Energy Conversion & Management (MBB-4223)

Energy conversion & management (MBB-4223)

3 Credits Core Course (Energy System)

Mechanical Engineering Department,
Universiti Teknologi PETRONAS

Facilitators :
1. 2. Syed Ihtsham-ul-Haq Gilani
E-mail: syedihtsham@petronas.com.my

Ext. 7029 Ext. 7690

Dr. Aklilu Tesfamichael

E-mail : aklilu.baheta@petronas.com.my

Energy conversion & management (MAB-4513)

ME Program Objective : To produce technically qualified well-rounded mechanical engineers who are creative and innovative with potential to become leaders of industry and the nation.

ME Programme Outcomes
Upon graduation, students should be able to:

NO PROGRAM OUTCOMES

1
2 3 4 5

Ability to acquire and apply knowledge of science and engineering fundamentals; Acquired indepth technical competence in a Mechanical Engineering discipline; Ability to undertake problem identification, formulation and solution in Mechanical Engineering; Ability to utilise systems approach to design and evaluate operational Performance in Mechanical Engineering; Understanding of the principles of design for sustainable development;

ME Programme Outcomes (Cont)

NO PROGRAM OUTCOMES Understanding of professional and ethical responsibilities and 6 commitment to them; Ability to communicate effectively, not only with engineers but also 7 with the community at large; Ability to function effectively as an individual and in a group with 8 the capacity to be a leader or manager ; Understanding of the social, cultural, global and environmental 9 responsibilities of a professional engineer; Recognising the need to undertake lifelong learning, and Possessing 10 /acquiring the capacity to do so. Demonstrate business acumen and entrepreneurship in Mechanical 11 Engineering and other related businesses.

Energy conversion & management (MAB-4513)

Expected Course Outcomes

Upon completion of the course, the student should be able to: 1. Analyse various conventional energy systems. 2. Develop an understanding for planning energy schemes. 3. Understand the impact of energy systems on the Environment. 4. Develop strategies to mitigate or eliminate such impacts by considering the technical, social and economic factors.

Energy conversion & management (MAB-4513)

Textbook & References

Textbook : Handbook of Energy Audits, 6th edition, by Albert Thumann & William J. Younger, Fairmont Press, Inc. Lilburn, Georgia & Marcel Dekker, Inc. NY. 2003

References : Energy management Handbook, 5th. Edition, by Wayne C. Turner, Fairmont Press, Inc. Lilburn, Georgia & Marcel Dekker, Inc. NY. 2005

Energy conversion & management (MAB-4513)

Assessment Criteria
Week # 1 to Week # 7 Dr. Syed Ihtsham-ul-Haq Gilani Quiz - A (01) Test - A (01) Assignments (02) 4 marks 8 marks 6 marks Week # 8 to Week # 14 Dr. Aklilu Tesfamichael Assignments Lab work Test - B (01) Site visit / Adjunct Lecture report Project presentation / viva Final Examination 8 marks 50 Marks 6 marks 6 marks 8 marks 4 marks

Energy conversion & management (MAB-4513)

Lesson Plan (First Part of semester)

(Facilitator : Dr. S. I. Gilani)
Week # 1 &2 Date Topics Assessment Assign. # 1 21-05-2012 Introduction & Energy auditing to Energy auditing basics 01-06-2012 Understanding the utility bill Energy survey instrumentation Building envelop audit Electrical system & HVAC audit, etc. 4-06-2012 Energy management to Effective energy management 15-06-2012 Energy management in buildings Monitoring Targeting and Reporting 18-06-2012 to 29-06-2012 2-07-2012 to 6-07-2012 Environmental impact Indoor air quality Advanced energy Industrial Energy Auditing (Case Study)

3&4

Assign. # 2

5&6

Quiz - A

Test A

Energy conversion & management (MAB-4513)

Lesson Plan (Second Part of semester)

