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Energy Audit -Types ,Instruments, reporting
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- 3. Outline • Need ofEnergy Audit • Types of energy audit • Energy audit methodology • Instruments, equipment used in energy audit • Analysis and recommendations of energy audit • Benchmarking • Energy audit reporting • Introduction to software and simulation for energy auditing • Current Energy Conservation Act and Electricity Act and its features
- 4. SPPU INSEM Questions 1.Explain the detailed Energy audit Methodology? 2. Explain preliminary energy audit and its importance ? 3. What is Energy Audit? What are different types of Energy Audit ? 4. Explain energy audit report format ? 5. What is energy audit and explain energy audit report format ? 6. List out instrument used in energy audit and explain any three ? 7. Elaborate the provisions of current energy conservation act ? 8. List out software used for energy auditing and elaborate the provisions of current energy conservation act ?
- 5. Energy Auditing Energy Audit:- It is the key to a systematic approach for the decision making in the area of the energy management. Energy Audit :- is fundamental comprehensive energy management programme. In the Indian Energy Conservation Act of 2001 (BEE 2008), an energy audit is defined as: “ Verification, monitoring and analysis of use of the energy including submission of the technical report containing recommendations for improving energy efficiency with cost benefit analysis and an action plan to reduce the
- 6. What is anEnergy Audit? • The energy audit is one of the first tasks to be performed in accomplishing an effective energy management program designed to improve the energy efficiency and reduce the energy operating costs of a facility. • An energy audit consists of a detailed examination of how a facility uses energy, what the facility pays for that energy, and finally, a recommended program for changes in operating practices or energy consuming equipment that will cost effectively save dollars on energy bills.
- 7. • The energyaudit is sometimes called an energy survey or an energy analysis, so that it is not confused with a financial audit. • The energy audit is a positive experience with significant benefits to the facility. • The term “audit” should be avoided if it clearly produces a negative image in the mind of a particular business, organization, or individual.
- 8. Need of EnergyAudit Three top operating expenses are 1. energy (both electrical and thermal), 2. labour 3. materials. •Energy would emerge as a top ranker for cost reduction •primary objective of Energy Audit is to determine ways to reduce energy consumption per unit of product output or to lower operating costs •Energy Audit provides a “ bench-mark” (Reference point) for managing energy in the organization
- 9. Objective of EnergyAudit • Assessing present pattern of energy consumption in different cost centers of operations • Relating energy inputs and production output • Identifying potential areas of thermal and electrical energy economy. • Highlighting wastage in major areas • Fixing of energy saving potential targets for individual cost centers • Implementation of measures of energy conservation and realization of sav ings. • To achieve and maintain optimum energy procurement and utilization, throughout the organization • To minimize energy costs / waste without affecting production & quality
- 10. Types of EnergyAudit 1. Preliminary Energy Audit 2. Targeted Energy Audit 3. Detailed Energy Audit Type of energy audit chosen depends on • Function and type of industry • Depth to which final audit is needed • Potential and magnitude of cost reduction desired
- 11. Preliminary Energy AuditMethodology 1) It is relatively quick exercise and uses existing or easily obtained area. 2) Established energy consumption in the organization (Energy Bill, Invoice ) 3) Obtained related data such as production for relating with energy consumption 4) Estimate scope of energy saving 5) Identify the most likely and easiest area for attention. 6) Identified immediate saving improvements. 7) Identified area for more detailed study measurements.
- 12. Targeted Energy Audit 1)Targeted Energy Audit often result from Preliminary Energy Audit. 2) They Provide data and detailed analysis on specified target project. 3) It involves detailed survey of the target subjects and analysis of the energy flow and cost associated with the target.
