energymanagementaudit-pp01

8/10/2019 energymanagementaudit-pp01

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Energy Management& Audit – An Overview

Pinaki Roy



WHAT IS ENERGY?

Definition: Energy is the capacity of a physicalsystem to perform work. Energy exists in severalforms such as heat, kinetic or mechanical energy,light, potential energy, electrical or other forms.

According to the law of conservation of energy, thetotal energy of a system remains constant, thoughenergy may transform into another form.For example, two billiard balls colliding, may come to

rest, with the resulting energy converting to soundand perhaps a little bit of heat, at the point ofcollision.



TYPES OF ENERGYMechanical energy

Mechanical energy is energy that results from movement or the locationof an object. Mechanical energy is the sum of Kinetic and PotentialEnergy.Thermal energy Thermal energy or heat energy reflects the temperature difference

between two systems.Nuclear energy Nuclear energy is energy resulting from changes in the atomic nuclei orfrom nuclearChemical energy

Chemical energy results from chemical reactions between atoms ormolecules. There are different types of chemical energy, such aselectrochemical energy etc.Electromagnetic energy Electromagnetic energy is energy from light or electromagnetic waves.







The Objectives of Energy Management

1. To achieve and maintain optimum energyprocurement and utilisation, throughout the

organization

2. To minimise energy costs / waste withoutaffecting production & quality

3. To minimise environmental effects.



Energy Management Objectives Clarified

The basic objective of any EnergyManagement System is to answer fivesimple questions:

How much energy is consumedHow is the energy consumedWhere is the energy consumedWhen is the energy consumedWhat is the quality of the energy consumed

In order to address these queries EnergyAudits are conducted. Lets understand audits







Types of Energy Audits

1. Preliminary Energy Audit

2. Targeted Energy Audit

3. Detailed Energy Audit



Preliminary Energy Audit

Preliminary energy audit uses existing or easilyobtained dataEstablishes the energy consumption in theorganizationEstimates the scope for savingIdentifies the most likely areas for attentionIdentifies immediate(no cost or low cost)

improvementsSets a „reference point Identifies areas for more detailedstudy/measurement





Detailed Energy Audit

Detailed Energy Audit evaluates all systems andequipment which consume energy and the auditcomprises a detailed study on energy savings

and costs.

Detailed Energy Audit is carried out in 3 phasesThe Pre-audit Phase

The Audit PhaseThe Post-Audit Phase



The Ten Steps for Detailed Audit

StepNo

PLAN OF ACTION PURPOSE / RESULTS

Step 1

Step 2

Phase I – Pre Audit Phase

Plan and organiseWalk through AuditInformal Interview withEnergy Manager, Production/ Plant Manager

Conduct of brief meeting /awareness programme withall divisional heads and persons concerned (2-3 hrs.)

Resource planning, Establish/organize aEnergy audit teamOrganize Instruments & time frameMacro Data collection (suitable to type ofindustry.)Familiarization of process/plant activitiesFirst hand observation & Assessment ofcurrent level operation and practices

Building up cooperationIssue questionnaire for each departmentOrientation, awareness creation



Step 3

Step 4

Phase II – Audit PhasePrimary data gathering,Process Flow Diagram, &

Energy Utility Diagram

Conduct survey andmonitoring

Historic data analysis, Baseline datacollection

Prepare process flow chartsAll service utilities system diagram(Example: Single line power distributiondiagram, water, compressed air & steamdistribution.Design, operating data and schedule ofoperationAnnual Energy Bill and energy consumption

pattern (Refer manual, log sheet, name plate,interview)

Measurements :Motor survey, Insulation, and Lighting

survey with portable instruments forcollection of more and accurate data.Confirm and compare operating data withdesign data.





Step10 Phase III – Post Audit phase

Implementation and Follow-up

Assist and Implement ENCON recommendationmeasures and Monitor the performance

Action plan, Schedule for

implementationFollow-up and periodic review





DETAILED ENERGY AUDITA TYPICAL INDUSTRIAL FORMAT

Energy Audit Team

Executive Summary – Scope & Purpose

Energy Audit Options & Recommendations1.0 Introduction about the plant

1.1 General Plant details and descriptions1.2 Component of production cost (Raw materials, energy, chemicals,

manpower, overhead, others)1.3 Major Energy use and Areas2.0 Production Process Description

2.1 Brief description of manufacturing process2.2 Process flow diagram and Major Unit operations2.3 Major Raw material Inputs, Quantity and Costs

3.0 Energy and Utility System Description3.1 List of Utilities3.2 Brief Description of each utility

3.2.1 Electricity3.2.2 Steam3.2.3 Water3.2.4 Compressed air3.2.5 Chilled water3.2.6 Cooling water



4.0 Detailed Process flow diagram and Energy& Material balance4.1 Flow chart showing flow rate, temperature, pressures of all input-

Output streams4Water balance for entire industry

5.0 Energy efficiency in utility and process systems5.1 Specific Energy consumption5.2 Boiler efficiency assessment5.3 Thermic Fluid Heater performance assessments5.4 Furnace efficiency Analysis5.5 Cooling water system performance assessment5.6 DG set performance assessment5.7 Refrigeration system performance5.8 Compressed air system performance5.9 Electric motor load analysis5.10 Lighting system

6.0 Energy Conservation Options & Recommendations6.1 List of options in terms of no cost, low cost, medium cost and high cost, annual energy

savings and payback6.2 Implementation plan for energy saving measures/Projects

ANNEXUREAl. List of instrumentsA2. List of Vendors and Other Technical details



All Energy Audits require many measurements.

