Ghana - Industrial energy efficiency activity, phase 1 (Vol. 2 of 2) : Consultant ' s reports

IEEEEUEEUEEUEEEEEEE Energv Sector nagement Asstance }rogramme Activity Completion Report Ghanla Industrial Energ Efficiency Activity, Phase I Volume I: Consultants' Reports Report No. 148B/92  ACTIVrIY COMPLETION REPORT GHKAA ENDUSTRAL ENERGY EFICIENCY ACTVITY, PHASE I INDUSTRIAL ENERGY AUDIT PROJECT Volume M: Constnts' Reports November 199X  FOREWORD Background. In 1986, the Energy Assessment Report on Ghana 1/identified energy rtonalizaon In the Industil sector as an Importat faor In mani eergy demand and povwzg the general viability of the energy sector. In response, the Goveranmet of Ghana requested techncal asite of the jon World Bank/UNDP Energy Secto- Management Assistce Progmm (ESMAP) In preparing and Implementg an action program which would lead to higher efficiency in the dustriW sector. EBO acivldes. Following the Ohanan request ESMAP completed an industi ener radonalization study in 1987/88. / Th report concluded that a govemment-supported energy efficiency program In the industi sectr was feasible and neceary, and suggesd that the program include policy and titutional measure as well as demonstation, training and dissm ion inives within the Industries. In 1989, the Government of Ghan and ESMAP agreed to start the demonstation and trainigphase of the program. Ihe Government of Canada, which had already funded te prelimnary ESMAP study through the Canadian Innatonal Development Agency (CIDA), areed to fund the demonstation and training phase, entitled indutla Energ Effidency Program: Phae l. The Industral Ener EMcency Program (Phse 1). Ts acdvity began in early 1989 and was completed in 1990. It was designed to (1) illustrate existing possibilities for energy consevation ad options for realizing them; (2) disseminate results and lessons leaned from pilot trining programs; and (3) train Ghaoian professionals to implement Improvements over the long term. ESMAP contcted with an erntional consultg firm, ACRES Ltd., to perform most of the field techical work, supervised the activity, assessed the preliminary resuts of the activity, and desigped the next phase of the program. Reports. Two types of repors have been prepared in connection with the executon of the activity. They are: (a) an Activity Completion Report Yi prepared by ESMAP ad separty bound. The lattr report summarizes the results of the Phase I activity and oudines the issues and ativities for a possible continuation. The ESMAP report has been designed not to overlap with the consultants' reports but to complement them mainy on the lessons learned from Phase I, and on how to build on tose lessons to desig and Implement a further phase of the program (b) Volume II. The present document which gathers together three consultants reports prepared by ACRES Ltd., In assocation with Asare Tsibu and Partners (ATP), a OhGan consulting firm. 41 Theso reports detai the methodology, fings, results LI Mma se and Options n de Ener Sector, Joint World B UNDP Ener cr SetoAan Progrmme, Rqwe No. 6234GH, Novembe 1986 / ow Ener Raon on h de wa S&etor, EMAP, Report No. 084/88, J1w 1988. I/ The task managerfr tde acivity wasDDama Moa*, ldMso,aspeclalW. The Actvity Copedon Report ws prepred by Djanl MostfW withe as_L e of &/i Sodxrsom I/ Mumr. Richad Cm.sin,fom ACRES, and Theo orn,from ATP, haw ld the reecw eow ofc nukam dring all dse p4jec  and mdos of te audts pemed by ACIES and ATP (dhe coomultants") for hee Industrl firms: Cocoa Processing Compay, Ghana Teo M I Company, and Tuma Food Corpation Company. Ihese reports have been extesivdy diusse and reviewed wih the audied firms as well as wi Ghaaan authoties and ESMAP in the course of the actvity eecuion; they have constitued the basi fir the action program undetaken by the lndustries; The conltants' reperb. The consultas reportu prents tie consultnt' findiW and, whilo they havo been extensively discussed with the Govment of Gharna, the aute Induties and ESMAP, do not necessarily represent the views of either Govenmt, the duswtres, the World Bank or ESMAP. Some editrial modificatiovi have been brought ito the report orgially prepaed by the oudtant and some backgound data updated when possible based on the most cent Inflormation obtned by ESMAP. These repcrs have been ditriuted to Ghanaian istutm and duwis. Addition copies of the reports are available on request.  