- 13. Detailed Energy Audit 1)Detailed Energy Audit is a comprehensive audit and the result in detailed energy project implementation plan. 2) It include detailed energy cost calculations, and project implementation cost. 3) Energy Balance 4) It based on inventory of energy using system assumptions, measurements and calculations. Evaluates all energy using system, equipment and include detailed energy savings and costs Carried out in 3 phases Pre-audit Phase Audit Phase Post-Audit
- 14. Ten Steps Methodologyfor Detailed Audit Step No PLAN OF ACTION PURPOSE / RESULTS Step 1 Phase I –Pre Audit Phase •Plan and organize visit •Walk through Audit •Informal Interview with Energy Manager, Production / Plant Manager • Resource planning, Establish/organize a Energy audit team • Organize Instruments & time frame • Macro Data collection (suitable to type of industry.) • Familiarization of process/plant activities • First hand observation & Assessment of current level operation and practices Step 2 • Conduct of brief meeting / awareness programme with all divisional heads and persons concerned (2-3 hrs.) • Building up cooperation • Issue questionnaire for each department • Orientation, awareness creation
- 15. Step No PLANOF ACTION PURPOSE / RESULTS Step 3 Phase II –Audit Phase •Primary data gathering, Process Flow Diagram, & Energy Utility Diagram • Historic data analysis, Baseline data collection • Prepare process flow charts • All service utilities system diagram (Example: Single line power distribution diagram, compressed air & steam distribution. • Design, operating data and schedule of operation • Annual Energy Bill and energy consumption pattern (Refer manual, log sheet, name plate, interview) Step 4 • Conduct survey and monitoring • Measurements: • Motor survey, Insulation, and Lighting survey with portable instruments for collection of more and accurate data. Confirm and compare operating data with design data.
- 16. Step 5 • Conductof detailed trials /experiments for selected energy guzzlers • Trials/Experiments: • 24 hours power monitoring (MD, PF, kWh etc.). • Load variations trends in pumps, fan • compressors etc. • Boiler/Efficiency trials for (4 – 8 hours) • Furnace Efficiency trials • Equipment’s Performance experiments etc. Step 6 • Analysis of energy use • Energy and Material balance & energy loss/waste analysis Step 7 • Identification and development of Energy Conservation (ENCON) opportunities • Identification & Consolidation ENCON measures • Conceive, develop, and refine ideas • Review the previous ideas suggested by unit personal • Review the previous ideas suggested by energy audit if any • Use brainstorming and value analysis techniques • Contact vendors for new/efficient technology
- 17. Step 8 •Cost benefit analysis • Assess technical feasibility, economic viability and prioritization of ENCON options for implementation • Select the most promising projects • Prioritise by low, medium, long term measures Step 9 • Reporting & Presentation to the Top Management • Documentation, Report Presentation to the top Management Step 10 Phase III –Post Audit phase •Implementation and Follow-up • Assist and Implement ENCON recommendation measures and Monitor the performance • Action plan, Schedule for implementation • Follow-up and periodic review
- 18. A) Preparation forenergy audit Defining the audit criteria Defining the audit scope Selection of energy audit team Making an audit plan Preparing an audit checklist Conducting the initial walk-through visit Collecting energy bills and available data and information Conducting the preliminary analysis B) Analyzing energy bills •Electricity bills •Calculating electricity use per day (kWh/day) •Calculating the Load Factor (LF) •Natural gas bills •Coal and fuel oil bills •Graphical analysis of historical energy use Energy audit methodology
- 19. Energy audit methodology C)Inventory and measurement of energy use The most common data measured during the auditing process are: •Liquid and gas fuel flows •Electrical measurements, such as the voltage, current intensity and power, as well as power factor •Temperatures of solid and liquid surfaces •Pressure of fluids in pipes, furnaces or vessels •Exhaust gases emissions (CO2, CO, O2 and smoke) •Relative humidity •Luminance levels •Electrical load inventory •Thermal energy use inventory •Energy system-specific measurements •Energy balance D) Analyzing energy use and production patterns •Load/Demand profile •Scatter diagram for presenting the dynamics of the energy-production relationship •Interpretation of energy-production data pattern on a scatter diagram
- 20. Energy audit methodology E)Benchmarking and comparative energy performance analysis F) Identifying energy efficiency and energy cost reduction opportunities •Electrical demand control •Cross-cutting energy-efficiency improvement options •Sector-specific energy-efficiency improvement opportunities for selected industrial sectors G) Cost-benefit analysis of energy-efficiency opportunities •Life-cycle cost analysis (LCCA) •Life cycle cost (LCC) method •Net present value (NPV) method •Internal rate of return (IRR) method •Simple payback period (SPP) method