(Facilitator : Dr. Aklilu Tesfamicheal)
8 9 10 11 July, 2012 Non Flow and Flow conversion processes July, 2012 Steam Power Plants July, 2012 Steam Power Plants August, 2012 Gas Power Plants Assign. # 4 Assign. # 3 Project Allocation

12

August, 2012 Gas Power Plants

Test - B

13

August, 2012 Combined power plants

14

August, 2012 Revisions & CW marks

Energy conversion & management (MAB-4513)

General Information
Lecturers perception :
Program Outcomes MAB 4513 Energy Conversion & Management 1 2 2 2 3 3 4 2 5 1 6 2 7 2 8 1

Prerequisites :
1. 2. 3. Mechanical Engineering Thermodynamics II Heat Transfer Fluid mechanics - II

General Notes:
1. 2. 3. 4. Attendance in class is must & students with poor attendance would be barred from taking final exams. Students must pass the two sets of grading separately i.e. (Assignment+Project+Test+Quizzes)=50% and the final examination = 50%. Marks would be deducted for late submission of assignments, Lab report or Project report. Plagiarism is strictly prohibited and anybody found guilty would be penalized.

Energy Management What is it ?

ENERGY MANAGEMENT Business, industry and government organizations have all been under tremendous economic and environmental pressures. Being economically competitive in the global market place and meeting increasing environmental standards to reduce air and water pollution have been the major driving factors in most of the recent operational cost and capital cost investment decisions for all organizations. Energy management has been an important tool to help organizations meet the critical objectives for their short term survival and long-term success.

Energy management helps to improve environmental quality. For example, the primary culprit in global warming is carbon dioxide, C02. A balanced equation (below), involving the combustion of methane (natural gas is mostly methane), shows that 2.75 pounds of carbon dioxide is produced for every pound of methane combusted. Thus, energy management, by reducing the combustion of methane can dramatically reduce the amount of carbon dioxide in the atmosphere and help reduce global warming.

Typical Savings Through Energy Management

Significant energy and money savings are available through energy management. Most facilities (manufacturing plants, schools, hospitals, office buildings, etc) can save according to the profile shown below.

Main Components of Energy Management There is no hard a fast rule of Energy Management but some of its necessary components, as adopted by many commercial organizations around the world are : Energy Policy : There must be some kind of acceptable policy. Organization : Set up the energy committee and/or coordinators. Training : Develop a training plan for the next year for all the employees, especially the committee members. Audits : There must be a detailed energy audit plan for the next one year. Reporting : Try to develop a simple reporting system. Schedule : A periodic action of the management program has to be finalized for the next year, at least.

Energy conversion & management (MAB-4513)

Energy Auditing Basics

Energy audits can mean different things to different individuals. The scope of an energy audit, the complexity of calculations, and the level of economic evaluation are all issues that may be handled differently by each individual auditor and should be defined prior to beginning any audit activities. This chapter will review the various approaches to energy auditing and outline a standard approach to organizing and conducting an energy audit. An energy audit can be simply defined as a process to evaluate where a building or plant uses energy and identify opportunities to reduce consumption.

TYPES OF ENERGY AUDITS

On the basis of its applications, Energy Audits can be divided into two categories:

Building Energy Audit

A building energy audit is basically a check on the utilization of all kinds of energy inside the building. It calculates the need of energy inside the building and tries to maintain its utilization as close as possible to its design point. This type of audit covers mainly offices, schools, Hotels and Hospitals.

Plant Energy Audit

It controls the energy usage in various processes (chemical or mechanical). Huge amounts of energy could have been saved inside a plant, if it is properly maintained and the equipment is working within the design limits. These types of audits are applied to Manufacturing and Processing plants, etc.

Energy conversion & management (MAB-4513)

BUILDINGS ENERGY AUDIT

Level 1 - The Walk-Through Audit

The walk-through audit, as its name implies, is a tour of the facility to visually inspect each of the energy using systems. It will typically include an evaluation of energy consumption data to analyze energy use quantities and patterns as well as provide comparisons to industry averages or benchmarks for similar facilities. It is the least costly audit but can yield a preliminary estimate of savings potential and provide a list of low-cost savings opportunities through improvements in operational and maintenance practices. The level one audit is also an opportunity to collect information for a more detailed audit later on if the preliminary savings potential appears to warrant an expanded scope of auditing activity.

