GENERAL_ASPECTS_OF_ENERGY_MANAGEMENT_AND_ENERGY_AUDIT
(CHAPTER 4:ENERGY MANAGEMENT AND AUDIT)
Definition and 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 definition of energy management is:
“The judicious and effective use of energy to maximize profits (minimize costs) and enhance competitive positions” (or)
“The strategy of adjusting and optimizing energy, using systems and procedures so as to reduce energy requirements per unit of output while holding constant or reducing total costs of producing the output from these systems”
The objectives of Energy Management include,
1.To achieve and maintain optimum energy procurement and utilisation, throughout the organization
2.To minimise energy costs / waste without affecting production and quality
3. To minimise environmental effects.
Successful energy management must combine an effective strategy with the right practical action.It begins with the key decision makers, and then involves every employee on a day-to-day basis. Many organisations would like to save energy, but to have the most impact and success, they need to give priority to energy management and make it an integral part of company management strategy.
Energy Audit Definition
Energy Audit is the key to a systematic approach for decision-making in the area of energy management.It attempts to balance the total energy inputs with its use, and serves to identify all the energy streams in a facility. It quantifies energy usage according to its discrete functions. Industrial Energy Audit is fundamental to a comprehensive energy management programme and is defined in EC Act 2001 as follows:
“Energy Audit” means the verification, monitoring and analysis of use of energy including submission of technical report containing recommendations for improving energy efficiency with cost benefit analysis and an action plan to reduce energy consumption.
Need for Energy Audit
In any industry, the three top operating costs are often found to be energy (both electrical and thermal), labour and materials. Among the three, energy has the highest potential for cost reduction. Energy audit will help to understand more about the ways energy is used in the industry, and help in identifying the areas where waste can occur and where scope for improvement exists. Such an audit programme will review variations in energy costs, availability and reliability of supply of energy, decide on appropriate energy mix, identify energy conservation technologies, retrofit for energy conservation equipment etc.
In general, energy audit is the translation of conservation ideas into realities, by evolving technically feasible solutions with economic and other organizational considerations within a specified time.
Types of Energy Audit and Approach
The type of energy audit to be performed depends on the type of industry, the depth to which final audit is needed, and the potential and magnitude of cost reduction desired. Thus energy audit can be classified into the following types: Preliminary Audit, Targeted Energy Audits and Detailed Audit.
Preliminary Energy Audit
Preliminary energy audit, which is also known as Walk-Through Audit and Diagnostic Audit, is a relatively quick exercise and uses existing, or easily obtained data. The scope of preliminary energy audit is to:
¢ Establish energy consumption in the organization (sources: energy bills and invoices)
¢ Obtain related data such as production for relating with energy consumption
¢ Estimate the scope for energy savings
¢ Identify the most likely and the easiest areas for attention (e.g. unnecessary lighting, higher
temperature settings, leakage etc.)
¢ Identify immediate (especially no-/low-cost) improvements/ savings
¢ Set up a baseline or reference point for energy consumption
¢ Identify areas for more detailed study/measurement
Some example of no-cost energy management measures are:
¢ Arresting leaks (steam, compressed air)
* Controlling excess air by adjusting fan damper
Some examples of low-cost energy management measures are:
¢ Shutting equipment when not needed (e.g. idle running of motors)
¢ Replacement with appropriate lamps and luminaires
Areas for detailed study/measurement are:
¢ Converting from direct to indirect steam heated equipment and recovery of condensate
¢ Installing / upgrading insulation on equipment
¢ Modifying process to reduce steam demand
¢ Investigating scheduling of process operations to reduce peak steam or water demands
e Evaluating waste heat streams for potential waste heat recovery
Targeted Energy Audits
Targeted energy audits often results from preliminary audits. They provide data and detailed analysis on specified target projects. For example, an organization may target its lighting system or boiler system or steam system or compressed air system with a view of effecting energy savings. Targeted audits therefore involve detailed surveys of the target subjects and analysis of the energy flows and cost associated with the targets. Final outcome is the recommendations regarding actions to be taken.
Detailed Energy Audit
Detailed energy audit is a comprehensive audit and results in a detailed energy project implementation plan for a facility, since it accounts for the energy use of all major equipment. It considers the interactive effects of various projects and offers the most accurate estimate of energy savings and cost. It includes detailed energy cost saving calculations and project implementation costs.
