Recommendations
reconfigure boiler feed water distribution with minimum no. of bend. must be use long bend in place of elbow in any distribution line, which will reduce the running cost of pump.
remove elbow from steam line by use long bend, which will reduce pressure drop and can be run boiler with low pressure, which will reduce the operation cost of steam boiler.
bar steam line without insulation has surface heat loss. advisable to insulate steam line, which can reduce steam consumption. generally bar steam line insulation project has less than two month payback.
it is advisable to reconstruct in side cylinder of steam boiler to reduce gas consumption. 6. conclusion energy audit is very important for identifying energy loss and accordingly corrective action can be taken which will result in saving energy, improving efficiency and reliability of machine and also gaining benefit in terms of rupees. during the measurement and after the analysis it is observed that power factor of some motors are poor. so install super heavy duty capacitor to improve power factor of satin weaves pvt (a2 plant) & well waves (b2 plant) and save rs. 10749/annum & rs. 17233/annum respectively with 9 months payback period. at present in plant already installed capacitor for maintain power factor at lt side. however during field study we have measured some capacitor power consumption is high compare to norms. so replace faulty capacitor by super heavy duty capacitor and save rs. 146122/annum with investment of rs. 10500 with 1 month payback period. during field study we also observed that in plant so many location we observed that in a day lights found on even there are sufficient day light available so there is a direct energy loss. so reduce power consumption by proper lighting management, rs. 98131/annum will be saving. retrofit the existing 40w/50w tube light by t5 (24 watt), rs. 94011/annum will be save with simple payback of 14.06 months. install voltage stabilizer in lighting feeder (servostabilizer) to regulate the voltage. thus improves the performances of lamps & ballast. a small reduction in voltage level saves the significant amount of energy without any significant drop in the illumination level. reduce the lighting voltage from 215 v to 205 v and save large amount of power consumption without any affect to illumination. so energy consumption will reduce by install voltage stabilizer and save rs. 71032/annum with 10.14 months payback period. it is observed that compressor no. 1 is used for cleaning purposes only. as per the general norm for any cleaning purposes 2.0 bar pressure is enough. existing pressure setting is too much high in reference to our use. so it should be required to reduce pressure setting in the range of 2 to 3 bar. same way in boiler air compressor, pressure setting is very high compare to requirement of 4.0 bar pressure for pneumatic function. it is also advisable to reduce pressure setting in the range of 2 to 3 bar in boiler air compressor to reduce power consumption in air compressed system. per each kg pressure reduction in air compressor will reduce 6 to 10% of compressor power consumption and save rs. 7709.24/annum with immediate payback period (1.5 month). advisable to replace a1 plant bore well pump to improve pump efficiency by replacing the existing lower efficiency pump with higher efficiency pump a huge amount of energy could be save around 23749 rs./annum with nominal payback period.(10 months) improve combustion efficiency of steam boiler by providing online flue gas (o2) analyzer with o2 trimming system to the steam boiler, the savings will be rs. 10579/annum and if only 60% savings will be consider, the simple payback will be only 3.40 months. install the economiser in steam boiler flue gas path, which exchange the heat between hot flue gas to feed water. thus feed water captures the heat from flue gas and lowering the flue gas temperature. for clean fuel such as natural gas, lpg or gas oil exit flue gas temperature limit is lower about well below 200° c, hence recovery of heat from this flue gas is significantly more. for every 1 c increase in feed water temperature, there is an approximate 4° c drops in flue gas temperature and increasing thermal efficiency 5 to 6 %. the saving potential of rs. 8411/annum while investing rs. 10000 in economiser and having money back after 14 months. overall remarks detai 1 avg.annual electrical bill in rs. 60l6 9637.0 2 max. annual saving possible in 04 68738.52 3 overall percentage energy saving 7.7 2 7. acknowledgement it is indeed a pleasure for me to express my sincere gratitude to those who have always helped me for this project work. first of all i would like to thank to my respected guide prof. s.v. damania and prof. vijay k. patel for his valuable time and constant help given to me. i am also thankful to asst. prof. c.n.desai & all the faculty members of mechanical department who gave me inspiration and helped me.