- 21. H) Preparing anenergy audit report Some key issues that should be kept in mind while writing an audit report are: •The audit report should be written in a way that provides suitable information to the potential readers of the report which could be the CEO or plant manager, the supervisor of engineering or maintenance, and the plant shift supervisor. •The audit report should be concise and precise and use direct language that is easy to understand. •Use more graphs rather than tables for the presentation of data, results and trends. •The recommendation section should be specific, clear and with adequate detail. •Assumptions made in the analysis should be explained clearly. How changes in the key assumptions can influence the results should also be explained. A sensitivity analysis is a very helpful tool for this. •The auditors should do their best to avoid mistakes and errors in the report especially in the results. Even a few errors could damage the credibility of the audit. •The energy audit report should be consistent in structure and terminology used. •The calculations made in the analysis work should be explained clearly. I) Post-audit activities •Create an action plan for the implementation of energy-efficiency measures
- 22. Flowchart of Penicillin-Gmanufacturing • A flowchart of Penicillin-G manufacturing is given in the figure below. • Note 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 area depends on several issues like consumption of input resources, energy efficiency potential, impact of process step on entire process or intensity of waste generation / energy consumption. • In the above process, the unit operations such as germinator, pre-fermentor, fermentor, and extraction are the major conservation potential areas identified.
- 23. Drawing process flowdiagram -Identification of waste streams and obvious energy wastage
- 24. Information to becollected during the detailed audit includes: - 1. Energy consumption by type of energy, by department, by major items of process equipment, by end-use 2. 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.) 3. Energy cost and tariff data 4. Process and material flow diagrams 5. Generation and distribution of site services (eg. compressed air, steam). 6. Sources of energy supply (e.g. electricity from the grid or self- generation) 7. Potential for fuel substitution, process modifications, and the use of co-generation systems (combined heat and power generation). 8. Energy Management procedures and energy awareness training programs within the establishment
- 25. Information to becollected during the detailed audit Existing baseline information and reports are useful to get consumption pattern, production cost and productivity levels in terms of product per raw material inputs. The audit team should collect the following baseline data: – Technology, processes used and equipment details – Capacity utilisation – Amount & type of input materials used – Water consumption – Fuel Consumption – Electrical energy consumption – Steam consumption – Other inputs such as compressed air, cooling water etc – Quantity & type of wastes generated – Percentage rejection / reprocessing – Efficiencies / yield
- 26. DATA COLLECTION HINTS •Measurement systems should be – easy to use and provide the information to the accuracy that is needed, not the accuracy that is technically possible measurement equipment can be inexpensive (flow rates using a bucket and stopwatch) • the quality of the data must be such that the correct conclusions are drawn (what grade of product is on, is the production normal etc) • Define how frequent data collection should be to account for process variations. • Measurement exercises over abnormal workload periods (such as startup and shutdowns) • Design values can be taken where measurements are difficult (cooling water through heat exchanger)
- 27. Energy Audit Instruments BasicRequirements Energy Audit Instruments 1)The Instrument must be portable 2)Easy for Handling , Durable 3) Initial cost is very low 4)Maintenance cost is very low 5)Relatively inexpensive https://slideplayer.com/slide/13722022/ https://egyankosh.ac.in/bitstream/ 123456789/47554/1/Unit-2.pdf
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- 34. Benchmarking • Energy benchmarkingand auditing is a process that measures a building's energy performance over time and compares it to similar buildings. • Energy Benchmarking is a method used to determine whether a building is using more or less energy than its peer facilities with similar occupancies, climates, and sizes. Benchmarking is done by taking a buildings total energy use and dividing by the building's total area • Benchmarking can be a useful tool for understanding energy consumption patterns in the industrial sector and also to take requisite measures for improving energy efficiency. FACTORS INVOLVED: • Scale of operation • Vintage of technology • Raw material specifications and quality • Product specifications and quality
- 35. Benchmarking for energyperformance • Internal Benchmarking Historical and trend analysis • External Benchmarking Across similar industries Scale of operation, vintage of technology raw material specification quality and product specification and quality https://www.cim.io/blog/a-comprehensive-guide-to-energy-benchmarking-benefits-process-and-tools#What %20are%20the%20benefits%20of%20benchmarking%20energy%20consumption
- 36. Bench Marking EnergyPerformance •Quantification of fixed and variable energy consumption trends vis-à-vis production levels •Comparison of the industry energy performance w.r.t. various production levels •Identification of best practices (based on the external benchmarking data) •Scope and margin available for energy consumption and cost reduction •Basis for monitoring and target setting exercises Benchmarking parameters Gross production related •kWh/MT clinker or cement produced (cement plant) •kCal/kWh Power produced (Heat rate of a power plant) •Million kilocals/MT Urea or Ammonia (Fertilizer plant) Equipment / utility related • kWh/ton of refrigeration (on Air conditioning plant) • % thermal efficiency of a boiler plant • kWh/NM3 of compressed air generated • kWh /litre in a diesel power generation plant.
