Energy Audit Report

Submitted By:
NEC Consultants Private Limited

Draft Report
November 01, 2011
Shafi Gluco-Chem (Pvt.) Ltd.
Energy Audit Report
Submitted to:
Mr. Yasir Shafi
Executive Director
Sshafi Gluco-Chem (Pvt.) Ltd.
Plot B 22-26 Hub Industrial Trading Estate
Distt Lasbella, Hub, Balochistan 54000
Pakistan.
Tel: (92-85) 3303-719-21
Fax: (92-85) 3303-952
NEC Consultants (Pvt.) Limited
Principal House, Mezzanine Floor, Plot No. 39C & 41C
22nd Commercial Street Off: Khayaban-e-Ittehad
Phase II Extension, DHA, Karachi
Tel: (92 21) 3589 3341 43
Fax: (92 21) 3589 3340
E-mail: epsd@nec.com.pk
Website: www.nec.com.pk
Submitted by:
For any clarification about this Report, please contact Mr. Ibad ur Rehman,
Manager (Environmental Studies Division Southern Zone) in NEC Karachi office.
Draft Report
November 01, 2011
Shafi Gluco-Chem (Pvt.) Ltd.
Energy Audit Report
Subject to Change after Review by SGC Management & NEC Quality Assurance.
Not to be Used for any Official Purpose.

NEC Consultants (Pvt.) Ltd. i

List of Acronyms

Chapter 1: Introduction 1 - 1

1.0 Introduction 1 - 1
1.1 Objective of the Audit 1 - 1
1.2 Scope of Work 1 - 2
1.3 Audit Methodology 1 - 3
1.4 Energy Audit Team 1 - 4
1.5 Audit Gadgets 1 - 4
1.6 Limitations 1 - 5

Chapter 2: Energy Consumption and Distribution 2 - 1

2.1 Introduction of Industry 2 - 1
2.2 Process Description 2 - 1
2.3 Utilities 2 - 3
2.3.1 Energy Sources, Consumption and Distribution 2 - 3
2.3.2 Water Cooling System 2 - 8
2.3.3 Cooling Tower(s) 2 - 9
2.3.4 Boiler(s) 2 - 9
2.3.5 Air Compressor(s) 2 - 10

2.4 Monthly Utilities Consumption & Unit Utility Rate 2 -11
2.7 Existing Energy Management Initiatives 2 - 11
2.8 Current Energy Status of the SGC 2 - 13

Chapter 3: Energy Saving Potential 3 - 1

3.1 Electrical Energy Saving Potential 3 - 1
3.1.1 Electrical Distribution System (Cable Sizing) 3 - 1

3.2 Power Factor 3 - 3
3.2.1 Power Factor Improvement Plant at Self Generation 3 - 3
3.2.2 Power Factor Improvement Utilizing KESC Connection 3 - 3

3.3 Electric Motors 3 - 4
3.3.1 Oversized and Undersized Motors 3 - 4
3.3.2 Efficiency of Motors 3 - 5
3.3.3 Maintenance Concerns 3 - 5

ToC

TABLE OF CONTENT
Shafi Gluco-Chem (Pvt.) Ltd. Energy Audit Report
NEC Consultants (Pvt.) Ltd. ii
3.3.4 Voltage Unbalance 3 - 6
3.3.5 Current Unbalance 3 - 8
3.3.6 Lighting System 3 - 9
3.3.7 Monitoring and Evaluation System 3 - 10
3.3.8 Variable Frequency Drives (VFDs) 3 - 10
3.3.9 Rewinding of Motors 3 - 11
3.310 Transmission Losses 3 - 11
3.3.11 Sustainable/Renewable Energy Sources 3 - 12

3.4 Thermal Energy Saving Potential 3 - 12
3.4.1 Monitoring and Evaluation 3 - 12
4.4.2 Boiler(s) 3 - 13
3.4.3 Feed Water Treatment 3 - 13
3.4.4 Blow down 3 - 14
3.4.5 Boiler Efficiency 3 - 16
3.4.6 Boiler(s) Combustion Analysis 3 - 16
3.4.7 Direct Fired Burners 3 - 17
3.4.8 Economizer 3 - 18
3.4.9 Steam Traps 3 - 18
3.4.10 Insulation 3 - 18
3.4.11 Leakages (Thermal) 3 - 20

3.5 Cooling Tower 3 - 21
3.6 Compressed Air System Concerns 3 - 21
3.7 Leakages (Compressed Air) 3 - 22

Chapter 4: Recommendations 4 - 1

4.1 Electrical Energy 4 - 1
4.1.1 Electrical Energy Sources 4 - 1
4.1.2 Transformers 4 - 1
4.1.3 Power Factor Improvement (PFI) Plants 4 - 1
4.1.4 Utilization of Diesel Generator 4 - 1
4.1.5 Utilization of KESC 4 - 2
4.1.6 Recommendation for Proper Distribution (Cable Sizing) 4 - 2
4.1.7 Proper Sized Motors 4 - 2
4.1.8 High Efficiency Motors 4 - 2
4.1.9 Preventive Maintenance 4 - 3
4.1.10 Voltage Unbalance 4 - 3
4.1.11 Current Unbalance 4 - 4
4.1.12 Lighting System 4 - 4
4.1.13 Monitoring and Evaluation 4 - 4
4.1.14 Installation of VFDs 4 - 4
4.1.15 Motor Consideration with VFDs 4 - 5
4.1.16 Use of Rewound Motors 4 - 5
4.1.17 Transmission Losses 4 - 6
4.1.18 Sustainable/Renewable Energy Sources 4 - 6
4.1.19 Solar PV Electricity Generating Panels 4 - 7
NEC Consultants (Pvt.) Ltd. iii
4.2 Thermal Energy 4 - 8
4.2.1 Monitoring & Evaluation 4 - 8
4.2.2 Feed Water Treatment 4 - 8
4.2.3 Blow down 4 - 9
4.2.4 Boiler(s) Efficiency 4 - 10
4.2.5 Combustion Efficiency Boiler(s) 4 - 10
4.2.6 Economizer 4 - 12
4.2.7 Steam Traps 4 - 12
4.2.8 Insulation of Pipes, Tanks and Boilers 4 - 12
4.2.9 Leakages 4 - 13
4.2.10 Cooling tower 4 - 14
4.2.11 Compressed Air System 4 - 14

List of Tables:

Table 2.1: Installed Capacity/Sanctioned Load 2 - 3
Table 2.2: Installed Capacity and Load Served by the Transformer 2 - 4
Table 2.3: Location and Capacity of Power Factor Improvement Plants 2 - 4
Table 2.4: Consumption Record for the Year 2010-2011, (Diesel Genset) 2 - 5
Table 2.5: Consumption Record of the Year 2010-2011, (KESC to Plant) 2 - 6
Tariff: TOD-B3
Table 2.6: Chiller Data 2 - 8
Table 2.7: Cooling Tower Data 2 - 9
Table 2.8: Boiler(s) Data 2 - 9
Table 2.9: Air Compressor Data 2 - 10
Table 2.10: Monthly Consumption of Utilities 2 - 11
Table 2.11: Unit Rate of Utilities 2 - 11
Table 2.12: Status of the SGC 2 - 13
Table 3.1: Electrical Cables Voltage Drop Calculation 3 - 1
Table 3.2: Findings of Low Power Factor Penalty 3 - 4
Table 3.3: Findings of Load on Electric Motors 3 - 4
Table 3.4: Top Causes of Failures in Electrical Distribution System 3 - 6
Table 3.5: Findings of Voltage Unbalance 3 - 7
Table 3.6: Current Unbalance 3 - 9
Table 3.7: Lighting Details 3 - 10
Table 3.8: VFDs Installed at SGC 3 - 11
Table 3.9: Transmission Losses 3 - 11
Table 3.10: List of Monitoring Equipment 3 - 12
Table 3.11: Steam Generator(s) Data 3 - 13
Table 3.12: Water Quality Results 3 - 14
Table 3.13: Minimum amount of Blow down Required 3 - 15
Table 3.14: Difference in Energy Lost Between Manual and Automatic Blow down 3 - 15
Table 3.15: Annual Losses due to Manual Blow down System 3 -16
Table 3.16: Boiler Efficiency 3 - 16
Table 3.17: Combustion Analysis Test Results 3 - 17
Table 3.18: Combustion Analysis Test Results (Direct Fired Burners) 3 - 17
Table 3.19: Annual Losses Due to Lack of Insulation of Steam Distribution Network 3 - 18
NEC Consultants (Pvt.) Ltd. iv
Table 3.20: Annual Losses due to Lack of Proper Insulation of the Feedwater Network 3 - 19
Table 3.21: Annual Losses due to Lack of Proper Insulation of the Blowdown Network 3 - 20
Table 3.22: Location of Steam Leakages 3 - 20
Table 3.23: Annual Losses due to Steam Leakages 3 - 21
Table 3.24: Annual Losses due to Compressed air Leakages 3 - 22
Table 4.1: Transmission Losses and Saving Opportunities 4 - 6
Table 4.2: Solar Power Systems 4 - 7
Table 4.3: TDS Reduction vs. Savings 4 - 9
Table 4.4: Combustion Analysis Test Results (Initial) 4 - 11
Table 4.4: Combustion Analysis test Results after Adjusting Boiler Air Intake 4 - 11

List of Figures:

Figure 2.1: Process Flow Diagram 2 - 2
Figure 2.2: Consumption Pattern for the Year 2010-2011 (Diesel Genset) 2 - 5
Figure 2.3: Consumption Pattern for the Year 2010-2011, (KESC to Plant) 2 - 7
Tariff: TOD-B3
Figure 2.4: Electricity Rate (Rs. /kWh) for the Year 2010-2011, (KESC to Plant) 2 - 7
Tariff: TOD-B3
Figure 3.1: Effects of Voltage Variation on Electrical Motors 3 - 3
Figure 3.2: Effects of Voltage Unbalance on Electrical Motors 3 - 8
Figure 3.3: Lack of Insulation in Evaporator Section 3 - 19
Figure 3.4: Right Lack of Insulation of Boiler Accessories 3 - 19
Figure 3.5: Lack of Insulation of Feed water Network 3 - 19
Figure 4.1: Energy Saving Comparison of Electrical Motors 4 - 3
Figure 4.2: Energy Saving with VFD by Reducing RPM 4 - 5

NEC Consultants (Pvt.) Ltd. v

CFL Compact Fluorescent Lamps
CO Carbon Monoxide
CO
2
Carbon Dioxide
GJ Giga Joules
HITE Hub Industrial Trading Estate
HPL Metal Halide Lamps
KESC Karachi Electric Supply Corporation
kW Kilowatt
kWh Kilowatt hour
LIEDA Lasbela Industrial Estates Development Authority
MCC Motor Control Center
MW Megawatt
NEC NEC Consultants (Pvt.) Ltd.
PEPCO Pakistan Electric Power Company
PKR Pakistani Rupees
PPM Parts Per Million
SGC Shafi Gluco Chem (Pvt.) Ltd.
TDS Total Dissolved Solids
VFD Variable Frequency Drives

LoA

LIST OF ACRONYMS

NEC Consultants (Pvt.) Ltd. 1 - 1

1.0 Introduction

Energy is the most important sources for growth of a country. Unfortunately,
Pakistan has been facing serious energy crisis since 2007. Despite of some strong
economic growth during the past decades and consequent rising demand of energy,
no appropriate steps have been taken to increase the energy supplies consistent
with the demand. Now, the demand exceeds supply and hence load-shedding is a
common phenomenon through frequent power shut downs. According to Pakistan
Electric Power Company (PEPCO), the current power generation of Pakistan is 12,175
MW of electricity per day, and the present demand is 18,160 MW per day. Thus,
there is a shortfall of about 5,985 MW per day
1
. This shortage is badly affecting
industry, commerce and daily life of the people.

