resources
are limited and the rate at which it is being
exploited in past decades and expanding over
time which will result in the end of resources.
Proper utilization of all resources is important
from both monetary as well as environmental
point of view. Utilization of energy will have a
certain impact on our environment such as global
warming, ozone layer depletion etc. etc. so, more
we consume energy resources higher will be the
impact. The basic objective is to utilize the energy
resource economically with least impact on the
environment without affecting production and
growth. It can be done with the help of energy
management. Energy management helps in
proper utilization energy along with reduction of
the wastage. An energy audit is one such tool for
energy management. An energy audit helps in
understanding the energy consumption pattern,
along with the amount of consumption
specifically for each and every machine in an
industry as well as homes & commercial
buildings. With the help of this, we can find the
promising areas where we can save energy. The
energy consumption pattern was studied for
various utilities of a plant in order to recognize
potential areas where energy saving is possible
practically.
1. Introduction:
Energy is the one of the most important resource
necessary for us. Energy is also known as
‘Strategic Commodity’, as the economic
functionality of any country depends on it. Proper
strategy should be made to have a balance between
demand & supply of energy, as a little uncertainty
about its supply can threaten the functioning of
entire economy. Fossil fuel is used for about 70%
power generation in India, in which 60% of India’s
total energy consumption is from coal, which is
also being imported from Australia and Indonesia;
which is followed by hydro power by 15% and
renewable energy which is 13% of the total power
generation. India relies on the import of a large
amount of fossil fuels, the average import of crude
oil is 16.44 Ton Million per month in 2014-2016.
Imperial Journal of Interdisciplinary Research (IJIR)
2. Energy Audit: A Tool
Energy audit is a tool for energy management,
which helps in improving the performance of
equipment that tends to reduce energy cost and
save energy. Energy audit is also known as
“Energy Study” or “Energy Assessment”, it
comprises of systematic study of any plant facility
or equipment which consumes energy. The study
involves three main points:
• Data Collection
• Analysis
• Recommendations
Energy Audit concentrates on the study of energy
consumption pattern and data of various equipment
in a plant. On the basis of that performance
analysis is done. Analysis helps in finding the gap
between the energy usage and delivery of work
according to the usage. This helps in identifying the
opportunities for conservation of energy in that
particular facility, process or equipment which is
also known as “Energy Conservation
Opportunities”. Energy Audit is a complete
analysis and provides a clear picture of energy
saving opportunities.
The study was done on various utilities for a
facility in which various promising areas for energy
conservation were identified. Energy conservation
opportunities and recommendation were given on
the basis of performance analysis of these utilities.
3. Energy Saving in Pumps
Measurements of pressures, water flow, and
electrical power were made on cooling water
pumps to estimate the operating efficiencies.
In Plant A, pump 101A has rated head and flow of
25m and 192 m3/h respectively. This pump been
operated at discharge pressures of 1.8 kg/cm2 (g)
and flow of 240 m3/h, consumes power in the range
of 19.4 kW, thus indicating pump efficiency to be
in the range of 60.5%, which is poor.
In Plant B, pump 301A has rated head and flow of
35m and 250 m3/h respectively. This pump been
operated at discharge pressures of 2.3 kg/cm2 (g)
and flow of 255 m3/h, consumes power in the range
of 32.7 kW, thus indicating pump efficiencies to be
in the range of 48.9%, which is poor.
Page 419
Imperial Journal of Interdisciplinary Research (IJIR)
Vol-2, Issue-12, 2016
ISSN: 2454-1362, http://www.onlinejournal.in

