INDUSTRIAL ENERGY AUDITING AND REPORTING

VIGNESH SBTG-12-037

INDUSTRIAL ENERGY AUDITING & REPORTING08/12/15 – TUESDAY

Introduction to Industrial Energy Efficiency Assessments

Types of Energy Audits Comprehensive Approaches Process flow diagrams Energy Audit Feasibilities Energy Audit Report Conclusion References

NEED FOR EA IN AN INDUSTRY

In any industry, the three top operating costs are often found to be energy (both electrical and thermal), labour and materials

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.

TYPES OF EA & IT’S 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:

I. Preliminary Audit

II. Targeted Energy Audit

III. Detailed Audit

INDUSTRIAL ENERGY EFFICIENCY ASSESSMENTS

AS PER EC ACT 2001 Industrial Energy Audit is defined as the verification, monitoring and analysis of energy use including submission of technical report containing all the recommendations for improving energy efficiency with cost analysis and an action plan to reduce consumption

Current situationRecommendations for improving energy

efficiencyCost-benefit analysis of recommended options

an action plan

PRELIMINARY AUDIT

Establish energy consumption in the organization Obtain related data such as production for relating with energy consumption

Estimate the scope for energy savings Identify immediate improvements/savings in an industry Identify the most likely and the easiest areas for attention Set up baseline or reference point for energy consumption Identify areas for more detailed study/measurement

TARGETED ENERGY AUDIT

Provide data and detailed analysis on specified projects.

For example, an organization may target its Lighting system/Steam 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 EA

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.

In carried out in three phases

I. Pre Audit Phase

II. Audit Phase

III. Post Audit Phase

AUDIT PHASE – I PRE-AUDIT PHASE

During pre-audit phase the following observations/inspection were completed within two days as per the schedule

Usage of machines and equipments in industries

AUDIT PHASE- II PRE-AUDIT PHASE

Depending on the nature and complexity of the site, a comprehensive audit can take from several weeks to several months to complete. Detailed studies to establish, and investigate, energy and material balances for specific plant departments or items of process equipment are carried out.

The audit report will include a description of energy inputs and product outputs by major department or by major processing function, and will evaluate the efficiency of each step of the manufacturing process.

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.

IDENTIFICATION OF ENCON

Fuel substitution : Identifying the appropriate fuel for efficient energy conservation

Energy Generation : Identifying efficiency opportunities in energy conversion equipment for high efficient electrical systems

Energy Distribution : Identifying efficiency opportunities in electrical systems.

Energy usage : Where the major opportunity for improvement lies. This analysis is a useful tool for integration.

TECHNICAL FEASIBILITY

Technology availability, space, skilled manpower etc

The impact of energy efficiency measure on safety, quality, production or process.

Reliability, services issues, maintenance requirements and spares availability.

ECONOMIC FEASIBILITY

Economic viability often becomes the key parameter for the management acceptance. The economic analysis can be conducted by using Payback method, Internal Rate of return, Net Present Value…etc

For low investment short duration measures, which have attractive economic viability, payback method is sufficient.

ENERGY AUDIT REPORT

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.

Audit report should conclude with specific recommendations for detailed engineering studies and feasibility analysis

CONCLUSION

• To minimize the electricity supply through non-renewable and electricity demand gap the best solution is to conduct is energy audit of all industries on regular bases

• The energy audit will determine energy wastage and losses, and provide techniques and ways to minimize the losses. The energy consumption techniques suggested by the energy audit will not only minimize the losses but also reduce electricity bill

REFERENCE

Energy Audit of an Industry, Dr S. Chatterji, Dr. (Mrs.) Lini

Industrial Energy Efficiency Assessments - Lynn Price

http://www.energy.wsu.edu/industry/research.htm

http://www.oit.doe.gov/pdfs/bestpractices.pdf

THANK YOU