The industrial sector of Pakistan is badly affected with the prevailing energy
predicament, destroying about 50 percent of the total industrial sector. The only
survival for the Pakistani industries is to act progressively by adopting a
comprehensive strategy encompassing assessment of the current energy
performance, detailed monitoring of the energy consumption patterns and
ultimately the conservation of the valuable resource by adopting best available
practices and employing energy efficient technologies.

Shafi Gluco Chem (Pvt.) Ltd. (hereinafter referred as SGC) being the judicious and
progressive industry has hired NEC Consultants (Pvt.) Ltd. (NEC) to carryout the
Energy Audit of its facility located at Hub Industrial Trading Estate (HITE) for
identification of potential energy conservation areas and providing the
recommendations on energy optimization and cost savings.

The field activities to collect the necessary audit data of SGC were carried out on 3
rd
,
5
th
. 7
th
and 17
th
of October, 2011. This data is then analyzed and a report of key
findings and recommendations is prepared.

1.1 Objective of the Audit

The overall objective of the energy audit is to review the existing energy
consumption practices in the industry, identify the key potential energy efficiency
and conservation areas and provide detailed recommendations on energy
optimization and cost savings.

1
http://pepco.gov.pk/pow_situation.php
CHAPTER
1

INTRODUCTION
1.2 Scope of Work

The overall scope of the audit is as follows:

Conduct a general survey of the plant to review the major energy conversion
installations, electric motors and machines, and thermal production processes;
Collect field data to examine existing energy consumption practices and identify
potential energy efficiency and conservation areas;
Review alternate possible technologies and assess their suitability under local
conditions;
Identify and finalize the scope of work for detailed investigations;
Investigate the selected technologies in detail and evaluate the saving potentials;
Prepare the energy audit report of key findings and recommendations which will
serve as implementation guideline to the plants management; and
Present the main findings and recommendations to the industry management in
a final oral presentation.

The aforementioned scope of work covers following aspects of energy
conservation in particular;

Thermal Aspects:

Boiler(s) and their Accessories;
Steam Distribution Network;
Boiler Blowdown Network;
Condensate Network;
Compressors and their Accessories;
Compressed Air Distribution Network;
Combustion Analysis of Boiler(s) and Direct Fired Systems;
House Keeping Issues pertaining to;
o Insulation
o Leakages
Cooling Towers and their Accessories;
Cooling Water Network.

Electrical Aspects:

Electricity Generation/Consumption Performance;
Electricity Distribution Network;
Motor Performance;
and Quality of Electric Power

1.3 Audit Methodology

Audit methodology comprises of the following three phases:

1. Set up Phase

a. Kick off Meeting:

The kick off meeting was held on September 06, 2011 to discuss the scope of
the audit, review the schedule of activities and clarify the roles and
responsibilities of the NEC and the SGCs team deputed with the NECs
energy experts. A checklist of some basic information, mandatory to proceed
with the detailed energy audit was also provided to the SGCs team at the
end of the meeting session.

b. Reconnaissance Visit:

The NEC audit team along with the SGCs team conducted reconnaissance
visit to the industry to gain familiarity with the product manufacturing
practices at the SGC, associated machinery and utilities. The visit facilitated
the audit team to device the better work plan for the detailed investigation
phase. The primary information about the unit was collected in accordance
with the data acquisition plan which comprised of a checklists to collect all
the concerned physical, technical and energy consumption data of the
industry.

2. Detailed Investigation Phase

a. Data Collection:

The audit team reviewed the data collected in the first visits and identified
additional data required. In this step, detailed information about the
industry is collected in accordance with the assessment checklist, as
discussed in the preceding step. Initially, the data available with the industry
is collected and reviewed. Later, the assessment team conducts detailed field
visits in the industry. Both qualitative and quantitative analysis is performed
in order to acquire energy relevant data from the industry.

b. Data Analysis:

The audit data was examined to identify energy saving potential in the unit.
Measures to be analyzed in more detail were decided upon in close co-
operation with the SGCs team. All measures were analyzed with regard to
their financial benefit and technical feasibility, starting with measures of
short pay-back periods to those having a mid to long-term payback period.

3. Concluding Phase

a. Preliminary Audit Report of Key Findings & Recommendations:

Initially, a draft energy audit report encompasses key audit findings and
recommendations along with detailed action plan is prepared and submitted
to the SGCs management for their review and comments.

b. Final Audit Report and Presentation:

After incorporating the comments from the SGC on the draft report and action
plan, a final report and action plan will be prepared and presented to the SGC
management.

1.4 Energy Audit Team

The assessment team comprises of the following professionals;

Mr. Faisal Aziz, Sr. Environmental Engineer/ Team Leader
Syed Mustafa Saeed, Mechanical Engineer
Mr. Faisal Shahzad, Electrical Engineer

1.5 Audit Gadgets

Following gadgets were used during the audit for acquisition of the primary energy
related data;

1. Stack Analyzer
Brand: Bacharach, Model: PCA3 265
2. Thermal Imaging Camera
Brand: FLIR, Model: FLIR i40
3. Ultrasonic Leak Detector
Model: MS6700
4. Ultrasonic Water Flow Meter
Brand: Greyline, Model: Stingray
5. Anemometer
Model: AVM-01
6. Infrared Temperature Gun
Model: 1327K
7. Power logger
Brand: FLUKE, Model: FLUKE 1735
8. Clamp-on Meter
Model: 6601 3
9. Stroboscope
Model: DT-2269
10. Verniers Caliper
11. Measurement Tape
1.6 Limitations

Services performed by the consultant are conducted in a manner consistent with that
level of care and skill ordinarily exercised by members of the engineering and
consulting profession. This report does not exhaustively cover an investigation of all
possible energy conservation aspects and circumstances that may exist.

In evaluating the subject site, consultants relied in good faith on information provided
by the SGC, management or employees. The Consultants assume that the information
provided is factual, accurate, and accepts no responsibility for any deficiency,
misstatements, or inaccuracies contained in this report as a result of omission or
misrepresentation of any person interviewed or contacted.

It should be recognized that the passage of time may affect the information provided in
this report. Specific circumstances and conditions of a site can change. Opinions
relating to the conditions are based upon information that existed at the time the
conclusions were formulated.


This chapter presents the detail of the different forms of the energy consumed and
distributed in the facility. Existing energy management practices in the industry and
current status of the SGC with regards to energy management are also briefly
discussed here.

2.1 Introduction of Industry

Shafi Gluco-Chem (Pvt.) Ltd. (SGC) is the most highly equipped, state-of-the art
Starch based Sweeteners production facility, located in Hub Industrial & Trading
State, Baluchistan. SGC makes a wide variety of rice syrups and proteins, all made
enzymatically from 100% whole rice. The raw material includes white rice, brown
rice and organic rice. SGC operates about 300 days a year and has a total workforce
of about 200 workers, working in 2 shifts of 12 hrs each. It started its production in
the year 2003 and having monthly capacity of producing 15,400 MT glucose syrup
and 3,000 MT proteins.

2.2 Process Description

This section briefly describes the production process of glucose syrup at SGC. The
rice flour was obtained from broken rice by using a dry milling method. The glucose
produced from the slurry of various raw materials by treating with enzymes. The
treated slurry is then subjected to filtration process, where rice protein is separated
from the slurry by using plate type filter press. Rice proteins are collected as residue
in the shape of filtered cakes, whereas the filtrate (glucose solution) is decolourised,
desalted in an ion exchanger column. The dilute glucose syrup is finally evaporated
under vacuum to raise the solids concentration. The concentrated syrup is
centrifuged in the disc type centrifuge and the precipitate is dried by spray drying.
The Figure 2.1, presents the process flow diagram of the production processes at
SGC.

CHAPTER
2

ENERGY CONSUMPTION AND DISTRIBUTION

Figure 2.1: Process Flow Diagram

Source: Visual observation acquired during the field visit, 2011

Rice Screening
Cleaning / Sorting

Milling

Storage

Slurry Preparation
Filtration
(Plate Type Filter Press)

Rice Protein Treatment/Dispatch

Enzyme Treatment

Purification
(Ion-Exchanger)

Evaporation

Glucose Syrup Filling & Dispatch
Centrifuge
(Disc Type Centrifuge)

Drying
(Spray Dryers)
Dispatch Dried Glucose
2.3 Utilities

Major utilities at SGC include gas, electricity, steam and compressed air. The brief
information on the utilities employed at SGC is as follow;

Steam Generator
SGC has installed two fire-tube type boilers for the generation of steam, each
have the capacity of generating 6 tons of steam per hour. The steam is utilised
mainly in evaporators, conversion, heating feedwater and for drum washing.

Cooling Towers
SGC has installed two induced draught cooling towers having capacities of 1,717
and 1,750 gpm, respectively. The cooling water from the cooling tower is used to
lower the temperature of heat exchangers installed in the process area.

Compressors
Two air compressors were installed to produce compressed air that is consumed
in the manufacturing process either directly and/or to run the pneumatic
equipment.

Chillers
There was one reciprocating chiller installed at SGC, to provide chilled water that
was utilized in the cold room for air conditioning. The chiller was not in
operation during the energy audit.

Generators
SGC uses LIEDA (KESC) as prime source of the electricity; In addition, it also has
one 1,500 kVA diesel genset as the standby source.

2.3.1 Energy Sources, Consumption and Distribution

Electricity Sources

In order to meet the electric power requirements at SGC there is one connection
taken from LIEDA (KESC) and one diesel generator-set. The connection from
KESC is used as prime source of electric power while the diesel genset is reserved
as a stand-by source. Table 2.1 below shows the installed capacity/sanctioned
load at SGC:

Table 2.1
Installed Capacity/Sanctioned Load

Source Installed Capacity/Sanctioned Load
LIEDA (KESC) 1,100 kW , 11 kV
Diesel Generator No. 1 1,500 kVA , 400 V
Source: The management of SGC, 2011

Distribution and Consumption

Transformers

The Diesel Generator installed at SGC generates electricity at 400 volts and
supplies electric power directly to the connected load after passing through
protecting equipments. Therefore no transformer is used with the diesel
generator. However the connection taken from KESC is at 11,000 V;
therefore a transformer is used to step this voltage down to 400 V.
Maintenance of this transformer is the responsibility of SGC. Details of the
installed transformer are given below:

Table 2.2
Installed Capacity and Load Served by the Transformer

Description Load Description Aprox. Load
1,250 kVA, 11 kV / 415 V From KESC to the Factory 1,100 kW

Power Factor Improvement Plants

High power factor is the basic requirement of a well organised electrical
distribution network. In order to improve power factor up to the desired value,
capacitor banks have to be installed at different locations of the plant.

Capacitor banks are installed at SGC to improve the power factor. These
capacitor banks operate only on the KESC connection. Automatic operation is
used with these capacitors that maintain the required power factor by
rearranging the number of capacitors according to the required compensation.
Following table shows the location and arrangement of the capacitor banks:

Table 2.3
Location and Capacity of Power Factor Improvement Plants

Location Description Total
Main LT Panel (LT Control Room)
9 steps of 50 kVAr
1 step of 25 kVAr

1 step of 25 kVAr
475 kVAr
Total 475 kVAr

Self Generation/Consumption Pattern

Diesel genset at SGC is operated only when electric power from KESC is not
available. The parameters recorded are time of operation (Hrs), electrical energy
units (kWh), electrical load (kW), AC frequency (Hz), voltage (V) and current (A).
The data provided during and after the field visit is analysed and the monthly
generation/consumption pattern for diesel genset is presented here as
Table 2.4. The graphical representation of the consumption pattern is presented
as Figure 2.2.