One of the key elements in a detailed energy audit is the energy balance. This is based on an inventory of energy-using systems, assumptions of current operating conditions, measurements and calculations of energy use.
Detailed energy auditing is carried out in three phases: a) Pre Audit Phase b) Audit Phase and c) Post Audit Phase. A comprehensive ten-step methodology for conducting detailed energy audit is suggested as follows. However, methodology is flexible and can be adapted depending upon the industry concerned.
Ten Steps Methodology for Conducting Detailed Energy Audit
Phase I — Pre Audit Phase
An initial study of the site should always be carried out as proper planning is a pre-requisite for an effective audit. An initial site visit should take only one day and gives the Energy Auditor an opportunity
to meet the personnel concerned, to familiarize with the site and to assess the procedures necessary to carry out the energy audit.
¢ During the initial site visit the Energy Auditor/Engineer should carry out the following actions:
¢ Discuss with the site’s senior management about the aims of the energy audit.
¢ Explain the purpose of the audit and indicate the kind of information needed during the facility tour
¢ Discuss economic guidelines associated with the recommendations of the audit.
¢ Analyze the major energy consumption data with the relevant personnel.
¢ Obtain site drawings where available — plant building layout, steam distribution, compressed air distribution, electricity distribution etc.
¢ Tour the site accompanied by site representative.
The outcome of this visit should be:
¢ To finalise Energy Audit team
¢ To know the expectation of management from the audit
¢ To identify the main energy consuming areas/plant items to be surveyed during the audit.
¢ To identify existing instrumentation and additional metering required prior to audit e.g. for measurement of electricity, steam, oil or gas consumptions
¢ To plan for audit with time frame
¢ To collect macro data on plant energy resources, major energy consuming equipments
¢ To build up awareness and support for detailed energy audit
Phase II — Detailed Energy Audit Phase
Depending on the nature and complexity of the site, a detailed audit can take from several weeks to several months to complete. Detailed studies would involve investigation and establishment of material and energy balances for specific plant departments or process equipment. Whenever possible, checks of plant operations are carried out over extended periods of time, at night and at weekends as well as during normal daytime working hours, to ensure that nothing is overlooked.
The information to be collected during the detailed audit includes:
1. Sources of energy supplies (e.g. electricity from the grid or self-generation)
2.Energy cost and tariff data
3.Generation and distribution of site services (e.g. compressed air, steam, water, chilled water).
4.Process and material flow diagrams
5.Material balance data (raw materials, intermediate and final products, recycled materials, use of
scrap or waste products, production of by-products for re-use in other industries, etc.)
6.Energy consumption by type of energy, by department, by major process equipment, by end-use
7.Potential for fuel substitution, process modifications, and the use of co-generation system
8.Review of ongoing energy management procedures and energy awareness training programs.
Energy audit team should ensure that the following baseline data are collected:
1. Quantity and type of raw materials
2. Technology, process used and equipment used
3.Capacity utilization
4. Efficiencies / yield
5. Percentage rejection / reprocessing
6. Quantity and types of wastes
7. Consumption of fuel, water, steam, electricity, compressed air, cooling water, chilled water
Energy auditor must specially interview the supervisors and equipment operators as they have information related to the equipment. Maintenance manager is often the primary person to talk about types of lighting, lamps, sizes of motors, A/c plant and electrical load and related performance problems.
Preparing Process Flow Diagram
An overview of unit operations, important process steps, material and energy use and waste generation is then assembled in the form of process flow diagram. Information from existing drawings, records and shop floor survey will help in preparing the flow chart. Simultaneously the team should identify the various inputs and output streams at each process step. A typical example of flowchart of Penicillin-G manufacturing is given in the Figure 4.1.
It may be noted that waste stream (Mycelium) and obvious energy wastes such as condensate drained and steam leakages have been identified in this flow chart. The audit focus will depend upon consumption of input resources, energy efficiency potential, impact of process step on entire process or intensity of waste generation / energy consumption. In case of Penicillin-G manufacturing, the unit operations such as germinator, pre-fermentor, fermentor and extraction are the major energy conservation potential areas identified.
Identification of ENCON Opportunities
Fuel substitution: Identifying the appropriate fuel for efficient energy conversion
Energy Generation: Identifying efficiency opportunities in energy conversion equipment/utility such as feasibility for high efficient DG sets, optimal loading of DG sets, boiler optimization - minimum excess air combustion with boilers / thermic fluid heating, optimising existing efficiencies, efficient energy conversion equipment, biomass gasifiers, Cogeneration etc.
