Modul Audit Energi [TM2]

7/23/2019 Modul Audit Energi [TM2]

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MODUL PERKULIAHAN

AuditEnergy

Energy Management

FakultasProgramStudi

ata!Muka

Kode MK Disusun Ole"

Teknik Teknik Mesin

#$MK%'& Darmansyah, M.Si

A(stra)t Kom!etensiTujuan energy management,metodologi audit energy,

Mahasiswa dapat memahami sertamengerti tentang fungsi dari menajemenenergi serta cara mengaudit energi.


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Introduction

1.11 Definition & Objectives of Energy Management

The fundamental goal of energy management is to produce goods and provide

services with the least cost and least environmental effect. The term energy management

means different things to different people. One definition of energy management is:

The judicious and effective use of energy to maximize profits (minimize costs) and enhance

competitive positions.

(apehart, Turner and !ennedy, Guide to Energy Management, "airmont

#ress $nc., %&&'

)nother comprehensive definition is:The strategy of adjusting and optimizing energy using systems and procedures so as to

reduce energy re!uirements per unit of output "hi#e ho#ding constant or reducing tota# costs

of producing the output from these systems.

The o*jective of +nergy Management is to achieve and maintain optimum energy

procurement and utiliation throughout the organiation and:

To minimie energy costs - waste without affecting production and uality

To minimie environmental effects.

1.12 Energy Audit: Types and Metodo!ogy

The energy audit is the /ey to a systematic approach for decision0ma/ing in the

area of energy management. $t attempts to *alance the total energy inputs with their use,

and serves to identify all the energy streams in a facility. $t 1uantifies energy usage

according to its discrete functions. )n industrial energy audit is an effective tool in defining

and pursuing a comprehensive energy management program within a *usiness.

)s per the +nergy onservation )ct, 233%, passed *y the government of $ndia,

energy audit is defined as the verification, monitoring and analysis of use of energy

including su*mission of technical reports containing recommendations for improving energy

efficiency with cost *enefit analysis and an action plan to reduce energy consumption.

1.12.1 "eed for Energy Audit

$n any industry, the three top operating e4penses are often found to *e energy (*oth

electrical and thermal, la*or, and materials. $n most assessments of the managea*ility of

the cost or potential cost savings in each of the a*ove components, energy would invaria*ly

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Audit EnergyPusat +a"an A,ar dan eLearning

5armansyah, M.6i http:--www.mercu*uana.ac.id


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emerge as a top ran/er, and thus energy management function constitutes a strategic area

for cost reduction. ) well done energy audit will always help managers understand more

a*out the ways energy and fuel are used in their industry, and help to identify areas where

waste can occur and where scope for improvement e4ists. The energy audit would give a

positive orientation to the energy cost reduction, preventive maintenance, and 1uality control

programs which are vital for production and utility activities. 6uch an audit program will help

to /eep focus on variations that occur in the energy costs, availa*ility, and relia*ility of supply

of energy, help decide on the appropriate energy mi4, identify energy conservation

technologies, retrofit for energy conservation e1uipment, etc.

$n general, the energy audit is the translation of conservation ideas and hopes into

reality, *y lending technically feasi*le solutions with economic and other organiational

considerations within a specified time frame. The primary o*jective of the energy audit is to

determine ways to reduce energy consumption per unit of product output or to lower

operating costs. The energy audit provides a *enchmar/, or reference point, for managing

and assessing energy use across the organiation and provides the *asis for ensuring more

effective use of energy.

1.12.2 Types of Energy Audits

The type of energy audit to *e performed depends on:

"unction and type of industry

5epth to which a final audit is needed, and

#otential and magnitude of cost reduction desired

Thus energy audits can *e classified into the following two types:

#reliminary audit

5etailed audit

1.12.# $re!iminary Energy Audit Metodo!ogy

The preliminary energy audit uses e4isting or easily o*tained data. $t is a relatively

1uic/ e4ercise to:

5etermine energy consumption in the organiation

+stimate the scope for saving

$dentify the most li/ely (and easiest areas for attention

$dentify immediate (especially no0cost-low0cost improvements-savings

6et a reference point

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$dentify areas for more detailed study-measurement

1.12.% Detai!ed Energy Audit Metodo!ogy

) detailed energy audit provides a comprehensive energy project implementation

plan for a facility, since it evaluates all major energy0using systems. This type of audit offers

the most accurate estimate of energy savings and cost. $t considers the interactive effects of

all projects, accounts for the energy use of all major e1uipment, and includes detailed

energy cost saving calculations and project cost.