Table 2.4
Consumption Record for the Year 2010-2011 (Diesel Genset)

Month
Electrical Units
(kWh/month)
Oct-10 32,680
Nov-10 11,300
Dec-10 60
Jan-11 9,680
Feb-11 6,980
Mar-11 1,300
Apr-11 24,000
May-11 13,840
Jun-11 2,920
Jul-11 41,220
Aug-11 8,720
Sep-11 27,420
Total 180,120
Source: The base data is provided by the management of SGC, 2011

Figure 2.2: Consumption Pattern for the Year 2010-2011 (Diesel Genset)

The diesel consumption for power generation is not recorded accurately and
data provided in this regard produced unseen results of unit price in terms of Rs.
/kWh. However during the field survey, discussion with technical staff and data
analysis yield that the average unit price is 33 Rs. /kWh; which is slightly higher
than the unit price observed typically in the industries.

Consumption Pattern Utilizing KESC Connection

The prime source of electric power at SGC is KESC. SGC had sanctioned a load of
1,100 kW from KESC for the plant.

The monthly consumption pattern for the plant is presented as Table 2.5 and
the graphical representation of the consumption pattern is presented as
Figure 2.3.

Table 2.5
Consumption Record of the Year 2010-2011
(KESC to Plant) Tariff: TOD-B3

Month
Off-Peak Units
(kWh)
Peak Units
(kWh)
Total Units
(kWh)
Amount
Rs.
Aug-10 191,487 23,987 215,474 2,060,390
Sep-10 238,196 32,297 270,493 2,618,335
Oct-10 231,124 30,677 261,801 2,932,699
Nov-10 201,012 26,890 227,902 2,376,336
Dec-10 237,244 30,779 268,023 3,003,225
Jan-11 254,092 31,360 285,452 2,626,044
Feb-11 172,673 23,161 195,834 1,844,172
Mar-11 227,482 29,286 256,768 2,424,961
Apr-11 240,970 30,910 271,880 2,515,277
May-11 88,233 10,764 98,997 1,097,670
Jun-11 405,346 80,524 485,870 4,598,120
Jul-11 247,048 47,610 294,658 2,924,220
Aug-11 150,250 33,510 183,760 1,912,829
Total 3,316,912 32,934,278

Figure 2.3: Consumption Pattern for the Year 2010-2011


The above graph shows the contribution of off-peak units and peak units to the total
consumption of the electrical energy. Height of each column represents the total
electrical energy consumed per month (kWh/Month). Tariff for peak units is almost
double as that of off-peak units; therefore peak units consumption should be
maintained at minimum possible level. Following graph shows the variation of unit
price (Rs. /kWh) against total unit consumption (kWh/month).

Figure 2.4: Electricity Rate (Rs. /kWh) for the Year 2010-2011


The variation in unit price (Rs. /kWh) is mainly affected by the maximum demand
during the month, operating power factor, power consumption during peak and off-
peak hours and the electricity tariff. The average unit price from the graph comes
out to be 10.02 Rs. /kWh.

2.3.2 Water Cooling System

There was one reciprocating chiller installed at SGC, to provide chilled water that
was utilized in the cold room for air conditioning. The chiller was not in operation
during the energy audit. However, the manufacturers details of chiller are
presented in the table below for reference. Table 2.6 below, shows running data of
the chiller(s) installed at SGC.

Table 2.6
Chiller Data

Description Chiller#1 Unit
Make YORK ---
Chiller Type Reciprocating ---
Serial Number L3332-F85 ---
Source of Energy Electrical ---
Motor Power 50 HP
Chilled water Inlet temperature 25 C
Chilled water outlet temperature 20 C
Chilled water Inlet Pressure 2 bar
Chilled water outlet pressure 1 bar
Cooling water inlet Temperature 30 C
Cooling water outlet Temperature 40 C
Cooling water Inlet Pressure 2 bar
Cooling water outlet pressure 1 bar
Operating Hours Not in Running

Source: Data provided by the management of SGC, 2011

2.3.3 Cooling Tower(s)

SGC has installed two induced draught cooling towers having capacities of 1,717 and
1,750 gpm, respectively. The cooling water from the cooling tower is used to lower
the temperature of heat exchangers installed in the process area. Table 2.7 shows
running data of the cooling towers present at SGC.

Table 2.7
Cooling Tower Data

Description C.Tower # 1 C.Tower # 2 Unit
Make KARGAR PROTEC ---
Type Bottle Bottle ---
Capacity(Ton) 1717 1750 gpm
Water Flow --- --- gpm
Air Flow 91,030 97,000 cfm
Water inlet temperature 44 37.2 C
Water outlet temperature 33 31.6 C
Air inlet temperature --- --- C
Air outlet temperature --- --- C
Operating Hours 24 Standby hr/day
Fan motor Power 15 15 HP
Chemical(s) used Scgon 345 Scgon 345 ---
Biogon 945 Biogon 945 ---

2.3.4 Boiler(s)

Some processes in SGC depend on thermal energy; this thermal energy was supplied
by steam. To cater for the amount of steam required, SGC has installed two boilers.
Table 2.8, shows running data of the boiler(s) present at SGC.

Table 2.8
Boiler(s) Data

Description Boiler # 1 Boiler # 2 Unit
Make LOOS 155 LOOS 156 ---
Model 1985 1985 ---
Serial No. 48409 48410 ---
Type Fire Tube Fire Tube ---
Heating Surface Area 125 125 m
3

Steam
Description Boiler # 1 Boiler # 2 Unit
o Capacity 6 6 ton/hr
o Design Pressure 13 13 Psi
o Working Pressure 10 10 Psi
o Temperature 180 180 C
Feed Water Temperature 95 95 C
Daily Running Hours 24 24 Hr
Days of Operation 300 300 Days

2.3.5 Air Compressor(s)

At SGC, three air compressors are currently being used for supplying compressed
air to different equipments. The manufacturers details of these compressors are
given in Table 2.9 below.
Table 2.9
Air Compressor Data

Description Comp # 1 Comp # 2 Comp # 3 Units
Make GA-22 GA-30 GA-30 ---
Status Standby Running/Standby Running ---
Cooling system Air Cooled Air Cooled Air Cooled ---
Type Screw Screw Screw ---
Free Air Delivery 76.1 76.7 81 L/s
Maximum Pressure 11 7.5 7.5 Bar
Working Pressure
Load
3 4 5 Bar
Working Pressure
Unload
6 6 6 Bar
Motor (kW) 22 30 30 kW
Hours of Operation 24 24 24 Per day

2.4 Monthly Utilities Consumption & Unit Utility Rate

The monthly utilities consumption & Unit utility rates of SGC are presented in
Table 2.10 and Table 2.11, respectively.

Table 2.10
Monthly Consumption of Utilities

S. No. Utilities Month Consumption
1 Gas 5,840,375 m
3
(Boilers)
2 Steam Not monitored
3 Water 3,261 m
3
(Boilers)
4 Electricity 270,157 kWh
Source: Data provided by the management of SGC, 2011, calculations based on 300 days per year.

Table 2.11
Unit Rate of Utilities

S. No. Utilities Unit Rate
1 Gas Rs. 382.37 / MMBtu
2 Steam Not monitored
3 Water Rs._____/1, 000 gal (LIEDA)
4 Electricity Rs. 10.02/kWh (KESC)
Rs. 33/kWh (Diesel Genset)

2.7 Existing Energy Management Initiatives

SGC, being an energy conscious organization progressively & pro-actively working in
the field of resource conservation. Some of the SGC energy interventions in this
regards are listed below:

Safety Gauges
Pressure and temperature gauges were installed on the utility equipment and
their respective distribution network.

Insulation
Adequate insulation was used to restrict heat loss from hot sources and heat
gain to cold sources.

Boiler Feed Water Control
A dedicated softener plant was installed to maintain the boiler feed water
quality.

Economizer
An economizer was installed on the boiler stack(s) to recover heat from flue
gases and was used to increase the temperature of feed water.

Condensate network
A condensate loop was installed for the recovery of condensate water.

Natural Gas Flow meter (Boiler)
A gas flow meter was installed to quantify the amount of natural gas consumed
by the boiler(s).

Water Flow meter (Feedwater)
A water flow meter was installed to quantify the amount of water consumed by
the boiler(s).

Variable Frequency Drives (VFD)
SGC has already installed VFDs on different motors. A total of 8 VFDs are
installed.

Power Factor Improvement
Capacitor banks are installed to improve the power factor. The Power Factor
observed at SGC ranges from 0.90 to 0.94 which is optimal for distribution
system.

Voltage Drop
Voltage was measured at Distribution Boards, motor panels and was found
satisfactory. No issue regarding voltage drop was observed during the field visit.

Load Management
The load is adequately managed at SGC by utilizing available resources.

Optimal Motor Sizes
No oversized or undersized motor was observed at SGC during field visit.

2.8 Current Energy Status of the SGC

The Table 2.12 below depicts the current Energy Status of SGC.

Table 2.12
Status of the SGC

S.
No.
Energy Indicators
Energy Status
Good Average Low
1 Boiler Feed Water Control - -
2 Safety Gauges - -
3 Condensate Network - -
4 Steam Traps - -
5 Insulation of Hot Surfaces - -
6 Economizer at Steam Generator - -
7 Steam Flow Monitoring System - -
8 Gas Flow Monitoring System - -
9 Feed water Flow Monitoring System - -
10 Compressed Air Monitoring System - -
11 Stack Monitoring System - -
12 Power Factor - -
13 Motor Loading / Sizing - -
14 Voltage - -
15 Variable Frequency Drives (VFDs) - -
16 Energy Efficient Motors - -
17 Energy Efficient Lights - -
18 Load Management - -
19 Data Management - -
Legend:
Energy Status
Good = No gap was observed, Average = Little gaps were observed, Low = Nothing has being done in this regards.
Note= The evaluation of Energy Status of the SGC presented above is based on observation taken during the field
visits and perception of the assessor related to the specific field of interest, hence the opinion related to specific area
might vary from person-to-person. The key objective of the evaluation is to present current picture of energy status of
the industry in a snap shot and to initiate the improvement in these areas. Detailed assessment of abovementioned
concerns are presented in Chapter-3 of this report.


The chapter elucidates the energy saving opportunities observed during the field
visits. The core emphasis is given to the excessive energy consumption, resulting
from diversified resource consumption at the plant. More specifically, resource
conservation potential and energy improvement areas are discussed in detail in the
following sections.

3.1 Electrical Energy Saving Potential

3.1.1 Electrical Distribution System (Cable Sizing)

Voltage measurement at MCCs and panels is done during the field visit and positive
results are observed. The voltage drop should not exceed 2.5% of the nominal
voltage at the designed current. As the voltage of the distribution system is 400V,
the cables having voltage drop less than 2.5 % or 10V are considered to be properly
selected. The calculated voltage drop of cables for which the data was provided is
presented in the Table 3.1.