Energy conversion & management (MAB-4513)

Level 2-Standard Audit

The standard audit goes on to quantify energy uses and losses through a more detailed review and analysis of equipment, systems, and operational characteristics. This analysis may also include some on-site measurement and testing to quantify energy use and efficiency of various systems. Standard energy engineering calculations are used to analyze efficiencies and calculate energy and costs savings based on improvements and changes to each system. The standard audit will also include an economic analysis of recommended conservation measures.

Energy conversion & management (MAB-4513)

Level 3-Computer Simulation

The level three audit will include more detail of energy use by function and a more comprehensive evaluation of energy use patterns. This is accomplished through use of computer simulation software. The auditor will develop a computer simulation of building systems that will account for weather and other variables and predict year-round energy use. The auditor's goal is to build a base for comparison that is consistent with the actual energy consumption of the facility. After this baseline is built, the auditor will then make changes to improve efficiency of various systems and measure the effects compared to the baseline. This method also accounts for interactions between systems to help prevent overestimation of savings. Because of the time involved in collecting detailed equipment information, operational data, and setting up an accurate computer model, this is the most expensive level of energy audit but may be warranted if the facility or systems are more complex in nature.

PROCESSING PLANT AUDIT

Plant lay out

Natural Gas PETRONAS GAS BERHAD (PGB) Hydrogen AMSB, PPTSB, EMSB

Carbon Monoxide BPPA ACETIC ACID PLANT Oxogas (H2/CO) OPTIMAL

PASB

Ammonia EXPORT (International) Ammonia OPTIMAL

UTILITIES Centralised Utilities facilities

Products and Nameplate Capacities Oxogas - 273 MT/day Carbon Monoxide (CO) - 740 MT/day Ammonia - 1350 MT/day Using feedstock & Utilities sourced from: PETRONAS Gas Bhd (PGB) PGB - Centralised Utilities Facilities (CUF) Aromatics (M) Sdn Bhd PPTSB EMSB

Utilities from CUF

Electricity Demineralised, Potable & Raw Water Steam Fire Water Instrument Air Low Pressure Nitrogen High Pressure Nitrogen

Utilities to CUF
Waste Water Condensate Return

Chemical Process
33 Kg G 24 Kg G 20.5 Kg G

Natural Gas

HYDROGENATION & DESULPHURISATION

STEAM REFORMING

CO2 Removal
32 Kg G

Process Steam

CO + H2 ( Oxogas ) To Optimal HP N2 ( CUF )

33.5 Kg G 30 Kg G 29 Kg G 30 Kg G

COLD BOX

CO to BPPA
37 Kg G

PRESSURE SWING ADSORBER

N2 WASH

NH3 SYNTHESIS
30 Kg G

REDLINE 1
30 Kg G

H2 : N2 Ratio
135 Kg G

NH3 to KTSB
8 Kg G

Hydrogenation and Desulphurization Section

Ammonia Refrigeration
K3-1901 AMMONIA REF. COMPRESSOR E3-1910 A/B AMMONIA CONDENSER

V3-1912 0.05 2.7 5.4 cw

E3-1808

E3-1807

NH3

NH3 PRODUCT

E3-1911

FLARE V3-1913 TO E3-1807

Ammonia Refrigeration
Main function of Refrigeration Unit Condensation of ammonia produced in ammonia converter ( R3-1801 ) Cooling down of ammonia product by flashing Recovery of ammonia from inert gases Refrigeration levels 1st level 0.05 kg / cm2g Flash vessel V3-1911 2nd level 2.7 kg / cm2g 2nd ammonia chiller E3-1808 Inert gas chiller E3-1911 3rd level 5.4 kg / cm2g 1st ammonia chiller E3-1807

Chiller Package

Energy conversion & management (MAB-4513)

THE AUDIT PROCESS

Once the level of audit to be performed is established, auditor can begin collecting information on the structural and mechanical components that affect building energy use, and about the operational characteristics of the facility. Much of this information can and should be collected prior to the actual sitevisit. A thorough evaluation of energy use and systems before going on-site will help identify areas of savings potential and help make best use of your on-site time. An organized approach to auditing will help you collect useful information and reduce the amount of time spent evaluating your facility. By splitting the audit process into three distinct components, pre-site work, the site visit, and post-site work.

