Electrical Energy Audit at Brothers Flour and Biscuit Factory
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Date
2018-10
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Addis Ababa University
Abstract
Electrical energy plays a vital role almost everywhere, especially those that are energy
intensive institutions. As there are limited resources and increased cost to generate
electricity, it is our keen duty to save resources for future use by doing research about
energy conservation, which energy audit is one to consider in different sectors such as the
one this research work is attempting. This would help the factory to be competent in the
market because their production cost depends on electric power.
This thesis presents about electrical energy audit in Brothers Flour and Biscuit Factory,
which is one of the intensive energy consumer industries currently flourishing in our
country. For the purpose of data analysis, a historical data regarding their energy
consumption and energy intensive equipment’s, such as electric motors and lighting
systems were collected. Countries with energy efficient Biscuit and Flour factory have
been selected as a benchmark to compare the energy efficiency of the factory. From the
data analysis it is found that the factory loses 31% and 22% of total energy for biscuit and
flour respectively due to inefficient electrical energy consumption and pays a total of
4,320,216 ETB/year.
Modelling and simulation of the whole power distribution system based on the primary
data collected and one-line diagram have been done with Electrical transient analyzer
program (ETAP 12.6.0) software package. Annual technical energy loss of the factory
power distribution system has been investigated and its value is 1.2%. i.e. ideal loss within
acceptable range, which is 3-6%. But, expenditure for technical energy loss due to
distribution transformers is high in comparison to distribution cables.
The factory accomplishes its activities with extra and inefficient lamps and also with low
efficiency of electric motor due to under load operation of the motor for specific
application. At the end of factory’s electrical energy audit the possible total energy saving
potential in KWh per year from lighting only was 338.7 MWH/year by using energy
efficient lamps and optimizing the illumination of the existing lighting system. Hence the
total saving in Ethiopian birr per year from lighting were 138,397.54 and their payback
period is less than 6 months. By replacing standard (low efficiency) motors with energy
efficient motor gives 49,482 KWh/year energy saving and cost saving of $1,484 per year
as well as payback period of less than 10 years as analyzed by Motor Master software.
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Keywords
energy Audit, Energy Conservation, Energy conservation opportunities (ECOs), technical energy loss, ETAP