Table 3.1
Electrical Cables Voltage Drop Calculation

S.
No.
Load Description
Full Load
Current
(A)
Size
(mm
2
)
Length
(m)
Calculate
d V. D
(V)
Percent
V.D
1 LT Panel to Spray Dryer 206 1 x 12
0
59 4.1 1.0
2 LT Panel to Rice Packing 32 1 x 16 107 8.0 2.0
3 LT Panel to Rice Flour 54 1 x 25 100 8.7 2.2
4 LT Panel to Boiler 65 1 x 12
0
40 0.9 0.2
5 LT Panel to Work Shop 36 1 x 50 26 0.8 0.2
6 LT Panel to Admin Offices 36 1 x 70 50 1.0 0.3
7 LT Panel to Cooling Tower 135 1 x 70 49 3.8 0.9
8 LT Panel to Silo 72 1 x 95 58 1.8 0.4
9 LT Panel to Compressor 126 1 x 70 98 7.1 1.8
10 LT to Raw Water Pump 3 54 1 x 35 107 6.4 1.6
11 LT Panel to Chiller 108 1 x 50 17 1.5 0.4
12 LT Panel to Panel N 54 1 x 25 85 7.4 1.8
13 LT Panel to Dry Feed 141 1 x 12
0
37 1.8 0.4
14 Ventilator 4.3.1 10 1 x 3 49 7.3 1.8
15 Ventilator 4.4.1 27 1 x 16 46 2.9 0.7
CHAPTER
3

ENERGY SAVING POTENTIAL
S.
No.
Load Description
Full Load
Current
(A)
Size
(mm
2
)
Length
(m)
Calculate
d V. D
(V)
Percent
V.D
16 Hammer Mill 289 1 x 70 37 6.1 1.5
17 Ventilator 7.3.2 33 1 x 16 46 3.5 0.9
18 Steam Blower 20 1 x 6 9 1.1 0.3
19 Displacement Pump 19.2 10 1 x 4 14 1.3 0.3
20 Displacement Pump 19.3 10 1 x 4 14 1.3 0.3
21 Centrifugal Pump 50 20 1 x 6 39 4.8 1.2
22 Centrifugal Pump 63.1 20 1 x 6 38 4.7 1.2
28 Vacuum Pump 47.7 27 1 x 16 15 0.9 0.2
29 Vacuum Pump 47.8 33 1 x 16 15 1.2 0.3
30 Vacuum Pump 47.1 40 1 x 16 15 1.4 0.3
34 Centrifugal Pump 111.1.10 54 1 x 10 23 4.6 1.1
35 Condensate Pump 100.17 14 1 x 3 21 4.3 1.1
36 Feed water Pump CR4 10 1 x 3 5 0.7 0.2
37 Blower 1 135 1 x 25 7 1.5 0.4
38 Blower 2 27 1 x 4 5 1.2 0.3
39 Atomizer 14 1 x 3 9 1.8 0.5
40 Blower 3 20 1 x 6 5 0.6 0.2
41 Mill Motor 198 1 x 70 5 0.6 0.1
42 Blower 45 1 x 6 20 5.6 1.4
43 China Grinder 27 1 x 6 5 0.8 0.2

In the above table, it is clearly indicated that voltage drop varies from 0.1% to 2.2%,
which is fairly low as compared to the standard voltage drop of 2.5%.

It has been assessed that voltage drop at different motors could cause change in
motor efficiency, power factor, running current and temperature of motor. If the
motor terminal voltage is below the rated voltage it will draw more current than the
rated current which will ultimately result in the overheating of the motor winding
and thus reduces life of the motor.

Figure 3.1, below illustrates the effects of voltage variations on motors in terms of
efficiency, power factor, torque and current of motors.

Figure 3.1: Effects of Voltage Variation on Electrical Motors

Source: www.motorsanddrives.com

3.2 Power Factor

3.2.1 Power Factor Improvement Plant at Self Generation

As discussed in the Section 2.3.1 earlier, that Capacitor Banks are installed at SGC,
but these capacitors operate only for KESC connection. No power factor
improvement unit is used with diesel genset.

3.2.2 Power Factor Improvement Utilizing KESC Connection

Power factor improvement plant installed at SGC operates only for KESC connection.
Utility bills provided during the field visit are analyzed and no power factor penalty
is observed. Table 3.2, provided below, indicates the power factor and the penalty
imposed for the year 2010-2011.

Table 3.2
Findings of Low Power Factor Penalty

Billing Month Off-Peak Time Readings Peak Time Readings Penalty
(Rs.)
K1 R1 p.f P1 X1 p.f
August-10 191,487 85,023 0.91 23,987 10,825 0.91 -
September-10 238,196 105,852 0.91 32,297 14,432 0.91 -
October-10 231,124 105,641 0.91 30,677 13,586 0.91 -
November-10 201,012 93,513 0.91 26,890 12,773 0.90 -
December-10 237,244 104,558 0.92 30,779 13,780 0.91 -
January-11 254,092 115,570 0.91 31,360 14,171 0.91 -
February-11 172,673 83,727 0.90 23,161 11,293 0.90 -
March-11 227,482 104,871 0.91 29,286 13,356 0.91 -
April-11 240,970 107,133 0.91 30,910 13,712 0.91 -
May-11 88,233 41,703 0.90 10,764 5,132 0.90 -
June-11 405,346 193,924 0.90 80,524 38,233 0.90 -
July-11 247,048 115,292 0.91 47,610 21,834 0.91 -
August-11 150,250 73,445 0.90 33,510 16,688 0.90 -
Total Penalty 0.00
Source: The base data is provided by the management of SGC, 2010- 2011

3.3 Electric Motors

3.3.1 Oversized and Undersized Motors

There are more than 50 motors installed at SGC. The running load of 21 potential
motors is measured during the field visit. The result of running load is presented in
the Table 3.3, below.

Table 3.3
Findings of Load on Electric Motors

S.
No.
Motor Description Volt
(V)
Current
(A)
P. F Meas.
Power
(kW)
Rated
Power
(kW)
Utilization
%
1 Hammer Mill 395 185 0.8
5
107.6 160 67
2 Cooling Tower Pump 2 387 39 0.8
6
22.5 37 61
3 Cooling Tower Pump 3 391 44 0.8
5
25.3 37 68
4 Ventilator Mill 1 396 23 0.8
4
13.3 18.5 72
5 Ventilator Mill 2 394 18 0.8
5
10.4 15 70
6 Vacuum Pump 1 395 23 0.9
8
15.4 15 103
7 Vacuum Pump 2 395 23 0.9
6
15.1 18.5 82
8 Spray Dryer Fan 389 118 0.8
6
68.4 75 91
9 Dry Feed Blower 402 26 0.8
7
15.7 25 63
10 Raw Water Pump 394 37 0.8
9
22.5 29.8 75
S.
No.
Motor Description Volt
(V)
Current
(A)
P. F Meas.
Power
(kW)
Rated
Power
(kW)
Utilization
%
11 Steam Blower 388 14 0.8
6
8.1 15 54
12 Cooling Tower Fan 388 11 0.8
5
6.3 11 57
13 Septic Tank Pump 387 14 0.8
8
8.3 11 75
14 Feed Water Pump 385 11 0.8
8
6.5 7.5 86
15 Blower Fan Boiler 1 389 14 0.8
4
7.9 18 44
16 Blower Fan Boiler 2 385 20 0.8
6
11.5 18 64
17 Condensate Pump 1 387 7 0.8
6
4.0 7.5 54
18 Condensate Pump 2 385 8 0.8
4
4.5 11 41
19 Pump 9 398 10 0.9
0
6.2 11 56
20 Compressor 1 393 56 0.8
5
32.4 30 108
21 Compressor 2 396 49 0.8
6
28.9 30 96
Source: The motor loading parameters measured during the field visit, 2011 (Digital Clamp on Meter,
Model: PS 6601)

Due to the variation of load on motors during 24 hours the over/under sized motors
could not be identified on the spot. However special attention should be given to
the values that are made bold under utilization column and loading on respective
motors must be monitored carefully. If these motors continuously operate at or
above 90% load then these motors must be replaced with higher rating motors. If
overloading occurs for short period of time then it will not affect motor
performance as every motor is designed to operate above 100% load for shorter
interval.

3.3.2 Efficiency of Motors

Motor efficiency is the ratio of mechanical power output to the electrical power
input and usually expressed as a percentage. Considerable variation exists between
the performance of standard and energy-efficient motors. There are three classes of
motors based on the efficiency. The highest efficiency level has been achieved by
some of the leading manufacturers. Improved design, high quality materials, and
optimized manufacturing techniques enabled energy-efficient motors to accomplish
more work per unit of electricity consumed.

Highest efficiency of a motor is achieved at 80-85% of its rated loading. Table 3.3
represents the utilization of the assessed motors. In order to achieve the highest
efficiency motor utilization should be limited to 80-85%, which could be achieved by
employing properly sized motors for which regular monitoring and inspection of
motors is required.

3.3.3 Maintenance Concerns

At SGC no maintenance issues are noticed during the discussion with the technical
staff. SGC has a proper maintenance program for machineries/equipments.
Maintenance of electrical machines is done regularly. Almost all machines are
opened and checked physically and electrically, which includes check for dirt and
moisture, winding heating, loose connections, transformer oil and silica gel
inspection, tightening and cleaning of the electrical connections, and bearing
lubrication. If any unusual object is observed, corrective steps are taken
immediately.

However electrical loads normally cycle between high and low demand; thus the
thermal expansion and contraction cause connections to loosen. Electrical panels
that are never cleaned, accumulate dust and dirt that deposit on these connections.
The loose and dirty connections provide high resistance paths that are directly
responsible for more than 30 percent of electrical failures. Another 17 percent of
electrical failures are attributed to live electrical components being exposed to
moisture. Table 3.4 given below, mentions the rate of failure by different causes:

Table 3.4
Top Causes of Failures in Electrical Distribution System

Cause Failure Rate
Loose Connections / Parts 30.3%
Moisture 17.4%
Line Disturbance (other than lightning) 10.4%
Defective / Inadequate Insulation 9.9%
Lightning 8.1%
Foreign Objects / Short Circuiting 7.3%
Collision 3.9%
Overloading / Inadequate Capacity 2.4%
Accumulation of Dust & Dirt 2.2%
All other causes 8.1%
Source: http://powerhawke.com/wp-content/uploads/2011/02/PowerHawke-Brochure.pdf

3.3.4 Voltage Unbalance

Voltages unbalance occurs in a three-phase power system when voltages of all the
three phases are not equal. Voltage unbalance exists in every three-phase system,
but the allowable limit is 1% (NEMA MGI). Beyond this limit voltage unbalance
causes larger current unbalance as a result motor/equipment operating
temperature increases. There are numerous causes of voltage unbalance, some of
them are:

Large and/or unequal single-phase loads (for example, arc furnaces, heater,
welders, and so on).
Faulty power factor correction capacitor banks.
Open delta or wye transformers.
Phase to phase loads this occurs with some equipment that require only single-
phase but at line to line voltage (for example, 415 V welders).

During the field visit three phase voltages are measured at different places and the
result of voltage unbalance is presented in the Table 3.5, below.

Table 3.5
Findings of Voltage Unbalance

S.
No.
Description
Voltage (V)
Voltage Unbalance
(%)
L1 L2 L3
1 Hammer Mill 395 394 395 0.17
2 Cooling Tower Pump 2 385 388 387 0.43
4 Ventilator Mill 1 397 396 395 0.25
5 Ventilator Mill 2 395 394 393 0.25
6 Vacuum Pump 1 394 395 396 0.25
7 Vacuum Pump 2 394 395 394 0.17
8 Spray Dryer Fan 388 388 389 0.17
9 Dry Feed Blower 401 402 401 0.17
10 Raw Water Pump 392 393 395 0.42
11 Steam Blower 388 388 387 0.17
12 Cooling Tower Fan 388 387 387 0.17
13 Septic Tank Pump 386 388 387 0.26
14 Feed Water Pump 384 385 385 0.17
15 Blower Fan Boiler 1 388 389 390 0.26
16 Blower Fan Boiler 2 385 386 384 0.26
17 Condensate Pump 1 386 387 386 0.17
18 Condensate Pump 2 384 385 385 0.17
19 Pump 9 397 398 397 0.17
20 Compressor 1 394 392 391 0.42
21 Compressor 2 396 397 395 0.25
Source: Voltages measured during the field visit, 2011 (Digital Clamp on Meter, Model: PS 6601)

From the above table it is clear that percentage voltage unbalance at SGC is less
than 1 %.