Energy Distribution: Identifying efficiency opportunities in electrical systems such as transformers, cables, switchgears and power factor improvement in electrical systems and chilled water, cooling water, hot water, compressed air, etc.
Energy Usage by Processes: This is where the major opportunity for improvement lies and many of them are hidden. Process analysis is a useful tool for process integration measures.
Technical and Economic Feasibility
The technical feasibility should address the following issues:
¢ Technology availability, space, skilled manpower etc
¢ The impact of energy efficiency measure on safety, quality, production or process.
¢ Reliability, service issues, maintenance requirements and spares availability
The Economic viability often becomes the key parameter for the management acceptance. The economic analysis can be conducted by using Pay back method, Internal Rate of Return method, Net Present Value method etc. For low investment short duration measures, which have attractive economic viability, payback method is sufficient. A sample worksheet for assessing economic feasibility is provided below:
Worksheet for Economic Feasibility
Classification of ENCON Measures
The potential energy saving measures (ENCON) may be classified into three categories:
(a) Low cost — high return
(b) Medium cost — medium return
(c) High cost — high return
Normally the low cost — high return projects receive priority. Other projects have to be analyzed, engineered and budgeted for implementation in a phased manner, Projects relating to equipment and process changes almost always involve high costs coupled with high returns, and required careful scrutiny before funds can be committed. They are complex and need long lead times before they can be implemented. Refer Table 4.1 for project priority guideline.
Energy Audit Report
The length and detail of energy audit report will depend upon the facility audited. The report should begin with an executive summary that provides the management of the audited facility with brief synopsis of the total savings and highlight of each energy saving measure. Executive summary should be tailored to non-technical personnel. The reader who understands the report is more likely to implement the recommended ENCON measures.
The main report should start with general description of the process or facility. Then annual energy consumption and bills should be presented with tables and graphs. This should be followed by description of energy inputs and outputs by major department or by major process and evaluation of efficiency of each step in the process. Then recommended ENCON measures should be presented with calculations for cost and benefits along with expected payback on any capital investment. The audit report should conclude with specific recommendations for detailed engineering studies and feasibility analyses, which must then be performed to justify the implementation of those conservation measures that require high investments. Regardless of the audience for the audit report, it should be written in a clear, concise and easy to understand format and style.
The following worksheets (refer Table 4.2 & Table 4.3) can be used as guidance for energy audit assessment and reporting in Executive Summary. Table 4.4 shows the reporting format for energy conservation recommendations in the main report.
Phase III-Post Audit Phase
On completion of energy audit, energy action plan should be prepared. The energy action plan list the
ENCONSs which should be implemented first, and suggest an overall implementation schedule. Energy audit is incomplete without monitoring and its associated feedback. Monitoring consist of collecting and interpreting data. The data to be collected depends upon goals chosen in the energy action plan. Electrical power consumption and fuel consumption must be evaluated and monitored. The monitoring data should provide direct feedback to those most able to implement the changes. Often additional instruments should be installed in various departments in addition to main metering.
Monitoring should result in more action. Good practices should be replicated. If the gap between planned objectives and actual achievements is large, reasons should be analyzed and new objectives, new actions should be initiated and results should be monitored. In this way, analysis, action and monitoring are a cyclic process.
Understanding Energy Costs
Contrary to common belief, energy costs are not a fixed overhead, there is often a huge potential for making savings. Understanding energy cost is vital factor for awareness creation and saving calculation.
In many industries sufficient meters may not be available to measure all the energy used. In such cases,
invoices for fuels and electricity will be useful. The annual company balance sheet is the other sources
where fuel cost and power are given with production related information.
Energy invoices can be used for the following purposes:
¢ They provide a record of energy purchased in a given year which gives a baseline for future reference
e Energy invoices may indicate the potential for savings when related to production requirements or to air conditioning requirements/space heating etc.
¢ When electricity is purchased on the basis of maximum demand tariff
e They can suggest where savings are most likely to be made.
¢ In later years invoices can be used to quantify the energy and cost savings made through energy conservation measures.