Some common Instruments used are shown above



Some more Energy AuditInstruments



Identification of EnergyConservation Factors & Areas

Steps for conserving energy can betaken if we know the correct factors

and areas to be studied and alsodetails of fuels used.These can be:

Energy generationEnergy distributionEnergy usage by processes

Fuel substitution





Energy Costs in Indian Scenario ?

Common Fuels• Fuel oil,• Low Sulphur

Heavy Stock (LSHS),• LightDiesel Oil (LDO),• LiquefiedPetroleum Gas (LPG)• Coal,• Lignite,• Wood

Fuels Cost Inputs & Factors Price at source, transportcharge, type of transport,Quality of fuelContaminations, Moisture,Energy content (GCV)

Power CostsIn India Electricity costsvary substantially not onlyfrom State to State, butalso from city to city andalso within consumerto consumer – thoughpower does the same

work everywhere.

Reason :•Tariff Structure



Understanding energy costs

Electricity (1 kWh) = 860 kcal/kWh (0.0036 GJ)Heavy fuel oil (calorific value, GCV) =10.000 kcal/litre ( 0.0411 GJ/litre)Coal (calorific value, GCV) =4000 kcal/kg ( 28 GJ/ton)

An industrial energy bill summary

Conversion to common unit of energy

ENERGY BILL EXAMPLEType of energy Original units Unit Cost Monthly Bill (Rs)Electricity 5,00,000 kWh Rs.4.00/kWh 20,00,000Fuel oil 200,kL Rs.11,000 KL 22,00,000

Coal 1000 tons Rs.2,200/ton 22,00,000Total 64,00,000



Benchmarking

Benchmarking can be a useful tool forunderstanding energy consumption patterns inthe industrial sector and also to take requisitemeasures for improving energy efficiency.

FACTORS INVOLVED:

Scale of operationVintage of technologyRaw material specifications and qualityProduct specifications and quality



Benchmarking for Energy Performance

• Internal Benchmarking

Historical and trend analysis

• External Benchmarking

Across similar industries

Scale of operation, vintage of technology,raw material specification and quality andproduct specification and quality



Bench Marking Energy Performance

Quantification of fixed and variable energyconsumption trends vis-à-vis production levelsComparison of the industry energy performance

w.r.t. various production levels (capacity utilization)Identification of best practices (based on theexternal benchmarking data)Scope and margin available for energyconsumption and cost reductionBasis for monitoring and target setting exercises





Measuring Energy PerformanceProduction Factor = C urrent year’s production

Reference year’s production

Reference Year Equivalent Energy Use

The reference year’s equivalent energy use (or reference year equivalent) is theenergy that would have been used to produce the current year s productionoutput.The reference year equivalent is obtained by multiplying the reference year energy use bythe production factor (obtained above)

Reference year equivalent = Reference year energy use x Production factor

Plant Energy Performance is the improvement or deterioration from the referenceyear. It is a measure of plant s energy progress.

Plant energy performance = Reference year equivalent – Current year’s energy x100

Reference year equivalent



Maximizing System Efficiencies- Some Measures

Replace pumps, fans, air compressors, refrigerationcompressors, boilers, furnaces, heaters and otherenergy conservation equipment, wherever significant

energy efficiency margins existEliminate steam leakages by trap improvementsMaximize condensate recoveryAdopt combustion controls for maximizingcombustion efficiency



Matching Energy Usage to Requirement

The mismatch between equipment capacity anduser requirement often leads to inefficiencies due topart load operations, wastages etc. It is thus

essential that proper energy matching studies arecarried out & actions implemented.Examples :Eliminate throttlingEliminate damper operationsFan resizing for better efficiency.Moderation of chilled water temperature for process chilling

needs



Optimising Energy Input Requirement

In order to ensure that the energy given to the system isbeing put to optimal use, site specific measures andchecks should be carried out regularly.

EXAMPLES:

Shuffling of compressors to match needs.

Periodic review of insulation thickness

Identify potential for heat exchanger networking and processintegration.



Fuel and Energy Substitution – key steps towards conservation

Fuel substitutionReplacement of coal by coconut shells, rice husk etcReplacement of LDO by LSHS

Energy substitutionReplacement of electric heaters by steam heatersReplacement of steam based hot water by solarsystems

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THANK YOU

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