Resistive loads are relatively unaffected by voltage unbalance. However the most
apparent effect of voltage unbalance is reduction in motor efficiency, performance
and life. It causes increase in current unbalance well in excess of voltage unbalance,
which causes additional heating losses. Motor may also become noisy because of
torque and speed variations caused by voltage unbalance and the motors will have
less effective torque and speed than normal. Figure 3.2 shows the standard de-
rating of motors based on percentage voltage unbalance.

Figure 3.2: Effects of Voltage Unbalance on Electrical Motors

Source: http://www.csanyigroup.com/motor-operation-efficiency-under-abnormal-conditions

3.3.5 Current Unbalance

Current unbalance exists when the currents in all phases of a three-phase power
system are not equal. There are two main causes of current unbalance.

Motor Related:

It includes
Unbalanced number of turns in the windings
Uneven air gap

Power System Related:

Includes
voltage unbalance
Harmonics

Voltage unbalance produces larger current unbalance. The ratio used for this
purpose is close to 1:8. Large current unbalance causes shortening of motor life,
decrease in its efficiency. The limit for current unbalance is usually considered to be
10%.

Table 3.6
Current Unbalance

S.
No.
Description
Current (A) Current Unbalance
(%)
L1 L2 L3
1 Hammer Mill 182 183 188 1.99
3 Cooling Tower Pump 3 44 43.2 43 0.62
4 Ventilator Mill 1 22 22.5 22.4 0.75
5 Ventilator Mill 2 18 17 18 3.77
6 Vacuum Pump 1 22 23 24 4.94
7 Vacuum Pump 2 22 22 22.7 1.64
8 Spray Dryer Fan 118 117 119 0.85
9 Dry Feed Blower 26 25 25 2.63
10 Raw Water Pump 37 36 37 1.55
11 Steam Blower 13 13.4 13.5 1.25
12 Cooling Tower Fan 10 10.8 10.4 2.53
13 Septic Tank Pump 13 14.4 14.2 4.77
14 Feed Water Pump 10 10.5 10.4 0.64
15 Blower Fan Boiler 1 13 13.5 13.9 6.02
16 Blower Fan Boiler 2 19 19.6 20.3 3.22
17 Condensate Pump 1 7 6.7 6.2 4.62
18 Condensate Pump 2 7 7.9 7.2 7.73
19 Pump 9 10 9.8 9.4 2.42
20 Compressor 1 55 56 55 1.20
21 Compressor 2 49 48.4 47 2.15
Source: Currents measured during the field visit, 2011 (Digital Clamp on Meter, Model: PS 6601)

A simple test, known as rotating the phases, is performed to determine if current
unbalance is related to motor or power system. According to this method, take
current readings at phase A, B and C. Now at the output of the motor starter,
remove all phase wires and then connect phase A to motor conductor 1, phase B to
motor conductor 2, and phase C to motor conductor 3, so that the motor rotation
remains same. Now measure the current readings again. If the high current moves
with the motor conductor then unbalance is due to the motor. If it stays with the
appropriate phase of the starter then it is due to power system.

3.3.6 Lighting System

Tube lights, compact fluorescent lamps (CFLs), search lights and high pressure lamps
(MHLs) are in use at SGC for illumination purposes. These luminaries can be replaced
with energy efficient luminaries. Table 3.7 show the detail of installed lighting
system:
Table 3.7
Lighting Details

Type Watts Qty.
Tube Lights 40 W 199
Energy Savers 65 W 92
High Pressure Mercury Lamps 250 W 18
Search Lights
400 W 10
250 W 2
Total Lamps 321

3.3.7 Monitoring and Evaluation System

At SGC, the electrical load at diesel generator is monitored and tabulated on hourly
basis at the control room. The fuel consumption of the generator is not recorded
carefully. The observed parameters of genset are voltage, current, time of
operation, electrical energy (kWh), and frequency, rpm etc. The electricity bills are
also checked and electricity consumption (kWh/month) is verified.

3.3.8 Variable Frequency Drives (VFDs)

VFDs belong to a group of equipment called adjustable speed drives or variable
speed drives. The operating speed of a motor connected to a VFD can be made
variable by simply changing the frequency of the motors supply voltage. This allows
continuous process speed control.

Motor-driven systems are often designed to handle peak loads that have a safety
factor. This often leads to energy inefficiency in systems that operate for extended
periods at reduced load. The ability to adjust motor speed enables closer matching
of motor output to load and often results in energy savings. Hence installation of
variable frequency drive (VFD) to a motor-driven system can offer potential energy
savings in a system in which the load vary with time.

At SGC a total of eight (8) VFDs are installed in the manufacturing plant at different
motors. The data provided for the installed VFDs is tabulated in Table 3.8.

Table 3.8
VFDs Installed at SGC

S.
No.
Motor
Description
VFD Rating
(kW)
Motor Rating
(kW)
Qty. Distance b/w Motor
& VFD (m)
1 Atomizer 7.5 7.5 1 10
2 Atomizer 1.5 1.5 1 3
3 Conveyer 4 4 1 10
4 Pump 12.1 3 3 1 5
5 Pump 12.2 3 3 1 5
6 Rice Mill 15 15 1 10
7 Feeder 0.75 0.75 1 10
8 Grader 0.75 0.75 1 10

3.3.9 Rewinding of Motors

Motor efficiency and losses vary considerably after rewinding. Even if the rewound
motors are restored to their original condition with proper stripping and rewinding,
losses are typically higher in rewound motors. At SGC, use of rewound motors is in
practice.

3.3.10 Transmission Losses

Certain machines, (e.g. fans) that are driven by electrical motors, use pulley belt
arrangement to transmit power from motor shaft to machine shaft. These kinds of
arrangements are sophisticated and always need proper alignment and
maintenance of belt and belt tightness to avoid slip losses. Energy losses in a belt
drive system occur due to improper alignment and /or looseness of the belt. If
either of these exists, the total power output of the motor shaft is not completely
transmitted to the driven shaft. For all practical purposes, there always are
transmission losses. But the maximum allowable limit for transmission losses is
4.5%; proper attention is required if it is above 4.5%. Assessment team has done
some measurement on field to get the RPM on the motor pulley and on the fan
shaft pulley which is shown in Table 3.9 below:

Table 3.9
Transmission Losses

S. No. Motor Description Rating
(kW)
Motor
RPM
Fan/Pump
RPM
Transmission
Losses %
1 Steam Blower 15 1476 1946 1.12
2 Compressor (Spare) 22 1458 2009 3.55
3 Dry Feed Grinder 11 1470 1894 8.78
4 Spray Dryer 75 1462 2248 3.90
5 Blower (Hammer Mill) 18.5 1468 2048 7.82
Source: The parameters measured during field visit, 2011(Digital Stroboscope, Model: DT 2269)
From the above table it is clear that transmission losses vary from 1.12% to 8.78%.
Special attention should be given to the machines having transmission losses more
than 4.5%. Corrective measures e.g. tightening the belt and correcting the alignment
of the pulleys should be done to keep these losses under the allowable limit.

3.3.11 Sustainable/Renewable Energy Sources

Electrical energy used at SGC is either taken from KESC or generated through diesel
genset. Currently no renewable energy sources are used at SGC to generate
electricity.

3.4 Thermal Energy Saving Potential

3.4.1 Monitoring and Evaluation

Monitoring devices are essential tools and are critical for running and maintaining a
high level of efficiency with in a plant. The table below shows a list of
equipment/devices used for monitoring and evaluation of the respective utilities.

Table 3.10
List of monitoring equipment

S.
No
Area / Utility Monitoring Device Installed Working
1. Boiler Steam Flow N N/A
2. Boiler Steam Temperature Y Y
3. Boiler Steam Pressure Y Y
4. Boiler Gas Flow Y Y
5. Boiler - Feed Water Water Flow Y Y
6. Boiler - Feed Water Water Temperature Y Y
7. Boiler - Feed Water Water Pressure Y Y
8. Boiler Stack Temperature Y Y
9. Boiler - Economizer Water Temperature (In) Y Y
10. Boiler - Economizer Water Temperature (Out) Y Y
11. Deaerator Water Temperature Y Y
12. Boiler Blowdown Water Flow N N/A
13. Header Boiler Room Steam Temperature Y Y
14. Header Boiler Room Steam Pressure Y Y
15. Header Converter Steam Temperature Y Y
16. Header Converter Steam Pressure Y Y
17. Header Evaporator Steam Temperature Y Y
18. Header Evaporator Steam Pressure Y Y
Source: Data provided by SGC Management and Data acquired during field assessment.
Key / Legend Y = Yes, N = No, N/A = Not applicable
3.4.2 Boiler(s)

At SGC, thermal energy was required in the manufacturing process for a number of
applications. This thermal energy was provided by steam, which was generated by
two identical boilers. The boilers details provided by SGC are listed in table below.

Table 3.11
Steam Generator(s) Data

Description Values Units
Type Fire Tube Boiler -----
Generation capacity per Unit 6 t/hr
No. of Units 2 ----
Total Steam Production Capacity 12 t/hr
Average steam production Unknown t/hr
Design pressure 13 Bar
Working pressure 10 Bar
Steam Temperature 180 C
Saturation Steam Temperature 184.154 C
Stack Temperature before
economizer
215 C
Stack Temperature after economizer 180 C
Average Fuel Consumption Variable
8,000 12,000
m
3
/24hrs
Av. Feed Water Consumption Variable
5.5-6.5
m
3
/24hrs
Main distribution Line size 4 Inch (Schedule 40)
Av. Feed Water Temperature 95 C
Hours of Operation per day 24 hrs
Days of Operation in a year 300 days
Source: Data provided by SGC Management and Data acquired during field assessment.

3.4.3 Feed Water Treatment

There was a six meter cubed feed water tank installed at SGC that also served the
purpose of a deaerator tank. The water used for steam generation was treated
water that was provided by the softener plant dedicated for the boiler(s).

After the raw water was softened, it was passed through two heat exchangers
before it found its way to the feedwater/deaerator tank. The first heat exchanger
was heated by condensate and blowdown water; the feedwaters temperature was
increased from 35C to 51C. The second heat exchanger was an economizer
installed on the boilers stack to recover waste heat from the flue gases and it
further increased the temperature of the feedwater from 51C to 75C degrees. In
the deaerator tank the water was heated to 95C+ using direct injection of steam.

The temperature of the feedwater was within the recommended feedwater
temperature range. A temperature of 95C+ reduces the effect of thermal shock on
the boiler and releases the absorbed gases from the feedwater primarily oxygen,
this further reduces the chances of corrosion in the boiler and the steam
distribution network.

Raw water, feedwater and boiler water quality was regularly tested for pH levels,
Hardness, Alkalinity and TDS. Their results are shown in the table below:

Table 3.12
Water Quality Results

Parameter Make-up Water Feed Water Boiler Unit
Actual Hardness 0 0 0 ppm
Hardness limit 10 10 10 ppm
TDS 350 400 3,000 ppm
TDS limit 400 550 3,500 ppm
Proton concentration 8.0 8.0 9 pH
pH limit 8.5 8.5 11 pH
Source: Data provided by SGC Management

The boiler TDS was maintained below 3,500 ppm by continuous surface blowdown,
intermittent and continuous bottom blowdown. An intermittent blowdown was
carried out regularly once in 24 hours and/or whenever the TDS came close to the
limit.

