PRACTICAL APPROACH

TOWARDS ENERGY AUDITS

IN THE MSME CLUSTER : July 2024
TO REDUCE YOUR ENERGY BILLS,
TO IMPROVE YOUR ELECTRICAL SAFETY &
TO IMPROVE YOUR PRODUCTIVITY.
Ashok Sethuraman,
BEE Accredited Energy Auditor, Coimbatore.
Mail to :- [email protected]
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 ENERGY LOSSES CREEP into UTILITY right from Day One.

Energy Efficient Equipments & Utilities bought, years back.

Sometimes, Wrong installation during commissioning done.

You revisit routinely, to your OEM’s condition monitored practices,

• Electrical Distribution Daily KVA & KW losses

• All production machines, focus wetted parts to restore
• End to End Energy losses in the following utilities.
• Compressors – Generation, distribution & usage.
• Fans & Blowers – Generation, distribution & usage
• Pumps – Generation & Distribution & optimization.
• HVAC – assess in air and water Sub circuit separately.
• Ref your EB input Hz, study RPM loss in your machines.
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We have to educate the users, that equipments / process are ageing
and deviating from the Best operated Norms by monitoring always.
User has to practically run process, at de-rated machine capacity.

It is time to routinely monitor Exhausted fluid’s energy parameters in

content & movement. Higher the wasted outputs, efficiency drops
either in Specific Energy Consumption or Less Productivity.

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 ENERGY CONSERVATION is a Low Hanging Fruit now.
If left un-plucked now, this will silently eat your
operating profit margin soon & later too.

•Having done hundreds of Energy audits in the industry now,

•We the CEA, propose 5 to 10 % savings with One year Payback period.

• If your Power & Fuel Bill is Rs 5 Lakh pm & Rs.60 Lakh per year,

• you can still save around 10% thro better energy saving practices

• ASK YOURSELF

•How much product to sell to earn above Rs. 6 Lakhs net / year

•This 6 Lakh Rs is within yourself and make use of it NOW ! 4

 Need for Energy Audit & what does it deliver to you?
• Three top operating expenses are

• Energy (both electrical and thermal),

• Labour and Materials.

• Primary objective of Energy Audit is

• to determine ways to reduce energy consumption
• per unit of product output
• And to lower operating costs of production
• As well, to increase the productivity rates.

• In this decade you know what was your production machine’s

ratings and utility machines matched rating to suit to production.

• But you are retaining your utility machines from your transformer
to motors, pumps, blowers, compressors all the same utility only.
 Energy Audit shows where we stand

• What to do,
• where to start,
• at what cost and
• for what benefits

• First step is start with Preliminary Audit with existing Data.

• Second step is Detailed Audit & Generate more Data.

• Indicative saving potential to achieve

• Good House-keeping yields 5 - 10%

• Minor Investment gives 10 - 15%
• Reasonable Investment pays back 20 - 25%
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Similar to BEE 5 Star versus 2 Star rated equipments, please assess
your equipments, their useful life, wear & tear & efficiency.

•Your old pumps’ and the pumping system efficiency say 30 to 40 %

and the 5 Star pump + piping modifications yield efficiency 70 to 80 %

•Your old compressor delivered 4 to 5 CFM per KW and now latest

compressor package power delivers 7 to 8 CFM per KW

•Your old blower’s overall system efficiency around 30 to 40 % and

latest blower system delivers at efficiency of 65 to 75 %

•Your old motors’ efficiency was low at IE1 & rewounded many times.

• New motors efficiency at IE2,IE3, IE4, etc is appreciably high and for
lower HP motors, efficiency difference is more between old & new.7
Energy to Process Interface:- Transmission & Distribution T & D Losses
Occur MORE in between the Incoming Energy port & Process demand
point! Compare the norms with respect to BEE guides & optimize now.
SEB Meter

Piping Network (60%) Only 30 %

Transformer
energy is
(98%)
delivered to
Heat
Control valve 70%) Exchanger /
Auxiliaries
production
machine

Motor
85% Pump (80%)

Bearing &
Coupling
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 MSME – DAY-TO-DAY OPERATIONS TO FINE TUNE
Energy Efficiency / Conservation Practices to follow now:-

• Relative energy Monitoring of production, auxiliary, utilities.

