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Report on Utility Power consumption Audit

(1) Scope of the study:

Auditing energy consumption of the following system like:

1. Cooling Water Usage and Power consumption.

2. Instrument Air Usage and Power consumption.
3. Lighting system and power consumption.
4. Line losses reduction.

(2) Preliminary Observations:

Based on the study on above subjects it is identified that:

1) The existing cooling water consumption is not according to the heat
dissipation requirement. A fixed flow is running continuously
irrespective of cooling requirement at individual plants due to no
automation is available.

2) Instrument Air compressor is operating with higher rating motor only

due to higher compressor capacity.

3) Lighting power consumption is appropriate according to the structure

requirement.

4) The average line losses observed at plant is about 1-2 % which

indicates the effective transmission system.
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Detailed Report

(1) Cooling Water System:

Observations:
 Maximum Cooling water requirement for Formaldehyde, Hexamine
and Resin plants are about 1000 M3/Hr max. at 30 m head max.
However, depends upon the plant operating capacities, this cooling
water requirement varies between 600-1000 M3/Hr.
 Water consumption in resin plant is very inappropriate, and a constant
flow is being consumed irrespective of overhead condenser outlet
temperature. This is causing more power consumption in cooling water
circuit directly. Photographs are attached for reference.
 Also, the Cooling water circuit system should work automatically in
header pressure balancing system at 3.0 Kg/sq.cm (g) setpoint. At
present it is in manual system, and adjusting the RPM depends upon the
pressure requirement.

Recommendations:
 Cooling water circuit system should operate in automatic header
pressure control system at 3.0 bar Kg/Sq.cm (g).
 Resin plant cooling water flow system adjustment should be on
overhead condenser temperature control, and the necessary system
should be implemented, either for Auto control or Manual control.
 In Resin Plant the pipe line size for Cooling water circulation should be
optimized according to the individual reactors vapor load and heat load.
 The common header flow meter to be installed in cooling water circuit
to identify the water circulation depends upon the plant loads, and if
there is any deviation in the flow circulation, then necessary actions can
be taken to reduce the water circulation rate. This will help in
optimization of cooling tower power consumption.
 However, the dependency on manual control without these necessary
requirements, could not control much on optimization of Cooling water
system.
 The Capex required for main header flow meter and temperature
control valves at resin plant to be further studied at microlevel and the
pay back in terms of power saving at cooling water system should not
be more than 2 years.
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(2) Instrument Air Compressor:

Observations:
 The instrument Air requirement for the entire plant except the Nitrogen
plant is 225 Cu.M/Hr tentatively.
 The Air requirement for Nitrogen Skid is about 180 Cu.M/Hr, in which
60 Cu.M/Hr air is directly used for Nitrogen to HTF pressurization.
 The existing compressor is having over capacity motor than the
theoretical power requirement. However theoretical to practical shaft
power difference shouldn’t be more than 20%.
 At present the compressor is being operated with reduced discharge
pressure setpoint than the UDHE specification, just to reduce the power
consumption. But this is not a suitable energy conservation technique as
compared to process stability.

Recommendations:
 40 Cu.M/Hr inst. air consumption will be reduced, if nitrogen
pressurization is replaced with inst. Air pressurization for HTF.
 Theoretically for 400 Cu.M/Hr air requirement, the motor capacity
should be maximum of 55 KW or less than that, whereas the existing
motor capacity is of 75 KW which is taking 25% excess power than the
actual requirement.
 Plant Air requirement has to be assessed once again according to the
present requirements and compressor has to be resized with the latest
requirement and with maximum loading hours working philosophy.
This will provide at least 20-25 % power saving.
 Also, for better process stabilization, the instrument air pressure
required is 5.5 to 6.0 bar (g), and the process licensor also
recommended the same. It is the universal practice also for control
valves functional reliability.
 The payback will be maximum of one year according to the following.
Direct Power reduction @ 400 Cu.m/Hr = 25 KW/Hr
Saving in power (20*24**350*5.9) = 1239000/- Rs.
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(3) Lighting consumption:

Observations:
 Lighting consumption as per building and structure requirement is
adequately in operation.
 The over all lighting power consumption is 2-3% of total power
consumption.

Recommendations:
 Lighting power consumption can be bringdown to 2% max of total
power consumption with minor changes in the lighting system.
 For microlevel tuning of lighting power consumption, it would be better
to implement central lighting control switch at individual plant level.
This is in implementation at Naidupeta site, which gives a control on
lighting as per the usage requirement at each floor level.
 For street lights and Tank farm area lighting purpose, we could go for
solar pole lighting system. Feasibility study to be conducted upon this
on trial basis. This will also be useful to satisfy the statutory minimum
illumination requirement in the industry premises at any time.

(4) Line losses:

Observations:
 Line loss in the power distribution circuit as per the industrial standards
minimum level only.

Recommendations:
 Over all line losses is about 1.5% of the total power consumption,
which can be bringdown upto 1% max of total power consumption.
 An internal Audit can be done for copper losses at maximum power
consumption and minimum power consumption to identify the losses
and necessary possible action to be taken to mitigate line losses.