Fuel Costs
A wide variety of fuels are available for thermal energy supply. Some of the fuels are listed below:
¢ Fuel oil
¢ Low Sulphur Heavy Stock (LSHS)
¢ Light Diesel Oil (LDO)
¢ Liquefied Petroleum Gas (LPG)
¢ Coal
¢ Lignite
¢ Wood etc
Understanding fuel cost is fairly simple and it is purchased in Tons or Kiloliters. Availability, cost and quality are the main three factors that should be considered while purchasing. The following factors should be taken into account during procurement of fuels for energy efficiency and economics.
* Price at source, transport charge, type of transport
* Quality of fuel (contaminations, moisture etc)
* Energy content (calorific value)
Power Costs
Electricity price in India not only varies from State to State, but also city to city and consumer to
consumer though it does the same work everywhere. Many factors are involved in deciding final cost
of purchased electricity such as:
¢ Maximum demand charges, kVA
(i.e. How fast the electricity is used?)
¢ Energy Charges, kWh
(i.e. How much electricity is consumed?)
¢ TOD Charges, Peak/Non-peak period
(i.e. When electricity is utilized ?)
¢ Power factor Charge, P.F
(i.e., Real power use versus Apparent power use factor)
¢ Other incentives and penalties applied from time to time
¢ High tension tariff and low tension tariff rate changes
¢ Slab rate cost and its variation
¢ Type of tariff clause and rate for various categories such as commercial, residential, industrial, Government, agricultural, etc.
¢ Tariff rate for developed and underdeveloped area/States
¢ Tax holiday for new projects
Benchmarking
Benchmarking can be a useful tool for understanding energy consumption patterns in an industrial sector and for taking measures to improve energy efficiency. Energy benchmarking for industry is a
process in which the energy performance of an individual plant or an entire sector of similar plants is compared against a common metric that represents ‘standard’ or ‘optimal’ performance. It may also entail comparing the energy performance of a number of plants against each other. Benchmarking forms the basis for monitoring and target setting
Since benchmark tool is used for comparison across a number of plants or sectors, there are two important features they should have. First, because they are applied to plants or sectors of different
sizes and outputs, the metric used should be common irrespective of plant size. The most common
metric used is energy intensity which measures ‘energy use per unit of output’. Second, the tool should
be used in a wide range of facilities so as to compensate for differences in production at similar facilities.
Industrial Benchmarking Programs
There are three approaches for energy benchmarking. The first approach is to evaluate an entire industrial sector, such as iron and steel, aluminum, cement, etc. This evaluation is used to answer the following questions: How well is this sector performing compared to how it would perform using the best available technologies? How well is it performing compared to the same sector in other countries? Has the sector been improving over time?
The second approach is the comparison of individual plants within a sector. A benchmark-type indicator is calculated for all the facilities within a sector so that they can be compared on even terms. This evaluation can answer the following questions: What is the state-of-the-art performance in this given sector? How does my plant compare against the state-of-the-art? How does it compare against the majority of other plants in the sector? In developing benchmarks at the level of individual plants, the issue of proprietary data becomes important. Individual companies are very reluctant to disclose information about their production processes, particularly if it will be released to their competitors. It is important that the indicators developed are general enough not to reveal any proprietary information and that a credible system is established that encourages plants to trust the process.
The third approach for energy benchmarking that has been seen widely in recent years is for large companies to set themselves energy efficiency goals by using historical best performance as benchmark.
Companies use this approach to set targets for reducing energy use by certain percentages over given time frames. Companies do not need to reveal any proprietary information, since the benchmarking is done internally.
Steps in energy conservation benchmarking are summarized below:
¢ Identify the best available technology for the individual process units.
¢ Collect information to thoroughly understand the process and identify key/controlling parameters.
¢ Determine the performance of the process unit.
¢ Analyse the gap between the existing and the benchmark for the key controlling parameters.
e Set targets or benchmarks, keeping constraints in view, and implement improvements based on the findings
The benchmark parameters for various sectors are given as follows:
¢ Gross Production Related
kWh/MT clinker or cement produced (Cement plant)
kWh/kg yarn produced (Textile unit)
kWh/MT, kcal/kg paper produced (Paper plant)
kcal/kWh Power produced (Heat rate of a power plant)
Million Calories/MT Urea or Ammonia (Fertilizer plant)
kWh/MT of liquid metal output (in a foundry)
Equipment / Utility Related
kWh/ton of refrigeration (on Air-conditioning plant)
% thermal efficiency of a boiler plant
% cooling tower effectiveness in a cooling tower
kWh/Nm; of compressed air generated
kWh/litre in a diesel power generation plant.
