Energy Audit Report

For
Brick manufacturing Company

Prepared By
Hussein Faisal Alsalehi
Lai De Chang
Abstract
List Of Figures
List Of Tables
1. Introduction
(1.1) Introduction
(1.2)
(1.3)
(1.4)
(1.5)
2. Desicribtion of Equipment/ Systen Audit
(2.1)
(2.2)
3. Observation and Findings
(3.1) Load Apportioning
(3.2) Main Incoming
(3.3) Lighting System

(3.4)Other Electrical Equipment

4. Analysis and Identification OF Energy Saving Measures

5. Conclusion
6. Appendix

PAGE 1
3. Observation and Findings
3.1 Load Profiling

In order to have a detailed picture of the energy consumption pattern in the plant, an energy
logger has been installed at the main intake of the plant for load profiling. Electricity
consumptions from 10 Sept. 2016 to 14 Oct. 2016 have been recorded.

A Power Logger 1730 was used for this study. Based on initial weekly total current data
provided by the plant manager, the maximum load current is 950A. For that reason, 1500A
current clamps were chosen for this measurement. Three current clamps rated at 1500A each
were used to measure current at each of the lines. Four voltage probes rated at 1000V were
used to measure line and phase voltages. Figure [] shows the connection diagram for the
measurement. Data logging started on 10 September 2016 and ended on 14 October 2016, for
a period of 34 days. Interval of data averaging is 1 minute whereas demand interval was set
to 30 min. Figures [] shows the actual site setup for measurement.
The complete single line diagram for the plant is given in appendix A.

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 Based on data collected for 32 days, figure
below show the load profile for one week it has been noticed a repeated pattern for the
power consumption.

For farther analysis figure [] shows the load profile for one typical working day in the
factory, its been notice an almost constant value of power consumption under working
shift 9AM to 9PM 12 Hour .Moreover, the power consumption is decreasing when the
day end, but still there power consumption because of some motors is still operating as
M9 & M8 with average

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 Table[] shows the motors and their respective efficiency and load factor

Table []: Summary of Motors load factor and Efficiency

NO Load Factor Efficiency (%) Remark
(%)
M1 40 75
M2 40 75
M3 36 75
M4 40 75
M5 40 75
M6 40 75
M7 83 85
M8 65.7 75
M9 50 90 Running with Inverter
M10 17 70
M11 15 70
M12 15 70

It has been noticed after looking in the data given that Most of the motor are
oversize and it has low load factor which means the motor is being under load this
kind of arrangement has huge impact of efficiency of the motor which will

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 increase the power consumption of these motor figure [] Show the relationship
between load Factor & efficiency.

Most motor are meant to operate at 50% to 100% of its rated load, the maximum
efficiency we can get from the motor it’s when operates at 75% of its load. When motor
load is below 50% of rated load it will Decrease efficiency and eventually energy
consumption will increase. In up-coming page we will elaborate more in these motors
and ways to increase efficiency.

The total power consumption for the motors in one month period is 428 MW where two
Motors M7&M8 is taken 56% off power consumption and we believe they can draw less
power with some few tricks will discuss farther more in the report. Figure [] shows the
power computation distribution

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Another figure [] show power consumption by section and its clearly shows that the clay
section is consuming more than other section and that mainly because it has M7 & M8
which the main motor in the factory.

3.2 Main Incoming

Clay Preparation

M7 - Extrusion Machine

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Data Collected:
Rating: 270 HP, 480 A, 420 V, 720 RPM, 8P (with inverter)
Daily Power Consumed: 167178.6
Running Hours/Day: 11
Energy Consumed per month: 73558.584
Bill (Each Month): $30894.60
True HP used: 250HP

From the motor data obtained, it is show that the load factor of the machine is running
well at 83%. So this should show that the machine does not need any improvement.
However I would like to introduce new improvement will help to increase Efficiency
farther More . As studied from the graph of Energy vs. Production figure [] and from the
load profile figure [] the other factor is playing role in the power consumption, it shows
that starting at the month of July till around September.

