COVER SHEET

Name: Lallmamode Junaid Muhammad Nissaar

Course: Diploma in Mechanical & Electrical Engineering
Class: AMEE 13
YEAR 2 Semester 3
Subject: Industrial Automation
Assignment title: Automation and Energy Management

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Table of Contents
Automation and Energy Management.........................................................................................................3
Question 1.................................................................................................................................................3
State the objectives of an energy audit...............................................................................................3
Identification of Energy Consumption Patterns...................................................................................3
Assessment of Energy Efficiency...........................................................................................................3
Cost Reduction.......................................................................................................................................3
Recommend Energy Efficiency Improvements.....................................................................................3
Risk Management:................................................................................................................................4
Environmental Impact Mitigation........................................................................................................4
Create a breakdown of all the energy sources on site and write down your observations..................4
Breakdown of energy on site................................................................................................................6
Observations..........................................................................................................................................6
Question 2.................................................................................................................................................7
Conclusions based on the information provided.....................................................................................8
Energy Consumption Patterns..............................................................................................................8
Potential Issues.....................................................................................................................................8
Usage Trends.........................................................................................................................................8
Cost Impacts..........................................................................................................................................8
Effectiveness of Operations..................................................................................................................8
Based on these conclusions, the following actions can be taken...........................................................9
Regular maintenance of both compressors.........................................................................................9
Load balancing between compressors.................................................................................................9
Monitoring energy consumption..........................................................................................................9
Implementing predictive maintenance strategies...............................................................................9
Examining the root causes of pressurization problems.....................................................................10

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Automation and Energy Management
Question 1:
a) State the objectives of an energy audit.

Energy efficiency and sustainability are major considerations in today's world, where energy
audits are essential. These audits accomplish a variety of goals, including regulatory
compliance, cost reduction, and protecting the environment.

An energy audit's primary goal is to thoroughly examine the patterns of energy use in a
process or facility. Audits uncover inefficiencies and areas for improvement by closely
examining energy consumption across a range of systems and operations. The attainment of
multiple overarching goals is predicated on this comprehensive evaluation:

 Identification of Energy Consumption Patterns:

Determining the energy consumption patterns within an organization is the main goal of
an energy audit. Audits give a clear picture of the areas and equipment where energy
use is most concentrated by looking at patterns of consumption across a variety of
processes and areas.

 Assessment of Energy Efficiency:

Assessment of energy-consuming machinery and systems is the goal of energy audits.
An audit can identify places where energy is being wasted or used less effectively by
examining variables including air leakage, insulation effectiveness, and equipment
performance. From there, corrective action can be taken to lower energy usage and
save costs.

 Cost Reduction:
The identification of cost-saving potential is one of the primary objectives of energy
audits. Organizations can reduce energy costs and improve their financial performance
and competitiveness by implementing the energy-saving recommendations and
inefficiencies identified during audits.

 Recommend Energy Efficiency Improvements:

Experts make suggestions for enhancing a building's energy efficiency based on the
results of an energy audit. These recommendations can involve installing energy-
efficient appliances, caulking air leaks, replacing insulation, or enhancing HVAC system
efficiency. When these changes are put into practice, there may eventually be large cost
reductions.

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  Risk Management:
Reducing the risks related to energy supply, fluctuation in prices, and energy security is
another goal of energy audits. Audits strengthen organizational preparedness and
resistance to energy-related issues by detecting inefficiencies and suggesting risk-
reduction tactics.

 Environmental Impact Mitigation:

In order to reduce the negative effects of energy use on the environment, energy audits
are essential. Audits support sustainability initiatives and assist companies in meeting
their CSR obligations by finding ways to minimize energy use and greenhouse gas
emissions.

In short, an energy audit aims to achieve a variety of interrelated goals that include financial,
environmental and strategic aspects. These goals are met by energy audits, which in a world
growing more complicated and energy-conscious, not only maximize energy performance but
also boost organizational success.

b) Create a breakdown of all the energy sources on site and write down your observations.

ENERGY BREAKDOWN
Oil 4%
Electricity 22%

Natural Gas 74%

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 COST BREAKDOWN
Oil 4%

Natural Gas 48%

Electricity 48%

CO2 BREAKDOWN
Oil
3%

Electricity
44% Natural Gas
53%

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Breakdown of energy on site:

 Electricity

o Quantity Purchased in Original Units: 2,750,000 kWh

o Quantity Converted in kWh: 2,750,000 kWh
o Cost: $330,000
o CO2 Emissions: 1,460 tonnes

 Natural gas

o Quantity Purchased in Original Units: 840,000 m3

o Quantity Converted in kWh: 9,240,000 kWh
o Cost: $323,400
o CO2 Emissions: 1,760 tonnes

 Oil

o Quantity Purchased in Original Units: 42,000 litres

o Quantity Converted in kWh: 445,200 kWh
o Cost: $25,200
o CO2 Emissions: 110 tonnes

 Other fuel

o No particular information was given.

Observations:

1. Electricity Consumptions:

Of all the energy sources used at the site, electricity is the one that is most
consumed. It makes up a significant portion of the quantity purchased as well as the
associated costs. For electricity, the conversion efficiency from purchased units to
kWh is one to one. Its CO2 emissions are less compared to those of natural gas,
despite the fact it contributes to the majority of costs.