• Production machines to have individual KWH, & Run hour meter

• If possible to have separate KWH monitor for auxiliary as well.

• KWH + run hour for utility to check they are matched to production

• Maintenance to be condition monitored with latest gadgets,

• with portable, in-situ, digital, or IOT devices to monitor & optimize.

 Energy conservation = short cut to generate Power
 Our Beloved Past President Dr.Abdul Kalam always used to say : -

 The cost of generation of 1 MW power is say 5 Crores of Rupees

 and takes many months to generate

 This generates 5000 KWH units per day for your use.

 The cost of 1 MW power conservation

 is only less than Rs. 1 Crore.

 The same 5000 units per day as said above,

 can be conserved inside your premises by spending Rs.1 Crore only.

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Result Of Energy Audit = Energy conservation & Energy Efficiency
comes next. Production Useful Output Increases &
Wasted Output Decreases & results in Reduced Energy Bills.
Apply this format below, to all your ENCON exercise. And you will
be pleasantly surprised at the Deliverables, Direct & Indirect.

Energy Input

Useful Output wasted output

ways to enhance output avoidable losses unavoidable losses

Recoverable loss Unrecoverable loss

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 You feel Shock, Relief & Delight – in your ENCON Exercise
• 3 stages of accepting results of energy conservation workings:-
Shock, Relief and, finally, Delight !
• The general wrong opinions about Maintenance
"Maintenance is a necessary evil"
• "Nothing can be done to improve maintenance costs”
• Please remove the opinions & now Remember:
• Where Safety (Conservation) Fails, Pollution Starts.
• This happens in every your process & utility machines.
So when the energy consumption per machine goes up means,
this is indicative of impending breakdown.
• Maintenance is a Tool to Productivity
• Utility to process is like Giving the Medicine in bottle to our body.
• Shake medicine bottle before use & shake our body after intake
for quick & better results of medicine.
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 Energy Efficiency Methods to implement / retrofit.
Generally practized Energy Efficiency methods in MSME
• VFD installation to suit to production machines for flexibility of
production rates to meet the daily market demands.

VFD retrofit to blowers, pumps and compressors to optimize their

outputs to variable process loading, and as well reduce KWH bills.
If they are variable torque loads, you will get huge energy savings.

• Insulation not replaced, Industry is runs still with decade-old stuff.

• New boiler installation, industries still run with oversized boilers.

• Fuel Switch – prevailing fuel prices force you to look for substitute.
• Waste heat recovery / other proposals to utilize the wasted heat.
• Plan for Solar heating, pre heating & roof top Solar simultaneously.
 MOTORS – what symptoms do your motors show?
• Motor loading – Is this in the efficient zone of say 60 to 80 %
• Basic, power & Energy Parameters is always a MUST to assess.
• Excess Input KW – means it is due to various factors IN & OUT?

• Why motor runs Hotter now? It can be warm, not hot or hotter.
• Shaft RPM measurement, rated and now what is running rpm?
• Thermal Image Scan of all axis from top to bottom DE & NDE

• Lubrication – conventional old grease caked out, acts as load.

• Ventilation – Allow all round ventilation & provide Sun Shade.

• Why No-load power goes up? – poor maintenance & rewindings

• Steps to take now to avoid the motor’s Accelerated Ageing next.
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 MOTOR SURVEY Recommendations
Following recommendations suggested after motor loading survey
Identify motors at what loading they are now?

• Below 50 % loading, - Inefficient loading, more losses.