While such benchmarks are referred to, related crucial process parameters need to be stated for meaningful comparison among similar industries. For instance, in the above case:
1.For a cement plant — type of cement, blaine number (fineness) i.e. Portland and process used (wet/dry) are to be reported alongside kWh/MT figure.
2.For a textile unit — average count, type of yarn 1.e. polyester/cotton, is to be reported along side kWh/kg figure.
3.For a paper plant — paper type, raw material (recycling extent), GSM quality are some important factors to be reported along with kWh/MT, kcal/kg figures.
4.For a power plant / cogeneration plant — plant % loading, condenser vacuum, inlet cooling water temperature, would be important factors to be mentioned alongside heat rate (kcal/kWh).
5.For a fertilizer plant — capacity utilization(%) and on-stream factor are two inputs worth comparing while mentioning specific energy consumption
6.For a foundry unit — melt output, furnace type, composition (mild steel, high carbon steel/cast iron etc.) raw material mix, number or power trips could be some useful operating parameters to be reported while mentioning specific energy consumption data.
7.For an A/C plant — parity of chilled water temperature level is crucial while comparing kW/TR.
8.For a boiler plant — fuel quality, type, steam pressure, temperature, flow are useful comparators alongside thermal efficiency and more importantly, whether thermal efficiency is on gross calorific value basis or net calorific value basis or whether the computation is by direct method or indirect heat loss method, mean a lot in benchmarking exercise for meaningful comparison.
9.For a cooling tower - Effectiveness — ambient air wet/dry bulb temperature, relative humidity, air and circulating water flows are required to be reported to make meaningful sense.
10.For a compressed air system - specific power consumption — is to be compared at similar inlet air temperature and pressure of generation.
11.Diesel power plant performance — is to be compared at similar loading %, steady run condition.
Energy Performance
Plant Energy Performance
Plant energy performance (PEP) is the measure of whether a plant is now using more or less energy to manufacture its products than it did in the past: a measure of how well the energy management programme is doing.
Plant energy performance monitoring compares plant energy use of a reference year and the subsequent years considering production output to determine the improvement (or deterioration) that has been made.
However, since the plants’ production output varies from year to year, it has significant impact on plant’s energy use. For a meaningful comparison it is necessary to determine the energy that would have been required to produce current year’s production output had the plant operated in the same way as it did during the reference year. This calculated value can then be compared with the actual value to determine the improvement or deterioration that has taken place since the reference year.
Production Factor
Production factor is the ratio of production in the current year to that in the reference year.
Production factor is used to determine the energy that would have been required to produce this year’s production output if the plant had operated in the same way as it did in the reference year.
Reference Year Equivalent Energy Use
The reference year's equivalent energy use (or reference year equivalent) is the energy that would
have been used to produce the current year’s production output.
The reference year equivalent is obtained by multiplying the reference year energy use by the production factor (obtained above)
Reference year equivalent = Reference year energy use x Production factor
Plant Energy Performance is the improvement or deterioration from the reference year. It is a measure of plant’s energy progress.
The energy performance is the measure of energy saved at the current rate of use compared to the reference year rate of use. The greater the improvement, the higher the number will be.
Plant energy performance (PEP) is the starting point for evaluating energy performance. It does not require detailed calculations of the energy used by every place of equipment, the energy use of every process or the energy use of buildings. It utilizes the most effective measure of energy savings, the actual measurement of energy consumption compared to production output. Yearly comparisons minimize seasonal effects.
Sometimes, once a plant has started measuring yearly energy performance, management wants more frequent performance information in order to monitor and control energy use on an on-going basis. In such cases PEP can just as easily be used for monthly reporting as yearly reporting.
Matching Energy Usage to Requirement
Mismatch between equipment capacity and user requirement often leads to energy inefficiencies due to part load operations, wastages etc.
The designer always considers safety margins while laying specifications for new equipment leading to oversized equipment. This presents opportunity for energy manager for matching the equipment capacity with user requirement. Some examples for matching energy usage to requirements are listed below:
¢ Eliminating throttling of a pump by impeller trimming, installing variable speed drives and resizing pump
¢ Eliminating damper operations in fans by impeller trimming, installing variable speed drives, pulley diameter modification for belt drives, fan resizing for better efficiency.