The hardness was maintained below 10 ppm, which is within operating
recommendations for fire tube boilers with a working pressure of 10 bar however
the TDS levels for the feedwater was around 400 ppm which is above recommended
levels.

High TDS levels require a greater amount of blowdown to keep the boiler water TDS
limits within range. This is a waste of energy as blowdown water has a temperature
close to saturation temperature and when it is replaced with feed water the boiler
has to do extra work to produce the same amount of steam.

3.4.4 Blowdown

There was no flow monitoring system installed to quantify the amount of water
leaving the boiler through blowdown, the minimum amount of blowdown required
to maintain the TDS concentration below 3,500 ppm in the boilers was calculated as
shown in the table below.

Table 3.13
Minimum amount of Blowdown Required

Boiler Pressure 10 bar g
Boiler Rating 6,000 kg/hr
Maximum Allowable Boiler TDS 3,500 ppm
Feedwater TDS 400 ppm
No. of Boilers 2 Units
Blowdown Rate 1,548.39 kg/hr
Source: Field assessment observation, calculations were made based on the minimum amount of
blowdown required.

At SGC blowdown was carried out manually, there were automatic blowdown valves
installed but they were not functional. The energy lost due to manual operation of
blowdown is shown in the table below:

Table 3.14
Difference in Energy Lost Between Manual and Automatic Blowdown

Maximum allowable TDS 3,500 TDS
Average TDS 400 TDS
Feedwater TDS 3,000 TDS
Manual Blowdown System
Required blowdown rate 15.38 %
Total feedwater supplied 13,846.15 kg/hr
Energy required to produce 12000 kg/hr steam 8,142.15 kW
Automatic Blowdown System
Required blowdown rate 12.90 %
Total feedwater supplied 13,548.38 kg/hr
Energy required to produce 12000 kg/hr steam 8,110.42 kW
Difference in energy required 31.73 kW
% saving in fuel cost 0.39 %
Fuel supplied to boiler per year 2,803,380 m
3
/year
Fuel saving per year 10,925.1 m
3
/year
Source: Field assessment observation, calculations were made based on the minimum amount of
blowdown required.

Table 3.15
Annual Losses due to Manual Blowdown System

Description Value Unit
Amount 147,508.2 PKR
Fuel Saving Potential 10,925.1 m
3

Source: Field assessment observation, calculations were made based on 300 days of work in an annum

3.4.5 Boiler Efficiency

The steam consumption was variable as it depended upon the number of processes
in operation. There was no steam flow monitoring system installed to quantify the
amount of steam being produced. The gas flow meter and the water flow meters
were common for both the boilers therefore the combined efficiency of the boilers
was calculated.

The quantity of steam was deduced from the amount of water consumed by the
boilers and the minimum amount required for blowdown.

Table 3.16
Boiler Efficiency

Description Values Unit
Quantity of Steam 3,887 kg/hr
Quantity of Feed Water 5,435 kg/hr
Enthalpy of steam 2,781 kJ/kg
Enthalpy of Feed Water 398 kJ/kg
Steam Energy 10,809,973 kJ/kg
Feed Water Energy 2,163,201 kJ/kg
Energy Required 8,646,772 kJ/hr
Fuel Consumption 391 m
3
/hr
Calorific value of fuel 37,000.0 kJ/m
3

Fuel Energy 14,462,930 kJ/hr
Boiler Efficiency 60 %
Source: Calculations were made based on data provided by SGC Management and data acquired
during the field assessment.

3.4.6 Boiler(s) Combustion Analysis

Excess air is required to ensure complete combustion, to allow for the normal
variations in combustion and to ensure satisfactory stack conditions. The optimum
excess air level for maximum efficiency occurs when the sum of the losses due to
incomplete combustion and losses due to heat in flue gases is at the minimum.

At SGC, no oxygen analyzer was installed on the steam generator(s) nor was a
combustion analysis conducted by a third party to evaluate the combustion efficiency
of the steam generator(s). A combustion analysis of the boilers was carried out by the
assessment team and the results are presented in the table below:

Table 3.17
Combustion Analysis Test Results

Description Values - Boiler 1 Values - Boiler 2 Unit
Excess O
2
0.1 0.1 %
CO Over 4,000 Over 4,000 ppm
CO
2
11.7 11.7 %
Excess Air 0.1 0.3 %
Stack Temperature 208 203 C
Ambient Air Temperature 36.8 39.6 C
Source: Data acquired from stack analysis of Steam generator(s).

Table 3.17 shows the results of the combustion analysis. The results show high
concentration of carbon monoxide and the low concentration of oxygen. This is an
indicator that there was insufficient oxygen required for stoichiometric combustion.

As a result, more fuel was being consumed to produce the same amount of energy
required for production of steam.

3.4.7 Direct Fired Burners

Table 3.18
Combustion Analysis Test Results

Description Protein Drier Spray Drier Unit
Excess O
2
16.7 19.2 %
CO 795 173 ppm
Source: Data acquired from stack analysis.

The result of the combustion analysis shows the presence of excess oxygen as well
as excess carbon mono oxide. Even though there is excess oxygen to facilitate
complete combustion, complete combustion is not taking place.

Incomplete combustion while there is excess O
2
present in the flue gas is caused by
the following factors:

Due to the misalignment of burner (Flame touches the sides of wall of
combustion chamber).
Due to the lack of maintenance of the burner.
Due to the use of low turndown ratio burner.
Due to the use of an inefficient burner.
Due to the improper mixing of Air and fuel

As a result, more fuel was being consumed to produce the same amount of
energy required for heating.

3.4.8 Economizer

An economizer was installed on the boiler stack to recover energy from the flue
gases leaving the boiler. The economizer was used to heat feedwater; the
feedwater entering the economizer had a temperature of about 54C and left at
about 71C.

The efficiency of the economizer could not be calculated as there was insufficient
data available.

3.4.9 Steam Traps

Steam traps are essential components of the steam distribution to remove
condensate formation with a negligible loss of live steam. Other advantages include
removing air from the steam distribution network, keeping the steam dry, reducing
waterhammer and making heat transfer from the steam more effective.

There were no steam traps installed at SGC to check their functionality.

3.4.10 Insulation

Steam Distribution Network

During the audit, it was observed that there were some gaps found in the
insulation of the live steam distribution network. The losses due to lack of
Insulation are presented in the table below.

Table 3.19
Annual Losses Due to Lack of Insulation of Steam Distribution Network

Energy 560.56 GJ
3



Feedwater Network

During the audit, it was observed that there were some gaps in the insulation of
the feedwater network. The losses due to lack of Insulation are presented in the
table below.

Table 3.20
Annual Losses due to Lack of Proper Insulation of the Feedwater Network

Energy 75.28 GJ
3


Figure 3.3: Lack of Insulation in
Evaporator Section
Figure 3.4: Lack of Insulation of Boiler
Accessories

Figure 3.5: Lack of Insulation of Feed Water Network

Steam Leakage at Drum
Washing

Blowdown

the blowdown network. The losses due to lack of Insulation are presented in the
table below.

Table 3.21
Annual Losses due to Lack of Proper Insulation of the Blowdown Network

Energy 100.09 GJ
3


Condensate Network

the condensate network. As the condensate is not reused in the boiler as feed
water, losses due to lack of insulation of the condensate network were not
added.

3.4.11 Leakages (Thermal)

Leakages at pipe fittings, valves and traps can
result in substantial energy loss and resources.
During the assessment, the steam, feedwater and
blowdown distribution network was inspected for
leakages.

Steam Leakages

Table 3.22
Location of Steam Leakages

Steam Leakage Locations
Evaporator Steam valve packing
Converter - Steam valve packing
Converter - Steam retention valve
Converter Tank
Drum washing Broken pipe valves
Drum washing Washing header pipe.
Table 3.23
Annual Losses due to Steam Leakages

Total Leakage rate 685,080 M3
Thermal Energy Wasted 1,905 GJ

Feed Water leakages

No leakages were found.

Blowdown leakages

No leakages were found.

3.5 Cooling Tower

There were two cooling towers installed at SGC, one primary and one on standby.
The cooling towers were used for cooling water requirements in the process area.

The primary cooling tower was recently installed and was in good working condition.
The cooling tower was clean and well maintained.

The cooling towers efficiency could not be calculated as a suitable location for flow
monitoring of the cooling water could not be established.

3.6 Compressed Air System Concerns

Air compressors are required to produce compressed air that is consumed in the
manufacturing process either directly and/or to run the pneumatic equipment.

There were three compressors installed, the primary compressor was run
continuously and was supported by the other two when the compressed air demand
was high. The primary compressor installed was run at full capacity for nearly 23
hours a day while it was supported by the secondary compressor for about 6 hours
in a 24 hour period.

The compressed air demand was variable and there was no air flow monitoring
system installed to calculate the amount of compressed air being produced by the
compressor and/or the amount of compressed air that was consumed by the various
departments and processes.

There was also a drier installed to keep the compressed air dry however, it was
malfunctioning and hence bypassed. As a result there was a lot of moisture in the
compressed air lines resulting in damaging of water filter(s) installed to assist in
moisture retention.

There were two receiver tanks installed to buffer the compressed air requirements.
The float traps installed on the tanks to remove water from the compressed air were
malfunctioning and the operators had to manually drain the accumulated water.

Draining the tanks manually should be avoided as over draining will result in
compressed air being wasted and insufficient draining will result in high levels of
moisture in the tank that will eventually find its way to the air driers. A compressed
air drier has to work harder to sustain dry air when more moisture finds its way due
to clogged filters or malfunctioning traps.

The compressed air accessories/equipment (especially in the evaporator area) was
covered in dust and/or mold, leakages, broken filters and the fact that the air dryer
was out-of-order for over two weeks projected the image that the compressed air
system was not given sufficient importance.

3.7 Leakages (Compressed Air)

Leakages at pipe fittings, valves and distribution points/sockets can result in
substantial energy loss and resources. During the assessment, the compressed air
distribution network was inspected for leakages.

Table 3.24
Annual Losses due to Compressed air Leakages

Compressed Air Leakage Locations
Boiler Room Air Distribution line - Damaged flexible pipe
Boiler Room Chemical dosing pump Pneumatic socket
Drier Bag filling machine - Pneumatic socket
Evaporator Air Distribution line - Pneumatic socket
Evaporator Steam reducing valve - Pneumatic socket
Conversion retention valve - Pneumatic socket
Mill Machine pneumatic sockets

Total Leakage rate 60,480 m
3

Amount 62,532 PKR
Electrical Energy Wasted 6,241 kWh


This chapter describes energy conservation measures for the energy saving potential
areas identified in the previous chapter. By adopting these measures, industry can
not only reduce its energy demand but also increase productivity and control
environmental pollution, consequently.

4.1 Electrical Energy

4.1.1 Electrical Energy Sources

The electrical energy used at SGC is either taken from KESC or generated through
diesel generator. The diesel generator can be replaced with gas fired generator. By
doing so substantial amount can be saved. A detail assessment of this opportunity is
provided in the action plan.

4.1.2 Transformers

One transformer of 1250 kVA is installed by the KESC for
supplying electric power to SGC. The maintenance, repair
and losses of this transformer are beard by SGC. Complete
Thermography of the transformer is done during the field
visit. The results show that transformer is operating
efficiently and ambient temperature is within safe limits.

4.1.3 Power Factor Improvement (PFI) Plants

Capacitor banks to improve power factor are already installed at SGC. The location
and arrangement of capacitors is shown in Table 2.3. Power factor at SGC is
recorded during the field visit and is also calculated from the electricity bills as
presented in Table 3.2. From the table it is clear that power factor is well above the
allowable limit i.e. 0.90, therefore no PFI penalty is imposed by the KESC. Hence no
PFI plant is proposed.