• 60 – 80 % loading, - practically found as efficient loading.
•over 100 % loading – Unsafe loading, needs instant correction.

• Identify motors with low voltage / power factor / voltage imbalance

to correct externally to improve Motor Input energy savings.

•Identify motors with machine side losses / inefficiencies like idle

operations, throttling / damper operations for avenues like automatic
controls / interlocks, variable speed drives, etc.
•Replace now in stages, your Old & Rewound smaller size motors.
• Reduce the load on 100% loaded motors or
• replace with higher size motors, especially compressor motors.
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 Your motor at less 50 % loading is a big energy loss. Motors less than
10 HP on replacement, gives excellent energy savings > 10 %, In
general, load side optimization must be first priority, low hanging fruit.

COMPARISION of IE VERSION MOTOR STANDARDS

TO IE 3 & PM MOTORS- Image Courtesy:-ABB motors.

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 Thermally Imaged MOTOR HOT SPOTS IN BEARINGS DE & NDE
DE - Drive End Bearing 140 * C here, but difference better be < 10 *C
NDE - Non Drive End Bearing around 60 *C, better be Ambient +10*C
Many of working motors suffer silently due to poor lubrication,
Apply Specialized Polyurea thickened grease to motor bearings.
Allow motor’s fan to effectively cool your TEFC motors fins all around.

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Motor failure – Major causes. It is high time you protect your 3 phase
motor with Affordable Electronic motor protection relay, this gives
fool-proof protection against motor overloading, single phasing,
current unbalance compared to your existing thermal overload relays.

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 Load End Compensation, enhances KW saving & KVA savings More

Load end Capacitor improves PF to 0.80 to 0.85 lagging

+ Field Fixed bank at SSB improves to 0.90 lagging PF +
Automatic 3 CT sensing PF control at Power house to fix precisely @ 0.97 lag.
For your VFD drives, Line Reactance choke is a Must at its Incoming.

Improved PF Correction on 50HP Motor gives significant results.

Now we understand, why Load End Compensation is
50 HP 50 HP motor % Change in required for our 3-Phase motors rated above 3 HP?
motor ( with Cap ) parameters Our motors are always around 50 to 75 % loading
Without Cap only except our overloaded compressor motor.

37.3 KW 36.2 KW 3% Decrease

28 KVAR 15.1KVAR 46%

Decrease

46.6 KVA 38.4 KVA 17%

Decrease

0.8 PF 0.92 PF 15%

Increase
VFD to blower, compressor, pump, variable torque loads has excellent energy
savings when the Modulating machine is around partly-loaded, it is OKAY.

But, VFD consumes more if applied to averaged fully-loaded machine. VFD

has many versatile features to automate your machine, make use, automatic
closed loop control of process, ramping times, PID tuning features etc.
 EARTHING TO BE WELL MAINTAINED TO BYPASS THE SURGES
(ATTACKING THE MACHINES) TO EARTH, EFFECTIVELY ALWAYS
CONVENTIONAL EARTHING –

PAINTING LOOKS OK?

BUT EARTHING IS POORLY
MAINTAINED or it needs
routine maintenance.

MAINTENANCE
FREE EARTHING :

EARTHING IS GOOD IN THE

LONG RUN & Fit & Forget type,
but still monitoring needed.
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COMPRESSOR & COMPRESSED AIR SYSTEM HEALTH
• AIR RECEIVER TEMPERATURE
•AUTO WATER DRAIN AT COMPRESSOR, DRYER, RECEIVER
•COMPRESSOR LOADED AND UNLOADED KW
• LOAD AND UNLOAD HOURS
•REF DRYER IN & OUT TEMPERATURE

•PRESSURE DROPS FROM COMPR. TO MAIN HEADER

•AIR INTAKE FILTER PRESSURE DROP DAILY CHECK
•COMPRESSOR NAME PLATE VERSUS RUNNING LOAD

•THERMAL IMAGING OF PIPING & COMPRESSOR PARTS.