- 37. A TYPICAL INDUSTRIALREPORT FORMAT Energy Audit Reporting Format Acknowledgement Executive Summary –Scope &Purpose Energy Audit Options &Recommendations 1. Introduction about the plant •General Plant details and descriptions •Energy Audit Team •Component of production cost (Raw materials, energy, chemicals, manpower) •Major Energy use and Areas 2. Production Process Description •Brief description of manufacturing process •Process flow diagram and Major Unit operations •Major Raw material Inputs, Quantity and Costs 3. Energy and Utility System Description •List of Utilities •Brief Description of each utility -Electricity, Steam, Water, Compressed air, Chilled water, Cooling water
- 38. 4. Detailed Processflow diagram and Energy& Material balance • Flow chart showing flow rate, temperature, pressures of all input-Output stream • Water balance for entire industry 5. Energy efficiency in utility and process systems •Specific Energy consumption •Boiler efficiency assessment •Thermic Fluid Heater performance assessments •Furnace efficiency Analysis •Cooling water system performance assessment •DG set performance assessment •Refrigeration system performance •Compressed air system performance •Electric motor load analysis •Lighting system 6. Energy Conservation Options & Recommandations • List of options in terms of no cost, low cost, medium cost and high cost, annual energy savings •Implementation plan for energy saving measures/Projects ANNEXURE Al. List of instruments A2. List of Vendors and Other Technical details A3. List of Audit Worksheet
- 39. Types and priorityof energy saving measures Type of Energy Saving Options Annual Electricity /Fuel savings KWh/KL /T Annual Savings (Rs Lakhs) Priority A • No Investment (Immediate) • Operational Improvement • Housekeeping B • Low Investment (Short to Medium Term) • Controls • Equipment Modification • Process change C • High Investment (Long Term) • Energy efficient Devices • Product modification • Technology Change
- 40. Reporting Format forEnergy Conservation Recommendations A: Title of Recommendation Combine DG set cooling tower with main cooling tower B: Description of Existing System and its operation Main cooling tower is operating with 30% of its capacity. The rated cooling water flow is 5000 m3 /hr. Two cooling water pumps are in operation continuously with 50% of its rated capacity. A separate cooling tower is also operating for DG set operation continuously. C: Description of Proposed system and its operation The DG Set cooling water flow is only 240 m3 /h. By adding this flow into the main cooling tower, will eliminate the need for a separate cooling tower operation for DG set, besides improving the %loading of main cooling tower. It is suggested to stop the DG set cooling tower operation.