¢ Moderating chilled water temperature as per process chilling needs
e Recovering energy lost in control valve pressure drops with back pressure turbine adoption
¢ Adopting of task lighting in place of less effective area lighting
Maximizing System Efficiencies
Once the energy usage and sources are matched properly, the next step is to operate the equipment efficiently through best operation and maintenance practices and adoption of best available technology, if feasible. Some examples are:
¢ Eliminating steam leakages by using appropriate steam traps
e Maximising condensate recovery
¢ Adopting combustion controls for maximizing combustion efficiency
¢ Replacing pumps, fans, air compressors, refrigeration compressors, boilers, furnaces, heaters and other energy conservation equipment, wherever significant energy efficiency margins exist
¢ Ensuring rated electrical parameters at the motor terminals
Optimising Input Energy Requirements
After fine-tuning the energy use practices, attention should be given for minimizing energy input
requirements. The measures include:
¢ Maximising heat recovery from waste energy streams, to minimize purchased energy
¢ Adopting cogeneration plants for balancing heat and power requirements, leading to reduced energy purchases
¢ Adopting cost effective renewable sources of energy such as solar, wind and biomass energy
Fuel and Energy Substitution
Fuel substitution is basically substituting existing fossil fuel with more efficient and less cost/less
polluting fuel such as natural gas, biogas and locally available agro-residues.
Fuel substitution has taken place in all the major sectors of the Indian economy.
Few examples of fuel substitution
e Natural gas is increasingly the fuel of choice as fuel and feedstock in the fertilizer, petrochemicals,
power and sponge iron industries.
¢ Replacement of coal by coconut shells, rice husk etc.
¢ Replacement of LDO by LSHS
There are two ways to reduce energy dependency; energy conservation and substitution.
Few examples of energy substitution
1. Replacement of electric heaters by steam heaters
2. Replacement of steam based hot water by solar systems
Case Study: Example on Fuel Substitution
A textile process industry replaced old fuel oil fired thermic fluid heater with agro fuel fired heater.
The economics of the project are given below:
Instruments and Metering For Energy Audit
The requirement for an energy audit is to identify and quantify where energy is being used necessitates measurements. These measurements require the use of instruments. The basic instruments used in energy audit work are listed below. These instruments are portable, durable, easy to operate and relatively inexpensive. Key Performance Parameters for Energy Audit
Basic Electrical Parameters in AC & DC systems — Voltage (V), Current (1), Power factor,
Active power (kW), Maximum demand (kVA), Reactive power (kVAr), Energy consumption (kWh),
Frequency (Hz), Harmonics, etc.
Parameters of importance other than electrical such as Temperature and Heat Flow, Radiation , Air
and Gas Flow, Liquid Flow, RPM , Air Velocity, Noise and Vibration, Dust Concentration, TDS, PH,
Moisture Content, Relative Humidity, Flue Gas Analysis — CO2, O2, CO, SOx, NOx, Combustion
Efficiency etc.
Some of the instruments commonly used in an energy audit are described as follows.
Bureau of Energy Efficiency (the manner and intervals of time for conduct of energy audit) Regulations, 2008
Intervals of time for conduct of energy audit
(1) Every designated consumer shall have its first energy audit conducted, by an accredited energy
auditor within 18 months of the notification issued by the Central Government
(2) The interval of time for conduct and completion of subsequent energy audits shall be three
years with effect from the date of submission of the previous energy audit report by the
accredited energy auditor to the management of the designated consumer.
Manner of energy audit
1. Verification of data of energy use
a) Verify the information submitted to the designated agency under the Energy Conservation
(the form and manner for submission of report on the status of energy consumption by the
designated consumers) Rules, 2007 for the previous two years
b) Establish specific energy consumption for the year referred to in clause (a);
c) Disaggregate the energy consumption data and identify major energy using equipment, processes and systems.
2. Scope of energy audit
The accredited energy auditor jointly with the energy manager of the designated consumer shall-
(a) Develop a scope of work for the conduct of energy audit with a view to ensuring adequate coverage in terms of the share of total energy use
(b) Select energy intensive equipment or processes for energy auditing;
(c) Agree on best practice procedures on measuring the energy efficiency performance of selected equipment and on methodology to estimate energy performance and energy savings;
(d) Collect energy consumption, and production data for the equipment and processes covered within the scope of energy audit, operating data, and schedule of operation, non proprietary process flow charts, and production level disaggregated by product, if applicable, and other related historical data essential by the accredited energy auditor for achieving the purpose of energy audit.