4.1.4 Utilization of Diesel Generator

Data provided during and after the field visit is analysed and concluded that diesel
generator operates at 49 % of its rated capacity. Consumption pattern is shown in
Figure 2.2. The highest efficiency of diesel generators is achieved at 60-80% loading.
In this region the fuel consumption of the generator is optimal. Hence for low unit
cost (Rs. /kWh) it is recommended to operate diesel generator at 60% 80%
loading.
CHAPTER
4

RECOMMENDATIONS
4.1.5 Utilization of KESC

Consumption pattern for KESC is shown in Figure 2.3 for plant load. This graph also
indicates variation in the unit price (Rs. /kWh). This variation is mainly affected by
the maximum demand during the month, operating power factor and the electricity
tariff. As power factor is already improved therefore in order to lower down the
electricity rate (Rs. /kWh) keep a regular check on the maximum demand. Load
distribution should be prioritised such that no peaks in the demand occur and the
demand remains constant. This could be achieved by avoiding operation of heavy
loads at the same time.

4.1.6 Recommendation for Proper Distribution (Cable Sizing)

The cable/distribution data provided by SGC and recorded through inspection is
analysed in Section 3.1.1. No cable is found having voltage drop more than 2.5% of
the nominal voltage at the designed current. This means the present distribution
system is working properly. However it is recommended to record voltage drop
regularly, especially after the addition of new loads.

4.1.7 Proper Sized Motors

The load of around 21 motors is recorded during the field visit which is computed in
Section 3.3.1. Load on each motor varies during 24 hours due to the variations in
the process involved. Therefore over/under size motors could not be pointed out at
this stage.

In order to find the proper sizing of motors, voltmeter and ammeter or energy
analyser should be installed at each MCC, and loading (kW) should periodical be
recorded against each motor. This practice will help to identify the over/under size
motors throughout the SGC. SGC can save substantial amount of energy by
employing properly size motors.

4.1.8 High Efficiency Motors

SGC can save electricity units by replacing the existing low efficiency motors with
high efficiency (class 2 or class 1) motors. The comparison of energy saving by
replacing efficiency class 3 motors with efficiency class 1 and efficiency class 2
motors is shown in the figure below:

Figure 4.1: Energy Saving Comparison of Electrical Motors

Source: Nico J. Kluwen, KWA Consultants, The Netherlands

From the above figure it is clear that at 75% load, the efficiency class 2 motor uses
6% less electricity than efficiency class 3 motor and efficiency class 1 motor uses 8%
less electricity than efficiency class 3 motor.

4.1.9 Preventive Maintenance

Preventive maintenance is a schedule of planned maintenance actions, aimed at the
prevention of breakdowns and failures. A preventive maintenance program,
combined with good operational practices, will reduce the need for much corrective
or emergency maintenance. All maintenance must be performed so that equipment
and systems operate efficiently and effectively. Improper maintenance and repairs
can lead to unsafe conditions and reduced system performance.

Preventive maintenance activities should also include equipment checks, partial or
complete overhauls at specified periods, cleaning the dust and dirt, lubrication of
the moving parts and so on. In addition, workers can record equipment
deterioration so that they know to replace or repair worn parts before they cause
system failure. It is far better to perform maintenance and repairs right the first time
than to risk the consequences of a mediocre approach because an ideal preventive
maintenance program would prevent all equipment failures before they occur.

4.1.10 Voltage Unbalance

The voltage unbalance is measured at different places and it is found to be less than
1% which is satisfactory. This result also indicates that the load distribution to each
phase is balanced.
However it is recommended to regularly monitor voltages at different locations to
verify that voltage unbalance is maintained below 1%. Also periodically check single
line diagrams for the verification of uniform distribution of single-phase loads.
Correct the over loaded equipments. An annual thermo graphic inspection of the
equipments may help to assess the voltage unbalance in the system.

4.1.11 Current Unbalance

The current unbalance is measured at different places and it is found to be less than
10% which is satisfactory. This result also indicates that the load distribution to each
phase is balanced.

However it is recommended to regularly monitor current at motor terminals to
verify that current unbalance is maintained below 10%. High current unbalance is
noted at no load. Therefore special attention should be given to the under-loaded
motors.

4.1.12 Lighting System

As discussed in Section 3.3.6, that there is a scope of energy saving in the lighting
system. Therefore existing luminaries can be replaced with energy efficient
luminaries who are discussed in detail in the Action Plan.

4.1.13 Monitoring and Evaluation

It is recommended that load on diesel generator should be monitored and recorded
on hourly basis. The parameters recorded should include voltage, current, power
factor, kWh, frequency, excitation voltage, excitation current etc. This practice
should also be done at each distribution panel and MCC, and motor load parameters
should be checked on hourly basis. This practice will help to know over/under size
motors and finally the proper size motors could be installed. This practice will also
help to know the running load and power factor of each section of the plant.
Knowing the installed load and required power factor of each section, corrective
measures could be taken to improve the overall plant efficiency. Moreover diesel
consumption for power generation should be recorded carefully and average unit
price (Rs. /kWh) should be calculated every month.

4.1.14 Installation of VFDs

Energy can be saved by using VFDs on motors having variable load. This energy is
saved by reducing motor speed according to the load. The potential of energy
savings can be understand with the help of graph given below:

Figure 4.2: Energy Saving with VFD by Reducing RPM

Source: The Energy Management Handbook, 6
th
Edition

After assessment of the installed motors it is recommended to install VFDs on some
of them. The detailed cost-benefit analysis of the proposed VFDs is provided in the
action plan.

4.1.15 Motor Consideration with VFDs

One drawback to pulse width modulated drives is their tendency to produce voltage
spikes, which in some instances can damage the insulation systems used in electric
motors. This tendency is increased in applications with long cable distances (more
than 50 feet) between the motor and drive and with higher-voltage drives. To guard
against insulation damage, inverter-duty motors, having special insulation systems
that resist voltage spike damage, are used.

In addition, some increased motor heating will inevitably occur because of the
inverters synthesized AC wave form. Insulation systems on industrial motors built
in recent years, and especially inverter-duty motors, can tolerate this except in the
most extreme instances. A greater cooling concern involves operating for an
extended time at low motor RPM, which reduces the flow of cooling air and
especially in constant torque applications where the motor is heavily loaded even at
low speeds. Here, secondary cooling such as a special blower may be required.

4.1.16 Use of Rewound Motors

When a motor fails, one has three options:

Repair the failed motor
Replace with a new standard efficiency motor
Replace with a new high efficiency motor
In a typical motor rewinding, the stator is heated to a temperature high enough to
burn out its winding insulation. The windings are then removed and replaced. The
higher temperatures increase losses by changing the electrical characteristics of the
motor's core. The average core losses are higher than what is normal for motors
that had been previously rewound and also indicates increased total losses. The
increasing losses result in decrease of efficiency.

Generally speaking, it is unwise to rewind a motor if the motor has already been
rewound, the motor has been damaged by heat, or if the cost of rewinding the
motor is more than half of the cost of a new energy efficient motor. During motor
rewinding ensure quality of conductor, quantity of conductor and proper size of
conductor. Avoid stator heating and hammering.

SGC should consider replacing the damaged motors with new high efficiency motors.

4.1.17 Transmission Losses

Transmission losses at belt drive systems are measured during the field visit and are
analysed in Section 3.3.10 of this report. No major hardware/auxiliaries are required
to overcome transmission losses. Simply take care of the alignment of the pulleys,
tightness of the belts and where ever needed replace the worn belts and pulleys.

Table 4.1 shows the machines having transmission losses more than 4.5% and the
saving opportunities associated with them:

Table 4.1
Transmission Losses and Saving Opportunities

Working Days = 300 days/yr
Working Hours = 12 hrs/day
Calculated Unit Price of Electricity = 10.02 Rs./kWh

S. No. Motor Description Rating
(kW)
Transmission
Losses %
Annual Energy
Loss (kWh)
1 Dry Feed Grinder 11 8.78 2090.4
2 Blower (Hammer Mill) 18.5 7.82 2879.8
Total Energy Loss (kWh) 4,970.20
Amount (Rs.) 49,801
Source: The base data is taken from Table 4.16

4.1.18 Sustainable/Renewable Energy Sources

Among the various renewable energy options, wind and solar energy have a larger
and possibly grid-scale potential. Due to the low installation cost wind energy
projects are encouraged by the state and wind farms may seem more feasible for
bulk power generation. However significant potential for wind farming exists only in
the coastal areas that are mostly far away from the national electricity grid.

Solar energy is in abundance almost all over the country and is justifiably seen as the
ultimate resource to tap. Although mainly supplemental in nature, it is also a
resource that addresses the problems of atmospheric pollution and climate change.

4.1.19 Solar PV Electricity Generating Panels

Photovoltaic (PV) cell is one of the many ways of using solar energy for electricity
generation. PV cells can convert incident sun energy directly into electricity. Each PV
cell produces very small amount of voltage. Therefore a solar panel contains number
of PV cells connected in series to build voltage up to 12-24 volts. Direct Current DC
produced by solar panels can be used to power the DC electric equipments or to
charge a battery.

Attempts have been made in Pakistan to install small-scale photovoltaic power
generators and create fabrication capability of PV. Imported solar panels are also
available in the open market in Pakistan.

Solar Power System

A solar power system comprises of solar panels, charge controllers, battery
banks and inverters. Following table shows certain specifications of different
solar power systems:
Table 4.2
Solar Power Systems

S. No. Solar Power System
(kW)
Available Energy
(kWh/month)
Initial Cost
(Million Rs.)
1 1 111 0.6
2 5 557 10.0
3 10 1,113 320.0
Source:
1- Local Vendors of Solar Power
2- Panasonic-Solar Cell Book
3- www.pide.org.pk/pdf/PDR/2004/Waqasullah.pdf

The best possible and the most feasible option for adopting green energy is
decreasing load on conventional sources, which can be accomplished by transferring
partial load to solar power system i.e. use solar panels for lighting load, for water
heaters etc. In this way initial cost and area required to build large solar power
systems can be minimized.

4.2 Thermal Energy

4.2.1 Monitoring & Evaluation

Steam Flow Meter(s)

In order to quantify, as to exactly how much steam is being produced and
consumed and at what cost, its flow measurement is essential. Once the flow
quantity is identified on a regular basis, its consumption patterns can be
identified and thus its savings procedures can be developed.

It is suggested to install steam flow meters at the following locations:

Steam outlet from each boiler
Steam inlet to the various consumer departments e.g. evaporators,
converters, etc.

The installation of a flow meter should be followed by proper monitoring and
analysis to create benchmarks for each individual steam producer and consumer.

The estimated cost of a good quality steam flow meter is Rs. 200,000 per piece.

Blowdown Flow Meter(s)

In order to quantify, as to exactly how much water is being blowdowned, its flow
measurement is essential. Once the flow quantity is identified on a regular basis,
savings procedures can be developed.

It is suggested to install water flow meter(s) at the following location(s):

Blowdown line from each boiler

analysis to create benchmarks of the amount of water being removed from the
boiler(s).

The estimated cost of a good quality steam flow meter is Rs. 15,000 per piece.

4.2.2 Feed Water Treatment

The TDS of the Feedwater was 400 ppm that is above the recommended level, even
though high TDS does not cause scaling it cannot be ignored, high TDS levels require
a greater amount of blowdown to keep the boiler water TDS limits within range. This
is a waste of energy as blowdown water has a temperature close to saturation
temperature and when it is replaced with feed water, the boiler has to do extra
work to produce the same amount of steam.

