Our Services

Energy Audit

An energy audit is a plant site survey, involving measurements and analyses of energy and material flows in an industrial plant or building, with the objective of understanding the energy dynamics of the system. Typically an energy audit is conducted to identify opportunities to reduce the energy demand of the system without affecting production volumes, quality or safety.

We, at Devki Energy, employ a systems approach that goes beyond equipment efficiencies and estimates the overall system efficiencies of important processes and supporting utilities. This approach helps identify inefficiencies and hidden losses that may exist due to the design philosophy, system design, existing equipment design and/or operating practices.

Methodology

Our energy audits begin with a briefing to the top management and plant team, wherein we communicate our methodology of work, the inputs needed from the plant and the deliverables from us. This interaction helps clarify the energy audit process and enables smooth flow of information and assistance during the course of work.

The site study involves detailed measurements and analyses of equipment operations and processes; frequent discussions with the plant team help improve our understanding of operations that enables understanding of the measurements and observations in the right perspective. Evolving energy saving ideas are discussed with the plant team so that any operational issues in implementing the measures are understood. Involvement of senior plant team members in the energy audit process is imperative for ensuring the quality of the deliverables of the study.



Equipment / System Areas for Improvement
Pumps & Blowers Flow/pressure optimization, piping/ducting system design modifications to reduce losses, reduction of throttling losses, appropriate impeller sizing, use of variable speed drives & better selection of equipments
Refrigeration & Air Conditioning Temperature optimization, end-use load reduction, use of favourable ambient conditions, flow optimization, substitution with less energy intensive alternatives, improvement of machine efficiency, better selection of equipments, improved instrumentation for control, innovative technologies for Precision Air Conditioning for Low Relative Humidity and inter-fuel substitution
Electrical Furnaces Temperature optimization, load reduction, reduction of thermal inertia, reduction of heat losses, improvement in operating practice, improved instrumentation for control, better selection of equipments and inter-fuel substitution
Boilers & Fired heaters Optimisation of excess combustion air, improved instrumentation for control, improvement in operating practices, incorporate heat recovery, reduction of heat losses, improved instrumentation for control and inter-fuel substitution
Heat Exchangers Identifying fouled heat exchangers, reduce demand of utilities like steam, cooling water, chilled water and chilled brine by heat integration by Pinch Analysis
Dryers Reduction losses by estimating heat balance, recycling waste heat and use of improved designs & technologies
Cooling Towers Improve cooling efficacy by evaluating water flow to air flow ratio, review condition of fills, rationalization of number of cells in operation, improvement in fan efficiencies and rationalization of operation
Compressed Air Optimisation of air pressure, reduction in leakage and inappropriate end-uses, evaluation of electro-mechanical alternatives, use of energy efficient air dryers, improving compressor control practices, improving compressor efficiencies and selection of energy efficient compressors & controls
Electrolysis Optimisation current density, electrolyte temperatures & cell voltages based on study of cell electrochemistry, reduction of voltage drops in bus bars and improved cell designs.
Electric Motors Identification of grossly under-loaded motors for possible replacement, improved controls and energy efficient motors
Lighting Optimising illuminance in work areas, optimization of feeder voltages, apply principles of task lighting and use of high efficacy lamps, gear and luminaires.
Cogeneration (Combined Heat & Power) Selection of appropriate equipments & systems based on heat to power ratios, feasible fuel linkages and fuel prices
Power System Maximum Demand control, Power Factor improvement, measurement of harmonics and estimation of distribution losses in transformers & cables

Instruments for Energy Audit

Accurate measurements and site observations are the key to understand operations and estimate energy efficiency values or figures of merit. We use portable instruments for measurements, which include electrical power analysers, ultrasonic flow meters (transit time & Doppler types), anemometers, digital manometers, psychrometers, temperature measuring devices (RTDs & thermocouples), pressure gauges, tachometers, lux meters, ultrasonic gas leakage detectors, data loggers etc. for relevant measurements. We also use installed plant instrumentation for measurements and cross-checks.

Energy Audit Report

The energy audit report provides detailed description & specifications of the proposed system modifications, retrofits, new equipments and information on relevant vendors. The recommendations may include measures without any investment, short payback retrofits and capital projects with both short and long payback periods. The report may also mention new emerging developments and technologies that may be relevant in the foreseeable future.

During the implementation of projects, we provide support services for drawing up equipment specifications, reviewing new system design, identifying competent vendors and post implementation monitoring and verification of energy savings.