Energy conversion & management (MAB-4513)

PRE-SITE WORK
Pre-site work is important in getting to know basic aspects of the building. This preparation will help ensure the most effective use of your on-site time and minimize disruptions to building personnel. A thorough pre-site review will also reduce the time required to complete the on-site portion of the audit. The pre-site review of building systems and operation should generate a list of specific questions and issues to be discussed during the actual visit to the facility.

Pre-site Tasks
1. Collect and review two years of utility energy data. Tabulate and graph the data. Check for seasonal patterns, unusual spikes, and accuracy of the billings. Graphing consumption and cost data makes it easier to understand how each building uses energy. By determining seasonal and base loads, then apportioning energy use among specific building systems such as heating, cooling, lighting and hot water, it becomes easier to identify areas with the greatest savings potential.

Energy conversion & management (MAB-4513)

2.

Obtain mechanical, architectural, and electrical drawings and specifications for the original building as well as for any additions or remodeling work that may have been done. Try the local building department or original architect if the owner doesn't have them. If any energy audits or studies have been done in the past, obtain a copy and review them. Draw a simple floor plan of the building on 8-1/2 x 11 or 11 x 17 inch paper. Make several copies to use for taking notes during the actual site visit. Use separate copies for noting information on locations of HVAC equipment and controls, heating zones, light levels and other energy related systems.

3.

Energy conversion & management (MAB-4513)

4.

Calculate the gross square footage using outside building dimensions multiplied by the number of stories. Substantial areas that are not conditioned and occupied can be subtracted from the gross square footage.
Use audit data forms to collect, organize and document all pertinent building and equipment data. Audit workbooks containing checklists, equipment schedules, and other forms are available from a variety of sources including ASHRAE and your State Energy Office. You may also find it useful to develop your own forms to meet your specific needs. To save time, fill out as much of the form as possible using the building plans and specifications before starting on-site work.

5.

Energy conversion & management (MAB-4513)

6.

Develop a building profile narrative that includes age, occupancy, description, and existing conditions of architectural, mechanical, and electrical systems. Note the major energy consuming equipment or systems. Calculate the Energy Use Index (EUI) in Btu/sqft/year and compare it with EUIs of similar building types using the chart in the Energy Accounting Section. The EUI is calculated by converting annual consumption of all fuels to Btus then dividing by the gross square footage of the building. It can be a good indicator of the relative potential for energy savings. A comparatively low EUI indicates less potential for large energy savings.

7.

Energy conversion & management (MAB-4513)

Develop a Site Sketch

Prepare a site sketch of the building or complex which shows the following information: Relative location and outline of the building(s). Name and building number of each building. (Assign building numbers if none exist.) Year of construction of each building and additions. Square footage of each building and additions. Location, fuel type and I.D. numbers of utility meters. Areas served by each utility meter. Location of heating and cooling plants and equipment. North orientation arrow.

Energy conversion & management (MAB-4513)

The Site Visit

Plan to spend at least a full day on-site for each building. The amount of time required will vary depending on the completeness of the pre-site information collected, the complexity of the building and systems, and the need for testing of equipment. Small buildings may take less time. Larger buildings can take two days or more. Have all necessary tools available on site. Try to anticipate basic hand tools and test equipment you will need to perform a thorough inspection. Some basic audit tools you'll want to bring along include: Notebook Calculator Flashlight Measuring Tape Pocket Thermometer Light Meter Camera

Energy conversion & management (MAB-4513)

Prior to touring the facility, sit down with the building manager to review energy consumption profiles and discuss aspects of the facility you aren't able to see such as occupancy schedules, operation and maintenance practices, and future plans that may have an impact on energy consumption.