Normally the condensate water is used along with makeup water to fulfill the
boilers water requirements. As condensate is distilled water, it does not
contain any TDS or hardness. This dilutes the TDS concentrations of the
makeup water.

At SGC, the condensate water collected is not used as feedwater as there is a
chance of sugar contamination. Therefore, it is advised to further treat water
to reduce to amount of TDS concentration in the feedwater. It is
recommended to keep TDS concentration in the feedwater below 150 ppm.
The table below shows the potential saving by reducing the amount of TDS
concentration of feed water.

Table 4.3
TDS Reduction vs. Savings

TDS
(ppm)
Blowdown
Required
(kg/hr)
Extra Fuel
Required to
Produce Steam
(m
3
/year)
Extra Fuel
Cost
(PKR/year)
Potential Fuel
Saving
(m
3
/year)
Potential Cost
Saving
(PKR/year)
400 1548.39 3169.16 42417.62 0 0
350 1333.33 2725.61 36526.28 443.55 6082.63
300 1125 2296.88 30819.05 872.28 11931.31
250 923.08 1882.26 25287.43 1286.88 17556.96
200 727.27 1481.158 19923.43 1688.00 22969.80
150 537.31 1090.19 14719.54 2076.23 28179.46
100 352.94 716.10 9668.72 2452.15 33194.99
50 173.91 352.86 4764.30 2816.29 38024.93

4.2.3 Blow down

Blowdown water contains energy that is lost to environment when drained,
recovering this energy can save feedwater heating costs significantly. Water
quality plays an important role as it determines the amount of blowdown
required to maintain good water quality in the boiler. Exceeding the required
amount of blowdown is a direct waste of water and energy. Excessive
blowdown can be controlled by installing an automatic blowdown system.

The main disadvantage of a manual blowdown system is that the operator is
unaware of the current TDS level of the boiler water and/or the optimal amount
of blowdown required at a given time. The result is that a greater quantity of water
is discharged than that required and hence a greater amount of energy is lost.

In an automated blowdown control system, the required TDS level limits can be set
and maintained with the minimum amount of blowdown required.

For further recovery of energy from blowdown a flash tank could also be installed.
Flash steam contains about 30-40% energy of blowdown and it can be
separated from the high TDS blowdown water by the use of a flash tank.

However, before a recommendation for a flash tank can be made, regular
monitoring and quantification of the amount and frequency of blowdown is
required.

4.2.4 Boiler(s) Efficiency

There was insufficient data to calculate the efficiency for each boiler.

It is recommended to accurately monitor and record the following parameters for
each boiler individually:

Quantity of steam produced
Temperature of steam temperature exiting the boiler
Quantity of feedwater consumed
Temperature of feedwater
Quantity of Natural Gas consumed
Quantity of intermittent and continuous blowdown

4.2.5 Combustion Efficiency Boiler(s)

The purpose of the burner is to mix fuel with molecules of air in optimum
proportions. It is essential for efficient boiler operation that the burner is
functioning as per requirement. A poor designed boiler with an efficient burner
works more efficiently than a very well designed boiler with an inefficient burner. An
efficient burner is designed on the basis of maximum burner efficiency with the
reduction in stack emissions.

A burner mixes air and fuel and injects into the combustion chamber. While
providing a proper combustion and maintaining a proper flame stabilization at
different firing rates.

Normally an efficient natural gas burner requires 2% to 3% excess oxygen and 10-15
% excess air to burn efficiently without producing excess carbon mono-oxide.

Burner maintenance Program:

Conduct stack analysis and calculate combustion at different firing rates e.g. full
load and part load time.
If the excess of oxygen exceeds 3%, consider modernizing the fuel / air control
system by using electronic monitoring, installing of oxygen trim system or a
tuning and repairing of burner.
A new energy efficient burner should be considered if repair cost becomes
excessive and reliability becomes an issue.
Combustion Efficiency Boiler(s):

Table 4.4 shows the results of the combustion analysis. The results show high
concentration of carbon monoxide and the low concentration of oxygen and carbon-
di-oxide. This is an indicator that there was insufficient oxygen required for
stoichiometric combustion.

Table 4.4
Combustion Analysis Test Results (Initial)

Excess O2 0.1 0.1 %
CO Over 4000 Over 4000 ppm
CO2 11.7 11.7 %
Efficiency --- ---

The air inlet was cleaned and the air intake was adjusted until the optimum burning
was achieved.

Table 4.5
Combustion Analysis test Results after Adjusting Boiler Air Intake

Excess O
2
1.8 2.2 %
CO 1 0 ppm
CO2 10.8 10.6 %
Efficiency 83.2 83.4

Table 4.5, are the result of combustion analysis after the air intake was adjusted.
The results now indicate optimum oxygen, carbon monoxide and carbon-di-oxide
concentrations.

It is recommended to conduct a combustion analysis and burner tuning 2 4 times a
year.

Combustion Efficiency Direct Fired:

The result of the combustion analysis shows the presence of excess oxygen as well
as excess carbon mono oxide. Even though there is excess oxygen to facilitate
complete combustion, stoichiometric combustion is not taking place. As a result,
more fuel was being consumed to produce the same amount of energy required for
heating.

Incomplete combustion while there is excess O
2
present in the flue gas is caused by
the following factors:

Due to the misalignment of burner (Flame touches the sides of wall of
combustion chamber).
Due to the lack of maintenance of the burner.
Due to the use of low turndown ratio burner.
Due to the use of an inefficient burner.
Due to the improper mixing of Air and fuel

It is recommended to conduct a combustion analysis and burner tuning 2 4
times a year.

4.2.6 Economizer

An economizer was installed to recover waste heat from the flue gases leaving the
boiler and this energy was used to increase the temperature of the feedwater. It is
recommended to continue this practice.

4.2.7 Steam Traps

Steam traps are essential components of the steam distribution to remove
condensate formation with a negligible loss of live steam. Other advantages include
removing air from the steam distribution network, keeping the steam dry, reducing
waterhammer and making heat transfer from the steam more effective.

Therefore it is recommended to install steam traps. An estimated cost of a good
quality steam trap is Rs. 15,000-20,000 per piece.

4.2.8 Insulation of Pipes, Tanks and Boilers

Thermal insulation on process/utility equipment and piping (Steam, Condensate
and, hot water, steam, etc.) has several functions:

Preventing losses and gain of heat;
Maintaining consistent process temperature;
Protecting employees from burn;
Maintaining comfortable working environment around hot process equipment.

The areas that lacked/had damaged insulation

Boiler and its accessories
Boiler feedwater network
Boiler blowdown network
Live steam network

It is recommended to enclose the all specified locations by an insulating medium to
conserve resources.

Insulation Maintenance Program:

Thermal insulation deteriorates over time, so systems should be regularly
surveyed to replace and repair deteriorated insulation.
System should be regularly surveyed to check for missing insulation.
An overall survey of steam lines should be conducted to identify areas where
insulation has deteriorated. Instruments (Infrared Temperature Gun) should be
used to measure the effectiveness of insulation.
Following any maintenance, areas where work has been performed should be
inspected to see wherever insulation should be replaced or repaired. Removable
insulation blankets should be installed on all equipment/areas that require
frequent access.
Economic insulation thickness should be applied to any hot surface equipment
and its accessories.

The estimated cost of Rockwool insulation is Rs. 1,600-3,000 per meter square and
the estimated cost an infrared temperature gun is Rs. 8,500 per unit.

4.2.9 Leakages

If the system leaks, the energy is lost along with the fluid medium. Leakage from the
distribution system continues as long as the system is under pressure. Furthermore,
the rate of leakage is almost constant, regardless of the load because the leakage is
continuous, even small leaks waste a considerable amount of energy.

The following procedures may be adopted by SGC management to prevent/manage
steam leakages:

Leakage Maintenance Program:

All leaks should be repaired as quickly as possible.
Leaks are one of the most visible forms of energy wastage.
Leakages can also pose a significant safety hazards.
Leakages do not get smaller; neither does the cost of fixing them.
Standard procedures should dictate that proper gaskets and packing be used in
the distribution system flanges and valves.
A leak-repair specialist/team should be assigned to repair leaks when the system
cannot be taken down.
All systems should be designed for minimum leakage. For example, flanges and
threaded piping should be minimized.

The estimated cost of fixing steam leakages is nominal.

4.2.10 Cooling tower

In order to quantify, as to exactly how much water is being circulated, its flow
measurement is essential. Once the flow quantity is identified on a regular basis,
savings procedures can be developed.

It is suggested to install water flow meter(s) at the following locations:

Main water line from cooling tower to the process area.

analysis to create benchmarks.

The estimated cost of a good quality water flow meter is Rs. 15,000 - Rs. 30,000 per
piece.

4.2.11 Compressed Air System

The following recommendations are listed in a priority order:

1) Compressed Air Drier

SGC has a lot of moisture in their compressed air lines and it can cause the
following problems:

a. Rusting
b. Scaling
c. Damaging of pneumatic equipment
d. Malfunctioning of control valves

After evaluating the amount of moisture in the compressed air lines, setting up a
compressed air drier is recommended as a top priority.

2) Leakage Control

The compressed air network is generally visually inspected; if there are leaks
(especially minor leaks) they are impossible to see with the naked eye. The best
solution is to use an ultrasonic acoustic air leak detector, which can recognize
the high frequency hissing sound associated with air leaks. Proactive leak
detection is recommended which could save the losses caused by these air leaks.

The estimated cost of a good ultrasonic leak detector is Rs. 25, 000 per piece.
Steps in simple shop floor method of leak quantification
2
:

The method for simple shop floor measurement for Leak Quantification of a
compressed air system are as follows:
Shut off compressed air operated equipment (or conduct a test when no
equipment is using compressed air).
Run the compressor to charge the system to the set pressure of operation.
Note the subsequent time taken for Load and Unload Cycles of the
compressors. For accuracy, take ON & OFF times for 8 10 cycles continuously.
Then calculate total ON Time (T) and Total OFF time (t).
Use the above expression(s) to find out the quantity of leakage in the system. If
Q is the actual free air being supplied during trial (m3/min), then the system
leakage (m3/min) would be: System leakage (m3/minute) = Q T / (T + t)

3) Maintenance

Carry out preventative maintenance of not just the compressor but also the
distribution network.
Replace old/worn out flexible pipes with new piping and replace plastic
piping with metal piping wherever possible.
Clean/replace filters and drain traps.
Clean dirt and debris off distribution pipes, local headers, gauges.
Regularly check for moisture in compressed air line, especially at end use
equipment
Make sure pressure and temperature gauges are working correctly.

4) Compressed Air Monitoring

In order to quantify, as to exactly how much compressed air is being used and at
what cost, its flow measurement is essential. Once the flow quantity is identified
on a regular basis, its consumption patterns can be identified and thus its savings
procedures can be developed.

Compressed air flow monitoring devices should be installed on the:

Output line of the compressors
Input line to the various consumer departments

The units of air compressed should be noted in every shift and a bench mark
should be established.

2
Steps in simple shop floor method of leak quantification
Electrical Energy Equipment: Compressors and Compressed Air Systems
Energy Efficiency Guide for Industry in Asia www.energyefficiencyasia.org
5) Purchase of a new compressor

Once all the aforementioned steps have been carried out, SGC will have a better
understanding of the actual compressed air requirement. Only then should SGC
consider purchase of a new compressor.

After preliminary analysis of the compressed air demand, it is recommended for
SGC to consider in the range of Atlas Copco GA 45 as the primary compressor
while keeping the current GA 30 compressor as standby/support.

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