$n a detailed audit, one of the /ey elements is the energy *alance. This is *ased on

an inventory of energy0using systems, assumptions of current operating conditions, and

calculations of energy use. This estimated use is then compared to utility *ill charges.

5etailed energy auditing is carried out in three phases:

#hase $ 7 #re0)udit

#hase $$ 7 )udit

#hase $$$ 7 #ost0)udit

A uide for 'onducting Energy Audit at a !ance

$ndustry0to0industry, the methodology of energy audits needs to *e fle4i*le. ) %30step

summary for conducting a detailed energy audit at the field level is listed *elow. The energy

manager or energy auditor may follow these steps to start with and add-change as per theirneeds and the industry type.

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$ase ( ) $re*Audit Activities

) structured methodology to carry out the energy audit is necessary for efficientimplementation. )n initial study of the site should always *e carried out, as the planning of

the audit procedures is of /ey importance.

(nitia! +ite ,isit and $reparation -euired for Detai!ed Auditing

)n initial site visit may ta/e one day and gives the energy auditor-manager an

opportunity to meet the personnel concerned, to familiarie him or her with the site, and to

assess the procedures necessary to carry out the energy audit. 5uring the initial site visit the

energy auditor-manager should carry out the following actions:

5iscuss with the site8s senior management the aims of the energy audit

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5iscuss economic guidelines associated with the recommendations of the audit

)nalye the major energy consumption data with relevant personnel

O*tain site drawings where availa*le 7 *uilding layout, steam distri*ution,

compressed air distri*ution, electricity distri*ution, etc.

Tour the site accompanied *y engineering-production staff

Te main aims of tis visit are:

To finalie energy audit team

To identify the main energy0consuming areas-plant items to *e surveyed during the

audit

To identify any e4isting instrumentation or additional metering that may *e re1uired

To decide whether any meters will have to *e installed prior to the audit9 e.g., /h,

steam, oil, or gas meters.

To identify the instrumentation re1uired for carrying out the audit

To plan the time frame

To collect macro data on plant energy resources, major energy consuming centers

To create awareness through meetings-program

$ase (( ) Detai!ed Energy Audit Activities

5epending on the nature and comple4ity of the site, a detailed energy audit can ta/e

from several wee/s to several months to complete. 5etailed studies to esta*lish and

investigate energy and material *alances for specific plant departments or items of process

e1uipment are carried out. henever possi*le, chec/s of plant operations are conducted

over e4tended periods of time, at nights and at wee/ends as well as during normal daytime

wor/ing hours, to ensure that nothing is overloo/ed.

The audit report will include a description of energy inputs and product outputs *y

major departments or *y major processing function, and will evaluate the efficiency of each

step of the manufacturing process. Means of improving these efficiencies will *e listed, and

at least a preliminary assessment of the cost of the improvements will *e made to indicate

the e4pected pay*ac/ on any capital investment needed. The audit report should conclude

with specific recommendations for detailed engineering studies and feasi*ility analyses,

which must then *e performed to justify the implementation of those conservation measures

that re1uire additional capital investment.

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Te information to be co!!ected during te detai!ed audit inc!udes:

%. +nergy consumption *y type of energy, *y department, *y major items of process

e1uipment, *y end0use

2. Material *alance data (raw materials, intermediate and final products, recycled

materials, use of scrap or waste products, production of *yproducts for re0use in

other industries, etc.

;. +nergy cost and tariff data

eneration and distri*ution of site services (e.g., compressed air, steam

?. 6ources of energy supply (e.g., electricity off the grid or self0generation

'. #otential for fuel su*stitution, process modifications, and the use of cogeneration

systems (com*ined heat and power generation

@. +nergy Management procedures and energy awareness training programs within the

esta*lishment

+4isting *aseline information and reports are useful to understand consumption

patterns, production cost, and productivity levels in terms of product per raw material inputs.

"or this the audit team should collect the following *aseline data:

A Technology, processes used, and e1uipment details

A apacity utiliation

A )mount B type of input materials used

A ater consumption

A "uel consumption

A +lectrical energy consumption

A 6team consumption

A Other inputs such as compressed air, cooling water, etc.