Confirm the floor plan on your drawing to the actual building and note major changes. Use copies of the floor plan to note equipment locations such as boilers, chillers, DHW heaters, kitchen appliances, exhaust fans, etc., as well as lighting types, levels, and switching, photo locations, room temperatures, general conditions and other observations.
Fill out the audit data sheets. Use them to organize your site visit and as a reminder to collect information missing from pre-site documents.

Energy conversion & management (MAB-4513)

Look at the systems relating to the Energy Conservation Measures (ECMs) and O&Ms on your preliminary list. Review the application of your recommendations and note any problems that may affect implementation. Add additional measures to your list as you tour the facility. Take pictures as you walk through the building. Include mechanical equipment, lighting, interior workspaces, common areas and halls, and the exterior including the roof. They are useful in documenting existing conditions, discussing problems and issues with colleagues, as ,well as serving as a reminder of what you inspected. Building managers will find them useful for explaining conservation measures to administrators and building occupants.

Energy conversion & management (MAB-4513)

POST-SITE WORK
Post-site work is a necessary and important step to ensure the audit will be a useful planning tool. The auditor needs to evaluate the information gathered during the site visit, research possible conservation opportunities, organize the audit into a comprehensive report, and make recommendations on mechanical, structural, operational and maintenance improvements.

Post-site work includes the following steps:

Immediately after the audit, review and clarify your notes. Complete information you didn't have time to write down during the audit. Use copies of the floor plan to clean up notes for permanent records. Review and revise your proposed ECM and O&M lists. Eliminate those measures lacking potential and document why they were eliminated.

Energy conversion & management (MAB-4513)

Process your photos and paste or import pictures on 8-1 /2 x 11 inch pages. Number the photographs and note on a floor plan the location where each photo was taken. Identify and add notes under the pictures as needed. Organize all charts, graphs, building descriptions, audit data sheets, notes and photos into a 3 ring binder. Energy auditing can be an ongoing process. By keeping all building information in a dedicated binder or file, records can be easily added or updated and can be very useful to architects and engineers if future work is done on the building.

Energy conversion & management (MAB-4513)

THE AUDIT REPORT

The general flow of audit activities is to identify all energy systems, evaluate the condition of the systems, analyze the impact of improvements to those systems, and write up an energy audit report. This report explains the existing conditions of the building(s) in terms of the envelope, equipment, lighting, and occupancy, followed by recommendations to improve efficiency through improvements in operation and maintenance items, or O&Ms, and through installation of energy conservation measures, or ECMs.
Effectively communicating audit findings and recommendations increases the chance of action being taken to reduce energy consumption. When preparing the audit report, keep in mind the various audiences that will be using each section and try to customize each section to most effectivelv reach that audience.

Energy conversion & management (MAB-4513)

Typical audiences for audit reports include:

CEO, Chief Operating Officer, Administrator, Superintendent, Facilities and Plant Managers, Controller, Plant Engineer, Operations and Maintenance Staff

Energy conversion & management (MAB-4513)

The following outlines the basic components of a well-organized audit report:

Executive Summary Building Information Utility Summary Energy Conservation Measures (ECMs) Operation and Maintenance Measures (O&Ms) Appendices

Energy conversion & management (MAB-4513)

SUMMARY
When you've completed your audit activities, you should have a good understanding of the primary drivers affecting facility energy use. By identifying the energy consuming components of a building or plant and documenting the existing conditions, conservation opportunities can be identified and prioritized. Set up a meeting with the building or plant manager to go over your report. Discuss your recommendations for conservation actions, methods of funding ECMs. Include training recommendations for building operators and occupants that will improve the operating efficiency of the building as well as training required for maintenance and operation of newly install measures.