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based on several factors such as the cutter failure, soil moisture we find that when the soil
is extra dry during that time as it should be the summer season around that time, so it
would be expected to be dry. From the data that has been collected the motor runs at
lower current at 270A when high soil moisture is used and higher current 290A when its
soil is dry. Hence the power is differ with less by 15kW when high soil moisture is used.

However from the report, it shows that the workers would have to manually wet the soil.
So if the clay bars produce still comes out crumble, then the workers would have to
adjust by adding more water. This may be the reason why there is high amount of energy
being consumed, but less production. This may be due to the fact that the workers have to
adjust the moisture of the soil every time.

Motor M8 – Clay Mixer 2

Rating: 150 HP, 195 A, 400 V, 500 RPM, 6P (with inverter)
Running Hours/Day: 11
Energy Consumed per month: 30326.2kw
Bill (Each Month): $12737

This machine is connected to a gearbox via belt. A clutch is used to connect and
disconnect the load to the gear box. The machine is disengaged from the load randomly
(based on several factors such as the cutter failure, soil moisture etc.). Motor draws
around 11.5 A under the no load condition. The motor draws around 140 A when it runs
with load. The motor is also connected to a 150 hp inverter. The inverter output
frequency is fixed at 48 Hz (2 Hz lower than line frequency 50 Hz). However this motor
running with 75% efficiency we believe lowering the Frequency will help to increase the
efficiency

Summary

1. Adding an IOT devices for both M7&M8 that can determine the dryness of the
soil. So from that, the workers or other automated device can wet the soil by how
dry the soil is. This could skip the adjustment period and go straight to
production. Thus saving time and energy.(whole IoT system will cost around
1500rm )

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 2. Lower Frequency for the inverter in M8 and test the operation for M8 if M8
operate without any failure then we set the new frequency for the motor that will
help increase the efficiency.

Clay preparation

Motor M11 – M12

These two motor has the same function which is Crush the coal to small pieces
the Rating for these motor are 75HP, 96A, 415V, 1470 RPM, 4 POLE each and
we can notice that the two motor are running in spite that each of these two are
running under-load as only 15% of their low hence these motor has very low
efficiency under 70%.

Due to low efficiency of 0.70 the motors have wastage of power by

Pe + Pe
n= =0.7=P E=16785 × 0.7=11749 kW
P M + PM

Solution
Is by using Motor 11 only by make it the primary motor and shut-down M12 and used it
when a high-Load is driven by doing so we have eliminate 850rm of monthly bill from
motor M12.further details will be discuss in Energy savings measures.

Tunnel Dryer Section

Motor M10 – Tunnel klin exhaust fan

This Exhaust Fan has Rating of 150HP, 200/182 A, 400/440V, 730 RPM, 8 Pole
and has power Consumption of 19.23kW and Efficiency of 70% even though the
fan has inverter it still run at low efficiency and cost around cost 7670$ monthly

Due to low efficiency of 0.70 the Fan has wastage of power by

P out
n= =0.7=P out =19023 ×0.7=13322.4 kW
P¿

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 As given from the data in this motor we can observe two major points that cause
increase in power consumption

1. Fan has been running for 16 years.

2. Low load Factor: the Fan only run 17% from its rated value.

Solution

The fan is being working 24h for 16 years and its oversized which let to
low load factor we believe than fan should be replace to new one with
lower rating . (new one with 50hp cost around 15000rm)

3.3 lighting system

4. Analysis and Identification Of Energy Saving Measures

There are 4 suggestions to minimize electricity bill in the plant. Firstly, we introduce Iot
system that will help to moister the soil which effect positively M7&M8 . Secondly, to
optimize the usage of M8 by lowering the Frequency of motor, thirdly replace M10 with
lower motor rating. Fourthly, turn off motor 12 and relay on motor 11. The details are
given in subsequent sections.