•SONIC IMAGING OF AIR LEAK IN ALL PIPES & TUBE JOINTS
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 •
On compressors’ top, Expanded Exhaust Ducting to fix and
At Suction, Daily cleanable Pre-filter, to improve compressor health.
Relocate your compressor Load-unload pressure control sensor to Air
receiver so that it can sense the non-pulsating, streamlined and
tanked pressure for smooth operation of compressor

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 Compressed Air Leakage – Effects – Direct & Indirect means.
Hence the compressed air leakage must be reduced
to minimum as per your industry segment norms.
Many industries are keeping 1 to 2 Bar higher header
pressure practically, to accommodate their running air leak. But to Minimize.
Time to change to Aluminum /SS piping. Avoid Sharp L & T Bends.
Plan for replacing PPR fittings with Brass /SS Fittings to avoid leaks.

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LOOK INTO THE DIFFERENCE BETWEEN LEAKAGE AND CLEANING HERE.

Air leak thro 6 mm hole in compressed air header is 104 cfm,

same 6 mm hose after 3 meter hose roll, delivers only 27 cfm ONLY, @
& still better with Energy Efficient nozzles /AMARJOTHI TEXTILES GOPI.
Cleaning Air appln needs Sized Air Receiver to avoid spikes in pressure.
CLEANING AIR GUN FLOW STUDY REPORT
– Metering Study in M/s.Amarjothi Textile mill at
GOPI, where Flow meter is fixed at header end
SL and air is used at other end, after the bundle roll CFM @ CFM LOSS %
NO of hose, to clean textile fluff in, machines, + etc. 6 BAR REDUCED Saving
1 6 mm cleaning hose (without gun) 27
2 8 mm cleaning hose (without gun) 48
8 mm cleaning hose
3 (with gun without nozzle) 45
8 mm cleaning hose
4 (with gun + power saving nozzle) 19 29 60
5 12 mm cleaning hose (without gun) 151
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Energy loss happening in Intermediate stages of power transmission.
Motor belt & pulley hotter than motor drive end.

When replacing the belt is routine, but the worn-out pulley also needs
to replace on condition monitoring the same,

RPM loss in power transmission, leads to Less Productivity at output.

Ref:- POWERON Projects Energy Audit report dt 2012.

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Your belt operated production machines lose productivity say by 5 % ,
where as your utility machines like belt operated blowers, pumps, etc
due to slippage between motor and machine lose power around 10 %.

This exercise pays back in few months, later only, motor replacement.
Courtesy:- Energy Audit study in TEA industry www:ramkalam.com

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 CASE STUDY 5 STAR rated AGRI PUMP REPLACEMENT
• BEE decided to swap old inefficient Agricultural pump with
5 star rated pump many years back to save up to 40 % power.

• 3530 pumps to replace in 6 months project cost Rs.7 Crores

• Pump OEM committed energy savings of 36 % PA over 5 years

• Cost of pump Rs.20,000/- includes the dismantling

the existing pump set, procurement & installation.
• For maintenance and repair / replacement for 60 months
provided free of cost to farmers.

• Rate of return = Rs.7200/- Hassle free investment of Rs.20,000

• ROI – Return on Investment say Rs.1000 in one year = Rs.360/- = 36%
• This is excellent Returns compared to other types of Financial Returns.