unloaded condition for 31% of the time; PSA air

In Plant C, the process cooling water pump 201A compressors #AC N2-1 and #AC N2-2 have
has rated head and flow of 35m and 250 m3/h operated in unloaded condition for 13% and 18% of
respectively. This pump was operating with the time respectively.
discharge pressures of 2.6 kg/cm2 (g) and flow of
200 m3/h, consuming power in the range of 22.7 The total air being consumed by the PSA plant and
kW, indicating pump efficiencies in the range of instrument air is also summarized. The energy
62.4%, which is poor. saving potential explored is around 40,000
kWh/annum i.e. Rs. 2.47 lakhs/annum. The
investment required for a 120 cfm variable speed
Two nos. of pumps were studied, the performance air compressor is expected to be Rs. 5 lakhs; the
of the pumps were evaluated shown below in table. payback period is expected to be about 25 months
Rated Values Est. Diff. Motor Pump
Pump
Speed Head Flow Flow Head input Eff. i.e. slight over 2 years.
Name
Rpm M m3/h m3/h m kW %
Pump Description Unit Overall
1475 25 192 240.0 18.0 21.6 60.5%
101 A
Pump Air compressor Total
1450 35 250 255.0 23.0 35.9 48.9%
301 A
Pump Actual capacity cfm 444
1450 35 250 200.0 26.0 25.2 62.4%
201 A
Loading % -
Table 1 Performance Evaluation of Pumps
Unloading % -
Replacement of Process Cooling tower pump Peak Off % -
(Plant-A) is recommended, which was consuming production Compressed air
month cfm 115
19.4 kW with poor efficiency and was running is consumption
replaced by another energy efficient Pump of 20 m Unloading energy
kWh 784
head, flow 250 m3/h and 86.2% efficiency. By penalty
replacing the Pump, a saving of 28,000 Loading % -
kWh/annum is found i.e. Rs. 1.73 lakhs/annum in Unloading % -
terms of monetary savings at a cost of Off peak Off % -
Rs.6.18/kWh. Total investment for 2 pumps (1 production Compressed air
month cfm 91
running & 1 standby) is Rs. 1.8 Lakhs, with a consumption
payback period of 13 months. Unloading energy
kWh 398
penalty
Also, replacement of Process Cooling tower pump Loading % -
(Plant-B) is recommended, which was consuming
Unloading % -
35.9 kW with very poor efficiency of 48.9% was Overall
replaced by energy efficient pump of 25 m head, from last 5 Off % -
260 m3/h flow and 81.5% efficiency. By replacing months Compressed air
cfm 105
data consumption
the pump, a saving of 85,300 kWh/annum is found
Unloading energy
i.e. Rs. 5.28 lakhs/annum in terms of monetary penalty
kWh 1837
savings. Total investment for 2 pumps (1 running
Table: Instrument Air Consumption
& 1 standby) is Rs. 2.4 Lakhs, with a payback
period less than 6 months.
Uni Overal
Description
t l
4. Energy Saving in Air Compressors:
Air compressor Total
The loading and unloading on each compressor is
shown below. Actual capacity cfm 222
Loading % -
Compressor No. Power Remarks
kW Unloading % -
21.8 Loaded Peak
AC INST-1 Off % -
5.6 Unloaded productio
n month Compressed air
22.3 Loaded cfm 183
AC-N2-1 consumption
14.6 Unloaded Unloading energy kW
23.0 Loaded 2636
AC-N2-2 penalty h
15.8 Unloaded
Loading % -
Compressed air is used mainly for pneumatic Off peak Unloading % -
controls in process and production machines. The productio
n month Off % -
prevailing air demand is catered by 2 nos. 111 cfm
(fixed speed) air compressors, leading to operate in Compressed air cfm 115

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Imperial Journal of Interdisciplinary Research (IJIR)
Vol-2, Issue-12, 2016
ISSN: 2454-1362, http://www.onlinejournal.in

consumption 64,700 TR-h. The energy saving potential explored

is about 40,000 kWh/annum i.e. Rs. 2.47
Unloading energy kW
penalty h
3858 lakhs/annum. The minor investment for
maintenance and impeller replacement is expected
Loading % -
to be about Rs. 10,000/-, with a payback period is
Unloading % -
Overall expected to be less than one month.
from last Off % - It was also observed that deficient performance of
5 months Compressed air the IBT chiller and chiller-A combination was
data cfm 166
consumption causing a lower productivity rate due to depleted
Unloading energy kW cooling rate. As cooling process in some of the
10759
penalty h equipment require chilled water cooling after the
Table: PSA Consumption brine water cooling. Insufficient cooling is also
Energy Saving in Chiller System: expected by the chilled water likely to increase the
load on the brine system. The specific power
consumption of the brine chillers was estimated in
Chiller-A has 2 nos. compressors: compressor-1/1 the range of 1.22 kW/TR (with brine @ 16.9°C)
is connected to a flooded evaporator with water on and 1.61 kW/TR (with brine @ -18.9°C).
the tube side. Compressor-1/2 is connected to Ice
Bank Tank (IBT). This system caters the chilling 5. Energy Saving in Dust Collector:
requirements of Plant-A. Both compressors share a
common evaporative condenser. 5 nos. of dust collector blowers are in operating in
the dust collector system. In PFIKC, there are 3
Chiller-B/C has 2 nos. compressors; both are nos. of blowers (2x50 hp and 1x10 hp); in RBIKC,
connected to a common flooded evaporator, with there are 2 nos. of blowers (40hp and 100hp)
water on the tube side; this system caters the
chilling requirements of Plant-B and Plant-C. Both The performance of these blowers was studied by
compressors share a common evaporative measurement of flows, pressures, power and
condenser. efficiency was estimated subsequently. The
pressures were measured with electronic
Improve Performance of Chiller- A by Manometer, air flows were measured with
increasing Primary Chilled Water Flow Anemometer and Pitot tube and Power with
portable Power Analyser. The details of the
111 TR Chiller-A’s primary flow is only 25 m3/h, measurements, analyses and energy saving
whereas required rated flow is 62 m3/h. The opportunities are discussed in subsequent sections.
refrigeration load is about 24.81 TR only and
specific power consumption (at compressor shaft) The no. of solenoid valves and filter bags has been
of 1.18 kW/TR. It is prominent that Chiller-B/C tabulated below for each dust collector.
has a specific power consumption (at compressor
shaft) of Sr. Dust Number Number
0.60 kW/TR, with chilled water at 8.2°C. No. Collector of of
Tag no. Solenoid Nozzles
valves
Chilled Motor Specific COP Nos. Nos.
water input power 1 PU-DC-U35 9 10
Equipment 2 PU-DC-U37 2 18
flow cons.
m3/h kW kW/TR 3 PU-DC-U36 9 10
4 RB-U-10 6 20
Chiller- 5 RB-U-9 14 20
25 32.76 1.18 2.99
Plant A Increase Operating time of sequential timers
Chiller IBT 61.16 0.60 5.85 of dust collectors.
Chiller-
103 60.45 0.60 5.81
Plant B/C
Pressure drop measured across RB-U-9 AND
Chiller-
Plant A
60 43 0.71 4.39 RB-U-10 were found to be 30mmWC and
7mmWC respectively; which are very low values.
Table: Chiller Measurements
Thus, for all dust collectors with pressure drops
During the concerned period, the total estimated less than 10mmWC, the pulsing time interval
refrigeration load on Chiller-A is 26,964 TR-h. should be increased from 1 minute to 2 minute or
Considering the same pattern for the complete year, more.
the refrigeration load on Chiller-A is expected to be

Imperial Journal of Interdisciplinary Research (IJIR) Page 421

Imperial Journal of Interdisciplinary Research (IJIR)
Vol-2, Issue-12, 2016
ISSN: 2454-1362, http://www.onlinejournal.in

Rated Air
Total REFERENCES
Compressed
Description Flow Quantity
Air Required
m3/h cft/cartridge
cfm
PU-DC-U35
(50 HP)
13250 0.72 7.22  https://en.wikipedia.org/wiki/Pump
PU-DC-U37  https://en.wikipedia.org/wiki/Flow_measurement#Ultras
4000 0.44 7.85
(10 HP) onic_flow_meters_.28Doppler.2C_transit_time.29
PU-DC-U36  Pump Handbook- Igor J. Karassik, Joseph P. Messina,
13250 0.72 7.22
(50 HP) Paul Cooper, Charles C. Herald
RB-U-10
12700 0.52 10.38  https://en.wikipedia.org/wiki/Dust_collector
(40HP)
RB-U-9 (100  http://www.dynavac.in/dust-collectors/cartridge-filter-
33400 0.58 11.70
HP) dust-collectors/
Table: Dust Collector Measurements  http://www.dynavac.in/dust-collectors/cyclone-dust-
collector/
Assuming a drop of 50% in air consumption by  http://www.dustcollectionbags.com/dust-collection-
increasing the operating time interval, the energy systems/
saving potential is estimated to be 16,000  https://www.forbesmarshall.com/fm_micro/news_room.a
kWh/annum i.e. Rs. 1.16 lakhs/annum. spx?Id=Boilers&nid=165
 https://www.forbesmarshall.com/fm_micro/news_room.a
Central dust collector system for multiple spx?Id=Boilers&nid=166
machines with isolation dampers & oversized  https://en.wikipedia.org/wiki/Air_compressor
blower.  https://en.wikipedia.org/wiki/Air_compressor
Central dust collector being connected to the  https://beeindia.gov.in/sites/default/files/3Ch3.pdf
common duct among numerous machines, air  http://energy.gov/eere/amo/compressed-air-systems
flow will be excessive in main duct and sub-  https://www.compressedairchallenge.org/library/factshee
ducts, when some machines remain idle. ts/factsheet07.pdf
Pneumatically controlled air dampers can be  http://www.airbestpractices.com/system-
installed which operate as per the operation of assessments/leaks/finding-and-fixing-leaks
machines. Also closure of these dampers can  https://en.wikipedia.org/wiki/Air_conditioning
sometimes lead to reduced air flow, which leads  https://en.wikipedia.org/wiki/HVAC
to settlement of chips and dust in the main duct,  https://books.google.co.in/books/about/Basic_Refrigerati
which can be counter parted by opening the duct on_and_Air_Conditioning.html?id=gniJE5lK0YAC
once in a week during the operation.  https://beeindia.gov.in/sites/default/files/3Ch4.pdf
 http://www.airconditioning-systems.com/air-conditioner-
6. Conclusion: refrigerant.html
 https://en.wikipedia.org/wiki/Bulk_tank
This report introduced energy saving  http://www.calmac.com/how-energy-storage-works
opportunities in auxiliaries like Air compressors,  http://www.calmac.com/icebank-energy-storage-model-c
dust collectors etc. as well as process utilities in a http://www.frigomech.com/en/main/systems-and-
plant like Pumps, chillers etc. We analysed and equipment/industrial-refrigeration/brine-chillers.html
presented information about the important and
energy saving perspectives that can be explored
in a plant.

Also, the recommendations for energy saving

along with cost savings are shared, considering
the required investment and payback period.

Imperial Journal of Interdisciplinary Research (IJIR) Page 422