- 41. D: Energy SavingCalculations Capacity of main cooling tower = 5000 m 3 / hr Temp across cooling tower (design) = 8 o C Present capacity = 3000 m3 /hr Temperature across cooling tower(operating) = 4 o C % loading of main cooling tower = (3000 x 4)/(5000 x 8) = 30% Capacity of DG Set cooling tower = 240 m3 /hr Temp across the tower = 5o C Heat Load (240x1000 x 1x 5) = 1200,000 K.Cal/hr Power drawn by the DG set cooling tower No of pumps and its rating = 2 nos x 7.5 kW No of fans and its rating = 2 Nos x 22 kW Power consumption@ 80% load = (22 x2 +7.5 x2) x.80 = 47 kW Additional power required for main cooling tower for additional water flow of 240m3 /h (66.67 l/s) with 6 kg/cm2 = (66.67 x 6) / (102 x 0.55) = 7 kW Net Energy savings = 47 – 7 = 40 kW E: Cost Benefits Annual Energy Saving Potential = 40kWx 8400hr = 3,36,000 Units/Year Annual Cost Savings = 3,36,000 xRs.4.00 = Rs.13.4 Lakh per year Investment (Only cost of piping) = Rs 1.5Lakhs Simple Pay back Period = Less than 2 months
- 42. Introduction to softwareand simulation for energy auditing • Software and simulation for energy auditing refers to computer programs designed to analyze and model a building's energy consumption. • It allows energy auditors to identify potential areas for improvement in energy efficiency by simulating different scenarios and design changes before physical modifications are made, ultimately optimizing energy usage and cost savings within a building or facility. Function: • It takes data from a building's physical characteristics (like insulation levels, window properties, HVAC systems) and operational patterns (occupancy schedules, equipment usage) to calculate energy consumption through simulations based on weather conditions and building design.
- 43. Benefits: •Detailed analysis: Providesa comprehensive view of energy usage patterns, identifying areas with high energy consumption and potential for significant savings. •Comparative analysis: Allows for "what-if" scenarios to compare different energy efficiency measures and predict their impact on energy consumption. •Cost-effective decision making: Helps prioritize energy-saving upgrades based on their potential return on investment. •Improved design process: Enables architects and engineers to incorporate energy efficiency into building designs early on.
- 44. Types of simulationmodels: •Hourly simulation: Detailed analysis of energy use throughout the day, considering variations in weather conditions and building occupancy. •Steady-state simulation: Simplified analysis for quick assessments of overall energy performance. Common features of energy audit software: •Building geometry input: Ability to create a 3D model of the building, including details like walls, windows, roofs, and floor plans. •Material properties: Database of material properties like insulation values, solar reflectance. •HVAC system modeling: Integration of heating, ventilation, and air conditioning system details to simulate their energy consumption.
- 45. • Weather datainput: Access to local weather data for accurate simulation results • Energy consumption analysis: Calculation of energy use by end-use (heating, cooling, lighting, appliances) • Cost estimation: Ability to estimate implementation costs of energy efficiency measures Examples of popular energy audit software: • Energy Plus: Open-source software widely used for detailed building energy simulations • TRNSYS: Comprehensive software for advanced building energy modeling • IES VE: Commercial software with integrated building design and energy simulation capabilities
- 46. Current Energy ConservationAct and Electricity Act and its features • The Energy Conservation Act is a legislation aimed at promoting energy efficiency and reducing energy consumption across various sectors in India. • Dr. Hermann Scheer is often referred to as the father of energy conservation for his advocacy and leadership in promoting renewable energy and energy efficiency. • The Energy Conservation Act was enacted in 2001 by the Indian Parliament. It stands as a crucial legislative framework aimed at promoting energy efficiency and sustainable development practices across India. • It also introduces guidelines such as the Energy Conservation Building Code (ECBC) to promote efficient construction practices. • Under the purview of the Act, the Bureau of Energy Efficiency (BEE) plays a pivotal role in formulating policies.
- 47. • The primaryobjective of the Energy Conservation Act 2001 is to institutionalize energy conservation measures through regulatory frameworks, standards, and policies. • It aims to mitigate the impact of energy consumption on the environment and promote sustainable development practices across industries, buildings, and appliances. Energy Conservation Act 2001 Salient Features : • Establishment of Bureau of Energy Efficiency (BEE): BEE serves as the apex body responsible for formulating and implementing energy efficiency policies and programs. • Energy Consumption Standards: Sets mandatory energy consumption norms and standards for appliances, equipment, and industrial processes to promote energy efficiency. • Energy Conservation Building Code (ECBC): Introduces guidelines for energy-efficient design and construction practices in commercial buildings. • Energy Audit Requirements: Mandates designated consumers to conduct energy audits periodically to assess energy use and implement conservation measures.