• This is part of EESL initiative in the National Replacement of Motors,

Pumps, Fans, Air Conditioners, and LED lights & Bulbs etc NOW.
 Star rated pump replacement is need of the hour today. But, Piping
pressure gradient analysis will yield the priority of replacing first the
Eccentric Reducers at the Suction & Delivery ports first and piping
replacement in sections of process & utility piping headers in industry.
Courtesy:- Energy Audit at textile mill www:poweronprojects.in
PUMPING SYSTEM – ENERGY CONSERVATION
To achieve energy conservation in the existing pump, the
piping loss, suction loss thro foot valve, pipe material
change to be focussed along with, when replacing the pump.
PARAMETERS NEW PUMP

Motor rating hp 7.5 5

Suction pipe mm 65 75
Delivery pipe mm 50 75
Piping material GI White PVC
Foot valve Local ISI
Discharge LPS 3.68 5.03
Input power KW 6.18 4.35
Increase in discharge 37 %
Input power reduction 30 %
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 How to implement Energy conservation ?
Motivation steps towards Employees yields instant results.
1. Allow participation in decisions making

2. Let them the know problems and reasons

3. Admire their work results & Believe in their responsibilities

4. Rewarding when success is achieved in Energy conservation.

5. It is wise for management to motivate your shop floor team

& reward them instantly to find out the energy losses happening

inside first and recover the losses immediately. This is Win-win

Situation and relatively low cost investment than replacements next.

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EXISTING MSME CONDITIONS & ENERGY SAVING POTENTIAL
• The company runs on market driven demands weekly /monthly.

• But they are not aware of their production machine power cost
versus their utilities like pumps, compressor, blower etc power cost

• For higher & lower production demands the same utility is running
on full load/speed & hence their power bill is still high at lean times.

• PRACTICALLY SPEAKING:-
• Many are not aware of their monthly low pf penalty payment to EB.

• Their compressors run to meet pneumatic demands of machines,

but more goes to leakages and frequent cleaning for all application.

• Their blowers used for material handling, suck /blow more output
than the required and consumes more power always. 34
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PEACE ENERGY AUDIT - This is the
scheme by Tamil Nadu Govt since
2017 and many industries are
benefitted by this scheme.

Energy Audit subsidy is Rs.1 Lakh,

an excellent opportunity for the
industries to monitor the break up
of energy consumption and target
to reduce their consumption.

MSME is motivated to conduct

energy audits and implement
Energy Efficient implementation
with a subsidy of Rs.10 Lakhs.

This needs to be done in all the

States of India to walk the talk on
energy efficiency improvements in
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industry &motivate to implement.
Case study of ‘PEACE’ type Energy Audit done in a textile mill. Before Energy
audit, mill consumed 71000 units/day Rs.20 Crores, their annual EB bill.
Now after Poweron Projects’ energy audit & implementation, same mill
consumes now 59000 units/day, average Rs.17 Crores annual EB bill.
Their EB bill reduced by 17 % & monthly EB bill reduced by Rs.25 Lakhs.
(SEC) 40s converted UKG reduced by 12 % from 3.64 to 3.22

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 The success of Energy Audit lies in the Successful Education &
Implementation EARLY. The Audit report gives energy conservation
proposals at zero cost, low cost and high cost,
once you start implementing the zero & low cost proposals,
you will be automatically motivated to implement High cost Proposals
immediately and make use of subsidy towards EE functioning.

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 ENERGY AUDIT INSTRUMENTS USED FOR INSTANT AND TREND
MEASUREMENTS to measure Electrical Energy, Power Quality, Lumens,
pressure, flow, temperature (by Imager), Pascal, RPM (by stroboscope)
 Links below to buy above my Energy conservation books & ebooks online:-
1. https://notionpress.com/read/practical-guide-to-energy-conservation-
management/paperback
2. https://notionpress.com/read/energy-conservation-management-in-textile-mills
3. https://notionpress.com/read/conserve-energy-and-restore-productivity-in-
machines-by-belts-and- pulley-drives
4. https://notionpress.com/read/energy-monitoring-conservation-practices-in-
residential-commercial-buildings
5. Subscribe to youtube/energymeasuretosave to view the past webinar videos.
6. All above 4 books are available in e-book format and paper back format in
amazon.in, flipkart.com in India / in amazon.com, amazon.co.uk internationally.
7. Kindly give your valuable feedback mail to:- [email protected] 40