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  Natural gas usage:

The second-most-used energy source on the site is natural gas. The conversion rate
to kWh is substantially higher even though the quantity purchased is less than that
of electricity. In comparison to electricity, this indicates natural gas has a higher
energy density. It incurs a substantial cost, almost comparable to electricity.

 Oil consumptions:

On the site, oil usage is considerably lower compared to the use of natural gas and
electricity. In contrast, it has a relatively high cost per unit compared to the other
energy sources. Both CO2 emissions and costs associated with oil consumption are
also lower compared to natural gas.

 Total Energy Consumption:

The total energy consumption on the site amounts to 12,435,200 kWh. This figure
represents the combined energy usage from electricity, natural gas, and oil.

Ultimately, the audit emphasizes the need for effective strategies to maximize energy use, with
an emphasis on lowering reliance on sources of high emissions, such as natural gas, while
possibly exploring alternatives or enhancing efficiency in electricity consumption.

Question 2:
You extract the following data from the meter reading system. What conclusion can you draw
from it? What actions would you put in place?
Compressor 1 appears to be continuously in operation during the period, according to the data
presented, but Compressor 2 is only occasionally turned on, usually in the event that
Compressor 1 experiences an issue.

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Conclusions based on the information provided:

1. Energy Consumption Patterns:

Compressor 1 seems to have a consistent energy usage pattern over time, with
irregular fluctuations. Compressor 2 has intermittent periods of activity and minimal
energy usage, in contrast. This shows that Compressor 2 is manually turned on as
needed rather than being in use all the time.

2. Potential Issues:

Compressor 1's steady energy consumption indicates that it is operating without

significant problems. However, Compressor 2's inconsistent consumption pattern
can point to possible problems like:

 Reliance on Compressor 2 as a backup due to maintenance or reliability

issues with Compressor 1.
 Since Compressor 1's insufficient capacity, Compressor 2 must be manually
activated.

 Usage Trends:

Compressor 1's utilization remains steady during the course of the observation
period, with no significant ups or downs. Compressor 2 shows intermittent usage,
with days of inactivity followed by periods of increased activity. The periods when
the compressor is manually turned on to meet higher demand or make up for
problems with Compressor 1 are likely when the energy usage spikes occur.

 Cost Impacts:

Compressor 2's manual activation may increase operating expenses because it will
use more energy during peak hours. It's critical to assess how much more affordable
it is to use Compressor 2 as a backup when compared to fixing any underlying
problems with Compressor 1 or implementing other changes.

 Effectiveness of Operations:

Looking into the underlying reason behind Compressor 2's irregular utilization.
In order to reduce energy consumption, compressor utilization scheduling should
also be optimized based on demand trends. Furthermore, to ensure maximum
efficiency and reliability, perform routine maintenance checks on both compressors.

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Based on these conclusions, the following actions can be taken:

1. Regular maintenance of both compressors:

Since there seem to be issues with Compressor 1 regarding its pressure and usage
frequency compared to Compressor 2, it is recommended to prioritize regular
maintenance for this compressor. This can entail looking for leaks, changing or
cleaning filters, and evaluating the condition of valves and seals. Strict adherence to
the maintenance schedule is necessary to avoid unplanned downtime or higher
energy usage as a result of broken equipment.

2. Load balancing between compressors:

Load balancing can be used to lessen Compressor 1's workload and ensure more
equitable use between the two compressors. This means that although both
compressors are running simultaneously, their output levels are being adjusted in
response to demand and the state of each compressor. In addition to ensuring that
the demand for compressed air is satisfied effectively and without interfering with
production processes, properly balanced loading would help prevent undue wear
and tear on either compressor.

3. Monitoring energy consumption:

It is imperative to consistently monitor the energy consumption of both compressors

in order to detect any patterns or deviations that may point to possible problems
with their functionality or effectiveness. Energy management systems can be used to
monitor data in real time and provide reports that show any odd trends in the
amount of energy used by either compressor over time. Then, by utilizing this data,
compressed air manufacturing activities may be made more efficient and the overall
energy costs can be decreased.

4. Implementing predictive maintenance strategies:

Before they result in major damage or unplanned downtime for either compressor,
predictive maintenance techniques such as vibration analysis and oil analysis can
assist in identifying such problems. These tactics enable scheduled breakdowns and
timely repairs instead of expensive emergency repairs during production hours,
when limiting downtime becomes essential for maintaining productivity levels and
successfully satisfying customer requirements.

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 5. Examining the root causes of pressurization problems:

In order to minimize downtime caused by manual compressor switching when

necessary for production processes that cannot afford interruptions in compressed
air supply (either due to safety concerns or process requirements), a thorough
investigation into the root cause analysis of the inflation issues experienced with
Compressor 1 should be conducted as soon as possible. This could entail locating
possible causes, such as leaks in pipelines or valves, clogged filters, failed seals, or
wear and tear on mechanical components, which could lead to shifts in system
pressure or, in certain cases, higher energy consumption by the impacted
compressor unit when exposed to specific circumstances (like high temperatures).
When a problem is found, it is important to act quickly to address it according to the
expert advice of trained specialists who are knowledgeable about the best practices
for designing and operating industrial compressed air systems.

Through the use of these measures, the organization may minimize downtime and maximize
productivity while simultaneously improving the compressed air system's cost-effectiveness,
reliability, and efficiency.