3. Monitoring and analysis of the use of energy data for energy audit
The accredited energy auditor shall-
(a) Verify the accuracy of the data collected in consultation with the energy manager as per standard practice to assess the validity of the data collected;
(b) Analyse and process the data with respect to-
(i) Consistency of designated consumers’ data monitoring compared to the collected data;
(ii) Recommendations to reduce energy consumption and improve energy efficiency;
(iii) Summary overview of energy consumption in plant by fuel type and by section;
(c) Conduct equipment energy performance measurements with due diligence and caution.
4.Preparation of recommendations on energy saving measures, their cost benefit analysis
The accredited energy auditor having regard to the overall efficiency of the production process, technoeconomic viability of energy saving measures, site conditions and capacity of the designated consumer to invest for their implementation, shall prepare a list of recommendations to save energy and the list shall include:
(a) A brief description of each recommended measure
(b) The estimated energy saving as well as energy cost reduction potential over a reasonable technical or economic life of the measure;
(c) Any known or expected technical risks associated with each measure;
(d) A preliminary assessment of the financial attractiveness of each measure or assessment of the maximum investment feasible based on the estimated energy cost saving potential over the life of the measure;
(e) Tabulated summary of recommendations listed as per their implementation schedule (short, medium and long term);
(f) Where different alternatives for implementation of an energy efficiency measure are available, the accredited energy auditor shall examine and discuss such options and recommend the techno-financially better option;
(g) Where the installation or implementation of any recommended energy saving measure affects procedures for operation and maintenance, staff deployment and the budget, the recommendation shall include discussion of such impacts including their solutions.
Prioritization and preparation of action plan
(1) The accredited energy auditor jointly with the energy manager shall select from the energy audit report such recommended measures which in the opinion of the designated consumer are technically viable, financially attractive and within its financial means, prioritise them and prepare plan of action for their implementation. This action plan shall include-
(a) Preparation of detailed techno-economic analysis of selected measures;
(b) A monitoring and verification protocol to quantify on annual basis the impact of each measure with respect to energy conservation and cost reduction for reporting to Bureau and the concerned State designated agency;
(c) A time schedule agreed upon by the designated consumer of selected measures taking into consideration constraints such as availability of finance and availability of proposed equipment.
(2) The accredited energy auditor based on the activities undertaken under sub-regulation (4) of regulation 4 and regulation 5 shall submit a report in Form 2 to the management of designated consumer.
(3) The accredited energy auditor shall evaluate the implementation of each recommended energy saving measure in the previous audit report and submit a report in Form 3 to the management of the designated consumer.
Structure of the energy audit report
(1) The energy audit report structure shall be jointly decided by the accredited energy auditor and designated consumer.
(2) The energy audit report shall highlight, details of specific energy consumption, list of recommendations to reduce energy consumption and costs, monitoring and evaluation of impact of selected measures and conclude with certification by accredited energy auditor stating that -
a) The data collection has been carried out diligently and truthfully.a)
b) All data monitoring devices are in good working condition and have been calibrated or certified by approved or authorized agencies and no tempering of such devices have occurred.
c) All reasonable professional skill, care and diligence have been taken in preparing the energy audit report and the contents thereof are a true representation of the facts.
d) Adequate training provided to personnel involved in daily operations after implementation of recommendations.
e) The energy audit has been carried out in accordance with the Bureau of Energy Efficiency (the manner and intervals of time for conduct of energy audit) Regulation, 2008.
3)The accredited energy auditor shall highlight the strengths and weaknesses of the designated consumer in the management of energy and energy resources in the energy audit report and recommend necessary action to improve upon method of reporting data, energy management system in detail along with their underlying rationale, and improving energy efficiency and reducing energy consumption of the designated consumer.
4)The accredited energy auditor shall sign the energy audit report under the seal of its firm giving all the accreditation details along with details of manpower employed in conducting the energy audit.
5) The energy audit report shall include a work schedule sheet duly signed by accredited energy auditor and energy manager of the designated consumer.
Solved Example:
An Energy Manager in a factory has gathered following data to arrive at the Plant Energy Performance.
Reference Year (2009) energy use : 12 million kcal
Production Factor (PF) for the current year (2010) : 0.9
Current year’s energy : 11 million kcal
What is the Plant energy Performance (PEP) of the factory for the year 2010? State your inference.
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Chaptert 5
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