Electrical energy usage optimization in industrial plants: case studies

In this paper, we present three case studies of energy savings opportunities pertaining to electrical machinery used as process equipment in industrial plants. Specifically, the three case studies described include results of optimization studies on an Auxiliary Cooling Water (ACW) pumping system, an Instrument Air Compressor System, and a Chiller Compressor System. The studies were undertaken using the standard methodology of energy audit wherein all relevant input -output parameters are measured followed by a systematic "first law" analysis using network! topological information of the system to derive current operational system efficiencies followed by deduction of methodologies for performance enhancement with view of effecting energy savings. Based on these optimization studies, a total electrical energy savings potential of Rs. 1 Crore was identified.