GHANA Indusil Energy Efficiency Activity Cocoa Procesig Company (PORTEM)  FOEORD The energy audit of the Cocoa Prceing Company Portem) factry s one of the prfom iunder the ndual Energy Audit Project. Te Tma Food Complex Coroation and Ghana Temle Ma -aIr- Company were the other fim audited. Ihe project was funded by the Canadian Interaonal Development Agency and adminsed by thie World Bank under its Energy Sector anement Programme (ESMAP). Project objectives were set in conforman with the National Energy Board's Energy Conservation Programme, a programme which Is designed to encourage Ghanaian Idustry participation in energy efficoicy and consevadon practices. Trainig of Ghanaian peroel In industrial eneg audit techniques was an importaut element of the project which commenced with a technial seminar and a management workshop. Ilu seminar Icluded a review of indust processes and Sinoerig issues and Idenified ways and men to achieve ene and cost savings. Case hisories of cnervation o i Ilemed by Canadian Industry in recet yes prvided practa exampes. TIh worklsop presented ene conservation from a management perspective, identfying the 'boom line' value of consetion, the organ onal requiremets for set up an er manUamt programme in an industry, and emphasiing the need for top management comketo consevation. The seminr, workshop and audi activities were directed by Acres Inteatonal Lnmited of Canda, supported by Asare Tsibu & Partnes of Accra. As part of the p nnel training objectives, a number of a assistat were sdected from Industrial and university sources to actively participate In the detailed audits. The assistnts were assigned specfic ts and given responsibility for peroming plant ipection and eqpnt ivgatios, settiDng up measuring eqUipment and recording data, identfying energy consevaion oppo an on completon, preparig report con s. mhis report reflects those contutons. Te document is intended as a source of referece to musate the aproach take to auditing, the level of plant ln necesary, as well as the invesdgative engieering and evuation required. Anees include background data, system and equpment sketches and process descriptions, plant condiion a and maintenance requirements. The detail preented is more eesive than would be the case with audits undetaken under normal commercial fing cns . Portable m uring equipment suppld for the ads has been retained by NEB for its use and the use of firm ta qualfy under the NED programme objectives. t Is recomendedthat the professional services of experienced audit personne, faml widi measurig techniques and the set up and oeation of portable equipment, be retned. A set of tecical rerence handbook issued to semar participants are retained by the NED for public reference. The list of handboos is uded in Annex 7.  ABBREVIATIONS C CedilI OC Degrees Cnigrade GI Gigajoule h Hour Igpd ImperIal gallons per day kg Kilogram kW Kilowatts kVA Kilovolt Ampere kVAR Reactive Klovolt Ampere lb Pounds (mass L litres MI Megajoule m Metre mm Millimetre p.f. Power factor PRV Pressure reducing control valve RFO Residual fuel oil TRV Temperature regulating control valve yr Year ECO Electricity Corporation of Ghana V Auction rate: C270 e US$ Foreign Exchange Bureau rate: C315 - US$  TABILE OF CONTENTS EXRCITI'J.VE WMMI~U AfiY ................................... .... I 1. PLANT AND ENERGY SYSTEM. .......................... ..1....... TEPLANT ......................... ...... , 0 .... PRODUCTION DATA ............................ ... I Process Oveiew ...........** .** ........... I ENERGY SYSTEM4S ................................. 2 EnergyCConsumptionandCosts .................... ............ 2 Enagy Pria ................. 00#..... ......... 3 H. MECIANICAL PLANT AUDI) .......... ....... . 4 INTODUCnON . ............................. ....... 4 STEAM PLANTAND DISTRIBUIIONSYSTEMS ......... .. ..... 4 Bolsr Plag .......................... . . . . . . . . . . 4 Steam and Condesatystns ........................ 8 Puel and Water Make-Up ................ ....... ... 