- 48. Significance of theEnergy Conservation Act 2001 •The Energy Conservation Act 2001 holds significant importance in India's energy landscape: •Energy Security: Enhances energy security by reducing dependence on fossil fuels through efficient energy use. •Environmental Sustainability: Mitigates greenhouse gas emissions and environmental impacts associated with energy consumption. •Economic Benefits: Promotes cost savings, improves industrial competitiveness, and stimulates economic growth through energy efficiency initiatives. •Compliance and Awareness: Encourages stakeholders to adopt energy-efficient technologies and practices. It fosters a culture of energy conservation and sustainability.
- 49. Issues Related tothe Energy Conservation Act 2001 •Despite its benefits, the Energy Conservation Act 2001 faces several challenges: •Implementation Challenges: Variations in compliance levels and enforcement capacity across different sectors and regions. •Technological Barriers: Limited availability and adoption of advanced energy-efficient technologies due to high costs and infrastructure constraints. •Capacity Building Needs: Requires continuous training and skill development initiatives to enhance awareness and expertise in energy conservation practices. •Policy Updates: Necessitates periodic revisions and updates to align with emerging technologies and global best practices in energy efficiency.
- 50. Energy Conservation (Amendment)Bill 2022 •The Energy Conservation (Amendment) Bill 2022 proposes amendments to strengthen and expand the provisions of the Energy Conservation Act 2001 in response to emerging challenges and opportunities in the energy sector.
- 51. Key Highlights ofthe Amendment Bill The key highlights of the Energy Conservation (Amendment) Bill 2022 include: •Enhanced Scope: Broadens the applicability of energy efficiency norms to additional sectors and industries. •Stricter Standards: Introduces more stringent energy consumption standards and targets for appliances, equipment, and industrial processes. •Incentivization: Provides incentives and fiscal measures to encourage investments in energy- efficient technologies and practices. •Capacity Building: Focuses on capacity building initiatives, awareness campaigns, and skill development programs to promote energy conservation. •Enforcement Mechanisms: Strengthens enforcement mechanisms and penalties for non-compliance to ensure effective implementation of energy efficiency measures.
- 52. The amendment isaimed at helping India fulfil its COP-26 commitments. India committed to (a) reach 500GW (gigawatt) non-fossil energy capacity by 2030 (b) meet 50 per cent of its energy requirements from renewable energy by 2030 (c) reduce total projected carbon emissions by one billion tonnes from the date of COP-26 to 2030 (d) Reduce carbon intensity of the economy by 45 per cent by 2030, over 2005 levels (e) achieve net zero emissions by 2070.
- 53. • KEY HIGHLIGHTSOF THE AMENDMENT ACT I. Carbon credit trading: • it generally refers to a tradeable permit, allowing the holder to emit a specified amount of carbon dioxide or other greenhouse gases. • The Carbon Credit Trading Scheme is aimed at reducing greenhouse gas emissions, and hence, addressing climate change . II. Obligation to use non-fossil sources of energy: • minimum share of consumption of non-fossil sources by designated consumers as energy or feedstock. Different share of consumption may be specified for different types of non-fossil sources for different designated consumers. III. Energy conservation code for buildings: • The Amendment Act substitutes the definition of ‘energy conservation building codes’ with ‘energy conservation and sustainable building code’ to mean the code which provides norms and standards for energy efficiency and conservation, use of renewable energy and other green building requirements for a building. • Building has been defined under the Act to mean any structure or erection or part of a structure or erection
- 54. IV. Standards forvehicles and vessels: •Prior to the Amendment Act, the energy consumption standards could be specified for equipment and appliances, which consumed, generated, transmitted, or supplied energy. The amended Act expands to include ‘vehicles and vessels. V. Penalty: •It brings in new penalties and aggravates existing penalties for violations of certain provisions of the Act. •In addition to the maximum penalty of ten lakh rupees under the Act, the Amendment Act brings in additional penalty of minimum two thousand and maximum five thousand rupees per appliance or equipment against which the non-compliance has occurred.
- 55. What are thenew amendments •Establishing a Carbon Market •Changes in the mechanism of Escort's •changes to the management structure of the BEE •Expansion of the GoI’s powers to notify energy consumption standards across sectors •Changing “Energy Conservation Building Code” to “Energy Conservation and Sustainable Building Code”: