Energy Audit

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Equipment Performance Study

Pumps Efficiency & Performance

The basic objective of the studies is to conduct detailed analysis of the specific equipment to assess the actual output, operating efficiency with relevant parameters as well as opportunities for improvements and optimization. The studies involve measuring flow, differential head as well as motor input power to assess operating efficiency of the individual pump.

The typical scope of the work covers
  • Measuring the flow with non-contact ultrasonic transit time flow meter
  •  Gauging Pressure at suction and discharge of the pumps with digital pressure gauge; wherever possible
  •  Determining Power with clamp on power meter
  •  Computing Hydraulic Power to assess overall Efficiency of the pump (and motor).
  •  Comparing the values with the design data to analyzing the gaps, if any.
  •  Assessing the performance and suggesting ways for improvement, as applicable
  •  Submitting the report

Refrigeration Compressors Efficiency & Performance

The studies involve measuring flow, differential temperature as well as motor input power to assess operating efficiency of the individual chiller.

The typical scope of the work covers
  • Measuring the flow with non-contact ultrasonic transit time flow meter
  • Gauging Temperature at inlet and outlet of the chiller with digital temperature indicator; wherever possible
  •  Determining Power with clamp on power meter
  •  Computing overall chilling effect and Energy Efficiency Ratio (EER) / specific power consumption / Coefficient of performance (COP) to assess overall Efficiency of the chiller (and motor)
  •  Comparing the values with the design data to analyzing the gaps, if any.
  •  Assessing the performance and suggesting ways for improvement, as applicable
  •  Submitting the report

Air Conditioning Units Performance

Air Conditioning (Ductable Split, Split, Window) Units Performance

The studies involve measuring air flow, differential enthalpy across the evaporator coil as well as motor input power to assess operating Energy Efficiency Ratio (EER) of the individual Air Conditioning Unit.

The typical scope of the work covers
  • Flow easement using anemometer (vane or hot wire type)
  • Measuring temperature and relative humidity of the return air to the air conditioning unit using Sling Psychrometer
  • Measuring temperature and relative humidity of the supply air from the conditioning unit using Sling Psychrometer
  • Power Measurement using clamp on or plug in type power meter
  • Calculation of Cooling Effect delivered by the conditioning unit
  • Determining Specific Power consumption as well as Energy Efficiency Ratio
  • Comparing the values with the design data to analyzing the gaps, if any.
  • Assessing the performance and suggesting ways for improvement, as applicable
  • Submitting the report

Cooling Towers Efficiency & Performance

The studies involve measuring flow of the cooling water, differential temperature across the tower, Enthalpy of ambient and exhaust air, air flow rate as well as motor input power to assess operating performance of the individual Cooling Tower.

The typical scope of the work covers
  • Measuring the flow of cooling water with non-contact ultrasonic transit time flow meter
  • Gauging temperature drop across the cooling tower with digital temperature indicator
  • Computing Heat Load on the cooling tower and delivered cooling effect
  • Determining fan Power with clamp on power meter
  • Noting down the ambient dry bulb and wet bulb temperature
  • Noting down the dry bulb and wet bulb temperature of the exhaust air
  • Measuring air flow rate to determine water to air ratio, if possible
  • Assessing the performance and suggesting ways for improvement, as applicable
  • Comparing the values with the design data to analyzing the gaps, if any.
  • Submitting the report

Fans & Blowers Efficiency & Performance

The studies involve measuring flow, differential pressure, fan speed as well as motor input power to assess operating efficiency of the individual fans & blowers.

The typical scope of the work covers
  • Measuring the flow with anemometer (vane or hot wire type) or Pitot tube, depending on the application
  • Gauging Pressure at suction and discharge of the fan with digital manometer gauge; wherever possible
  • Determining Power with clamp on power meter
  • Computing Pneumatic Power to assess overall Efficiency of the fan & blower (and motor)
  • Comparing the values with the design data to analyzing the gaps, if any.
  • Assessing the performance and suggesting ways for improvement, as applicable
  • Submitting the report

Air Compressors Efficiency & Performance

The studies involve computing the flow (by pump up test of suction velocity measurement), measuring pressure as well as motor input power to assess operating performance of the individual equipment.

The typical scope of the work covers
  • Measuring the compressor output (Free Air Delivery – FAD) by conducting Pump-up Test, if possible
  • Measuring the air velocity at the compressor suction
  • Noting down cross-sectional area of the suction
  • Computing output through suction velocity measurement method
  • Determining Power with clamp on or plug in type power meter
  • Gauging pressure drop across the suction duct, if possible
  • Gauging pressure drop across the suction filter, if possible
  • Noting down pressure at inlet and outlet of each stage of the compressor
  • Noting down temperature at inlet and outlet of each stage of the compressor
  • Determining Specific Power
  • Comparing the values with the design data to analyzing the gaps, if any.
  • Evaluating performance and energy consumption of Air Dryers
  • Estimating pressure drop in the interconnecting piping and equipment’s till compressor house outlet
  • Assessing the performance and suggesting ways for improvement, as applicable
  • Submitting the report

Heat Exchanger Performance

The studies involve computing the flow (by pump up test of suction velocity measurement), measuring pressure as well as motor input power to assess operating performance of the individual equipment.

The typical scope of the work covers
  • Measuring the flow of the utility fluid with non-contact ultrasonic transit time flow meter
  • Gauging temperature change of the utility fluid across the heat exchanger with digital temperature indicator
  • Computing Heat transferred to the cooling utility side and comparing the same with process data
  • Measuring the flow of process fluid with non-contact ultrasonic transit time flow meter, if possible
  • Gauging temperature change of process fluid across the heat exchanger with digital temperature indicator
  • Computing Heat transferred for the process side & comparing with the utility load
  • Noting down the pressure drops on the utility side, if possible
  • Noting down the pressure drops on the process side, if possible
  • Estimating Heat Transfer Coefficient based on the design data
  • Comparing the values with the design data to analyzing the gaps, if any.
  • Assessing the performance and suggesting ways for improvement, as applicable
  • Submitting the report

Steam Turbines Efficiency & Performance

The studies involve noting down key parameters (flow, pressure & temperature) at turbine inlet & individual extraction, power generation to assess stage efficiency, heat rate as well as specific power generation the individual equipment.

The typical scope of the work covers
  • Collecting trends for key parameters like power generation and steam pressure, temperature and flow at inlet, exhaust as well as at the outlet of each stage during normal plant operation.
  • Assessing the average values of key parameters like power generation and steam pressure, temperature and flow at inlet, exhaust as well as at the outlet of each stage during normal plant operation.
  • Computing isentropic efficiency for each stage as well as on the overall basis.
  • Comparing the values with Heat & Mass Balance Data (HMBD) to analyzing the gaps, if any.
  • Collecting instantaneous values for key parameters like power generation and steam pressure, temperature and flow at inlet, exhaust as well as at the outlet of each stage during normal plant operation.
  • Computing isentropic efficiency for each stage as well as on the overall basis.
  • Comparing the values with Heat & Mass Balance Data (HMBD) to analyzing the gaps, if any.
  • Assessing the performance and suggesting ways for improvement, as applicable
  • Submitting the report

Electrical Motors Efficiency

The studies involve measuring electrical parameters for the motor at no load and normal load operation as well as stator resistance motor speed to assess operating efficiency of the individual equipment.

The typical scope of the work covers
  • Computing / Measuring the fluid flow rate of the waste stream at the inlet of the recovery system
  • Gauging the temperature drop across the recovery system for the waste stream

Waste Heat Recovery Efficiency & Performance

The studies involve measuring electrical parameters for the motor at no load and normal load operation as well as stator resistance motor speed to assess operating efficiency of the individual equipment.