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4.1 ESM M7&M8

The propose would be to add an IOT device that can determine the dryness of the soil. So
from that, the workers or other automated device can wet the soil by how dry the soil is.
This could skip the adjustment period and go straight to production. Thus saving time and
energy.
From the data that has been collected the motor runs at lower current at 270A when high
soil moisture is used and higher current 290A when its soil is dry. Hence the power is
differ with less by 15kW when high soil moisture is used.

Potential saving for both Motor 7 and Motor 8

15 kW ×11 hr ×30 days=4 95 0 k Wh × 2=9900 kW

Each kWh cost 42 cent
0.42 ×9900=416 7 rm

Which can be easily eliminated if we use two Iot soil Moistures system
The two Iot Moistures system will cost around 3000rm + water bill 200 monthly

Payback

Within the first month

Motor8

Another approach to reduce the monthly cost off M8 is by Lower Frequency for the
inverter in M8 and test the operation for M8 if M8 operate without any failure then we set
the new frequency for the motor that will help increase the efficiency.

Currently is running at 48Hz with power consumption of 70kW

Suggesting frequency is 46hz

4 4 Hz 73 kw
= =P New =66 .9 67 kW
48 Hz P New

By reducing the frequency we were able to cut off 6 kw from the power consumption
now we test the fan if everything runs smoothly we can even reduce it more for more
saving but if face difficulty we can increase the frequency until is settle and run smoothly
.

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Potential Saving

6 kW × 11 hr × 30 days=1980 kWh

Each kWh cost 42 cents

1980 kWh × 0.42=832 rm

It will save around 832rm per month

This is great approach because we were able to reduce the cost without any investment.

4.3 ESM M10

Due to low load factor of 17% and been running for 16 years it led to have low
efficiency of 0.70 the Fan has wastage of power by

P out
n= =0.7=P out =19.023 ×0.7=13.33 kW
P¿

That’s mean the motor need 19.023kw to get 13.3224kW Hence there is around
5.7006kW 6 5 .700 6 ×24 × 30=4104.43 k Wh waste of energy per month which
will cost around
4104.43 × 0.42=1682.82 rm and yearly 20193rm

Solution will be by Replace the the motor for suitable rating which 50 HP motor.

The efficiency of the new motor will b 90 95 % .

Potential saving

19. 023
×24 × 30=14417.4 k Wh × 0.42=6392 RM
0.95

19023
×24 × 30=15218. .4 k Wh × 0.42=6391.7 RM
0.90

The current bill 7670Rm

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 1614 1280 rm per month

Pay Pack

The prices for 50Hp fan in the market is around 15k to 20k

9 months to 14 months

4.3 ESM M11 &M12

These two motor has the same function which is Crush the coal to small pieces
the we can notice that the two motor are running in spite that each of these two
are running under-load as only 15% of their low hence these motor has very low
efficiency under 70%.

Due to low efficiency of 0.70 the motors have wastage of power by

Pe + Pe
n= =0.7=P E=16 . 785 ×0.7=11 .749 kW
P M + PM
the is wastage of power by 5 kW .

A solation for that Is by using Motor 11 only by make it the primary motor and shut-
down M12 and used it when a high-Load is driven by doing so we have eliminate 850rm
of monthly bill from motor M12. This also will help to incrase the load Factor which is
lead to increase in the efficiency the figure shows the relationship between Load factor
and efficiency

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This method will increase the efficiency to 85% from 70%

Potential saving

Current Bill is 846RM

After increasing the load Factor

8.4 kW
×6 hr × 30=1778 kWh
0.85

Each kWh cost 42 cents

1778 kWh × 0.42=746 Rm

We have saved 100rm from M11 and additional to saving come from stop running M12
which is 850rm we have saved 950 rm per month

This is good approach because it doesn’t required any investment.

Total potential saving

From M7&M8 =5000Rm

From M 10 = 1620 rm
From M11&12= 950rm
Total = 7570

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PAGE 15