11 OTHER SERVICES ... ............ ...... 13 Hot Water .................................... 13 Compressed AirSystem. . ...... .......... ... .. . 14 Chflled Watrand ArConditionng ......... ...... .. 16 Cooling Water .......................... . . . . . . . . . 17 COCOA HOUSEPLANT ... ..................... .. 20 Roast .............................. ..... 20 Iass Storage Ta .... ....... .......... 21 ButterPres se..... .................... .. 23 CHOCOLATE HOUSE PLANT . ......................... 24 Energy System .. .. ........ . ............. . ..... .. . . 24 plant iesdsadaos ....................0......*....... 24 Energy Conservation M ures ................ ..... .. .. ... . 24 SUMMARY OF MDECHANICAL CONSERVAT1ON MEASURES . ........... 25 li-pienR-Iietion and Enrgy Ieme ............... .#. . ............. . 25 UL ELECTRICAL PLANT AUDff ........................... .............. 27 INNRODUClON ................................... ........... 27 PLANT POWER SUPPLY ................. ........... ............... 28 Meteing... . .......... ....... ...... . .... 28 MdlntenanceCath-Up ................................. 3C Energy Conservation Meases ............................... 30 POWBERFACTORINVESTIGATIONS . ............ #. 30 MotErgDaCs Saving Mea .. ..................... . 31 Substeon ......................... . . . . . . . . . . . 33 Enetyad Cod Swing MeBum ............................0 33  TALE OF CONTS (Cont'd) PLANT AND OFFICE L1GHTING ....... ................................ 34 Lighting lvestigations . .................................. .... 35 Maintenance Catch-Up ...... .......... ........ ............ 37 Energy Conservation Measures .... ....................... . ... .. . . 37 SUMMARY OF ENERGY MEASURES AND IMPLEMEN.CATION ............ 38 Conservation Measures .... ......... .......................... 38 Inplementatlon and Energy Man*gement ............................ 38 TABLES 1.1 Annual Production 1985-1989 ....... ...................................... 1 1.2 Energy Consumption and Costs ................. .......................... 3 1.3 Energy Price Trends .. ........................................... 3 2.1 ConibustionEfficiency Tests ....................... ................ . 6 2.2 Pipe Insulation Condition Assessment . .................................... 8 2.3 Steam Trap and Masse Tank Temperatures ............... ............... . 9 2.4 Roaster Combustion Tests ......................................... 21 2.5 Mechanical Plant Audit - Summary of Conservation Measures .................... 26 3.1 Summary of Plant Light Levels ...................................... 36 3.2 Electical Plant Audit - Summary of Conservadon Measures ............. ..... 39 FIGURES 2 Fuel and Water Consumption Trends ........... ....................... 12 3 Electrical Single Line Diagram ...................................... 29 ANNEXES 1 Plant and Process Descriptions 2 Pipe Insulation Data 3 Motor Replacement Calculations 4 Power Factor Correction Calculations 5 Plant Lighting Investigations and Lighting Data Sheets 6 Implementation and Energy Management Review 7 List of Technical Reference Books  EXECUTIE SUMAY 1. Ihe Cocoa Procesing Company factory at Tema has been operating since 1963, producing cocoa liquor, butter, powder and residual cak and a variety of chocolate confectionary. Most of the factory's output Is exported. Production has steadily increased, with annua outut expanding from 2,300 tonnes in 1985 to nearly 7,000 tonnes in 1989. Work Is proceeding on etending plant capacity through refiurbishing and adding new equipment to increase total production to 20,000 tonnes over the next few yeas. Production is continuous, with plant operatng 3-shifts, 7-days per week. A 4-week annual shutdown s scheduled for major overhaul and repairs. Routine maint ce and emergency repairs are fted in as necessay. Plant housekeeping and general upkeep are good. Eeg Ed Emu Prim 2. Gas oil is used to geneae steam for process heating and to roast cocoa beans. Electricity provides motive power and lighting. CPC is committed to energy conservation. Energy costs are of the order of 10% of the total production costs exclusive of cocoa bean purchases. The cost of energy in 1988 was Z72 million (US$300,000) covering