The studies are tailored to meet the specific plant requirements and are difficult to generalize. However, the typical scope of the work studies could cover:

The typical scope of the work covers
  • Computing / Measuring the fluid flow rate of the waste stream at the inlet of the recovery system
  • Gauging the temperature drop across the recovery system for the waste stream
  • Assessing the heat generation in the system, if applicable
  • Computing / Estimating the total heat recovered in the system
  • Computing / Measuring the fluid flow rate of the recovery stream at the inlet of the recovery system
  • Gauging the temperature drop across the recovery system for the recovery stream
  • Assessing the heat transferred to the recovery stream an analyzing the gaps, if applicable
  • Assessing the heat losses through various sources.
  • Carrying heat and mass balance analysis
  • Assessing the performance and suggesting ways for improvement, as applicable
  • Submitting the report

Boilers Efficiency & Performance

The studies involve carrying out possible measurements to determine boiler efficiency by indirect method as well as the heat and mass balance computations to estimate the useful heat and to assess operating efficiency.

The typical scope of the work covers
  • Measuring Oxygen, Carbon Mono-Oxide & Temperature Contents in flue gas at Air Preheater/ Economizer outlet
  • Measuring Oxygen Contents in flue gas at outlet of APH & inlet of ID Fan.
  • Noting down surface temperature and area for the boiler system (up to APH outlet)
  • Computing surface heat loss for the boiler system
  • Analyzing heat loss through unburnt contents in ash based on inhouse data
  • Analyzing feed water quality
  • Studying the blow down practices
  • Computing Combustion Efficiency of the boiler, based on the inhouse fuel properties
  • Estimating air ingress in Air Preheater, Bag Filter / Electrostatic Precipitator (ESP)
  • Assessing the performance and suggesting ways for improvement, as applicable
  • Submitting the report

Thermopacs & Thermic Fluid Heaters Efficiency

The studies involve carrying out possible measurements to determine boiler efficiency by indirect method as well as the heat and mass balance computations to estimate the useful heat and to assess operating efficiency

The typical scope of the work covers
  • Measuring Oxygen, Carbon Mono-Oxide & Temperature Contents in flue gas at Air Preheater/Economizer outlet
  • Measuring Oxygen Contents in flue gas at outlet of APH & inlet of ID Fan.
  • Noting down surface temperature and area for the system (up to APH outlet)
  • Computing surface heat loss for the system
  • Analyzing heat loss through unburnt contents in ash based on inhouse data
  • Computing Combustion Efficiency of the thermopac, based on the inhouse fuel properties
  • Estimating air ingress in Air Preheater, Bag Filter / Electrostatic Precipitator (ESP)
  • Assessing the performance and suggesting ways for improvement, as applicable
  • Submitting the report

Furnaces & Ovens Efficiency & Performance

The studies involve carrying out possible measurements to determine boiler efficiency by indirect method as well as the heat and mass balance computations to estimate the useful heat and to assess operating efficiency

The typical scope of the work covers
  • Noting down quantity of material and temperature at feed / initial stage
  • Noting down quantity of material and temperature at outlet / final stage
  • Noting down maximum temperature of materia
  • Noting down energy consumption (fuel of electricity)
  • Noting down material characteristics required for heat and mass balance studies.
  • Measuring Oxygen, Carbon Mono-Oxide & Temperature Contents in flue gas at Air Preheater / Economizer outlet
  • Measuring Oxygen Contents in flue gas at outlet of APH & inlet of ID Fan.
  • Noting down surface temperature and area for the system (up to APH outlet)
  • Computing surface heat loss for the system
  • Analyzing heat loss through unburnt contents in ash based on inhouse data
  • Computing Combustion Efficiency of the thermopac,based on the inhouse coal properties
  • Estimating air ingress in Air Preheater, Bag Filter / Electrostatic Precipitator (ESP)
  • Conducting heat and mass balance studies.
  • Computing Efficiency
  • Assessing the performance and suggesting ways for improvement, as applicable
  • Submitting the report

Steam Trap Performance Assessment

The studies involve capturing thermal image of the traps and / or detecting performance with ultrasonic steam trap tester to assess functioning of the individual trap.

The typical scope of the work covers
  • Checking the traps with thermal imager and / or ultrasonic trap tester
  • Qualitatively assessing the performance
  • Tagging the points (if the tags are provided by the plant)
  • Suggesting ways for improvement, as applicable
  • Submitting the report