A uantity B type of wastes generatedA #ercentage rejection - reprocessing

A +fficiencies - yield

DATA 'O//E'T(O" 0("T+

$t is important to plan additional data gathering carefully. Cere are some *asic tips to

avoid wasting time and effort:

Measurement systems should *e easy to use and provide information to the level of

accuracy that is actually needed, not the accuracy that is technically possi*le

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Measurement e1uipment can *e ine4pensive (flow rates using a *uc/et and

stopwatch

The 1uality of the data must *e such that correct conclusions are drawn (what the

grade of product is in production, is the production normal, etc.

5efine how fre1uent data collection should *e to account for process variations.

Measurement e4ercises over a*normal wor/load periods (i.e., startup and shutdown

5esign values can *e ta/en where measurements are difficult (i.e., cooling water

through a heat e4changer

$rocess f!o diagram to identify aste streams and energy astage

)n overview of unit operations, important process steps, areas of material and

energy use, and sources of waste generation should *e gathered and should *e represented

in a flowchart as shown in "igure %.@. +4isting drawings, records, and a shop floor wal/0

through will help in ma/ing this flowchart. 6imultaneously the team should identify the

various inputs and output streams at each process step.

Eamp!e: A f!ocart of a production !ine for penici!!in is given in "igure %.@. Dote that a

waste stream (Mycelium and o*vious energy losses such as condensate drainage and

steam lea/ages are identified in this flowchart.The audit focus area depends on several

issues such as consumption of input resources, energy efficiency potential, impact of

specific process steps on the entire process, or intensity of waste generation-energy

consumption. $n the e4ample process, the modularied operations such as germinator,

prefermentor, fermentor, and e4traction are the major conservation potential areas identified.

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(dentification of Energy 'onservation Opportunities

3ue! substitution: $dentifying alternative fuels for efficient energy conversion

Energy generation: $dentifying efficiency opportunities in energy conversion

e1uipment-utilities such as captive power generation, steam generation in *oilers, thermic

fluid heating, optimal loading of diesel generator sets, minimum e4cess air com*ustion with

*oilers-thermic fluid heating, optimiing e4isting efficiencies, efficient energy conversion

e1uipment, *iomass gasifiers, cogeneration, high efficiency diesel generator sets, etc.

Energy distribution: $dentifying efficiency opportunities networ/s such as transformers,

ca*les, switchgears, and power factor improvement in electrical systems and chilled water,

cooling water, hot water, compressed air, etc.

Energy usage by processes: This is one of the major opportunities for improvement and

many of them are hidden. #rocess analysis is a useful tool for process integration measures

that can greatly improve energy efficiency.

Tecnica! and economic feasibi!ity

Technical feasi*ility assessment should address the following issues:

Technology availa*ility, space, s/illed manpower, relia*ility, service, etc.

The impact of energy efficiency measures on safety, 1uality, production, or process

Maintenance re1uirements and availa*ility of spare parts and components

+conomic via*ility often *ecomes the /ey parameter for acceptance *y top

management. The economic analysis can *e conducted *y using a variety of methods.

+4amples include #ay*ac/ method, $nternal Eate of Eeturn method, Det #resent Falue

method, etc. "or low investment, short0duration measures, which have attractive economic

via*ility, the simplest of the methods 7 pay*ac/ 7 is usually sufficient. ) sample wor/sheet

for assessing economic feasi*ility is provided *elow:

+amp!e 4or5seet for Economic 3easibi!ity

Energy Efficiency Measure:

1. (nvestment

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+1uipment

ivil wor/s

$nstrumentation

)u4iliaries

2. Annua! operating cost

ost of capital

Maintenance

Manpower

+nergy

5epreciation

#. Annua! savings

Thermal energy

+lectrical energy

Eaw material

aste disposal

'!assification of Energy 'onservation Measures

Gased on the energy audit and analysis of the plant, a num*er of potential energy

saving projects may *e identified. These may *e classified into three categories:

%. How cost 7 high return

2. Medium cost 7 medium return

;. Cigh cost 7 high return

Dormally the low cost 7 high return projects receive priority. Other projects have to *e

analyed, engineered, and *udgeted for implementation in a phased manner. #rojects

relating to energy cascading and process changes almost always involve high costs coupled

with high returns, and may re1uire careful scrutiny *efore funds can *e committed. These

projects are generally comple4 and may re1uire long lead times *efore they can *e

implemented. Eefer to Ta*le %.2 for project priority guidelines.

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Da$tar %ustaka

Shigeo Takenaka, Working Manual on Energy Auditing in Industry, &sian

%roducti'ity (rgani)ation *&%(+, 2##

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Modul Audit Energi [TM2]