4. Energy loss in any industrial process or plant is
inevitable; it is a foregone conclusion.
But its economic and environmental impacts are
not to be taken lightly, thus explaining the
growing need for industrial energy efficiency.
Put simply, the level of energy efficiency a plant
or process can achieve is inversely
proportionate to the energy loss that occurs; the
higher the loss, the lower the efficiency.
Energy Losses
5. Where and how do most of the losses occur,
how much energy is actually lost and are they
controllable or recoverable? The answers to
these questions remain well concealed in a
black box where once energy is input, we do
not know what really happens to it inside and
how much the losses are.
It is only when we look into the black box and
extract these details that we are able to
ascertain the performance of the overall or
process levels and respond more effectively to
the weaknesses in energy management.
6. Overall energy losses in a plant can result from losses
due to designs that do not incorporate energy efficient
specifications such as heat recovery option;
operations that run on inefficient methods; and poor or
non-energy efficiency-conscious maintenance
programme.
Reducing these losses will substantially increase the
plant's efficiency, but we need data to identify and
quantify the losses and subsequently suggest suitable
techno-economic solutions to minimize the losses.
This data can be acquired through energy audits.
7. • As per the Energy Conservation Act, 2001,
Energy Audit is defined as "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".
8. Need for Energy Audit
• Energy Audit will help to understand more about the
ways energy and fuel are used in any industry, and help
in identifying the areas where waste can occur and
where scope for improvement exists.
• The Energy Audit would give a positive orientation to
the energy cost reduction, preventive maintenance and
quality control programmes which are vital for
production and utility activities.
• Such an audit programme will help to keep focus on
variations which occur in the energy costs, availability
and reliability of supply of energy, decide on
appropriate energy mix, identify energy conservation
technologies, retrofit for energy conservation
equipment etc
9. • In general, Energy Audit is the translation of
conservation ideas into realities, by lending
technically feasible solutions with economic and
other organizational considerations within a
specified time frame.
• The 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 and
also provides the basis for planning a more
effective use of energy throughout the
organization.
11. This will indicate the performance at the overall
plant or process level.
The energy manager can compare these
performances against past and future levels for a
proper energy management.
The main part of the energy audit report is energy
savings proposals comprising of technical and
economic analysis of projects.
Looking at the final output, an energy audit can
also be defined as a systematic search for energy
conservation opportunities.
12. This information can be transformed into energy savings
projects.
It will facilitate the energy manager to draw up an action
plan listing the projects in order of priority.
He will then present it to the organization's management for
approval.
Providing tangible data enables the management to be at a
better position to appreciate and decide on energy
efficiency projects.
Adopting this activity as a routine or part of the
organization's culture gives life to energy management, and
controlling the energy use by energy audit is what we refer
to as Energy Management by Facts
13. Type of Energy Audit
• The type of Energy Audit to be performed
depends on: -
• Function and type of industry
• Depth to which final audit is needed,
• Potential and magnitude of cost reduction
desired
• Thus Energy Audit can be classified into the
following two types.
• i) Preliminary Audit
• ii) Detailed Audit
14. Walk-through or preliminary audit
Walk-through or preliminary audit comprises one day or half-
day visit to a plant and the output is a simple report based on
observation and historical data provided during the visit. The
findings will be a general comment based on rule-of-thumbs,
energy best practices or the manufacturer's data.
15. Preliminary Energy Audit Methodology
• Preliminary energy audit is a relatively quick exercise
to:
• Establish energy consumption in the organization
• Estimate the scope for saving
• Identify the most likely and the easiest areas for
attention
• Identify immediate (especially no-/low-cost)
improvements/ savings
• Set a 'reference point'
• Identify areas for more detailed study/measurement
• Preliminary energy audit uses existing, or easily
obtained data
16. Preliminary Energy Survey
Quick overview of energy use patterns
• Provides guidance for energy accounting system
• Provides personnel with perspectives of processes and equipment
• Identify energy – intensive processes and equipment
• Identify energy inefficiency ,if any
• Set the stage for detailed energy survey
17. Detail audit
Detail audit is carried out for the energy savings
proposal recommended in walk-through or preliminary
audit.
It will provide technical solution options and economic
analysis for the factory management to decide project
implementation or priority.
A feasibility study will be required to determine the
viability of each option.
18. Detailed Energy Audit Methodology
• A comprehensive audit provides a detailed
energy project implementation plan for a facility,
since it evaluates all major energy using systems.
• This type of audit offers the most accurate
estimate of energy savings and cost.
• It considers the interactive effects of all projects,
accounts for the energy use of all major
equipment, and includes detailed energy cost
saving calculations and project cost.
19. • In a comprehensive audit, one of the key
elements is the energy balance.
• This is based on an inventory of energy using
systems, assumptions of current operating
conditions and calculations of energy use.
• This estimated use is then compared to utility
bill charges.
• Detailed energy auditing is carried out in
three phases:
• Phase I, II and III.
20. • Phase I - Pre Audit Phase
• Phase II - Audit Phase
• Phase III - Post Audit Phase
21. Phase I -Pre Audit Phase Activities
• A structured methodology to carry out an
energy audit is necessary for efficient working.
• An initial study of the site should always be
carried out, as the planning of the procedures
necessary for an audit is most important.
22. Initial Site Visit and Preparation Required
for Detailed Auditing
• An initial site visit may take one day and gives the
Energy Auditor/Engineer an opportunity to meet
the personnel concerned, to familiarize him 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 the aims
of the energy audit.
23. • Discuss economic guidelines associated with
the recommendations of the audit.
• Analyse the major energy consumption data
with the relevant personnel.
• Obtain site drawings where available - building
layout, steam distribution, compressed air
distribution, electricity distribution etc.
• Tour the site accompanied by
engineering/production
24. The main aims of this visit are
• To finalise Energy Audit team
• To identify the main energy consuming areas/plant
items to be surveyed during the audit.
• To identify any existing instrumentation/ additional
metering required.
• To decide whether any meters will have to be
installed prior to the audit eg. steam, oil or gas
meters.
• To identify the instrumentation required for carrying
out the audit.
• To plan with time frame
• To collect macro data on plant energy resources,
major energy consuming centers
• To create awareness through meetings/ programme
25. Phase II- Detailed Energy Audit
Activities
• 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.
• Whenever possible, checks of plant operations
are carried out over extended periods of time, at
nights and at weekends as well as during normal
daytime working hours, to ensure that nothing is
overlooked
26. • 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.
• Means of improving these efficiencies will be listed,
and at least a preliminary assessment of the cost of the
improvements will be made to indicate the expected
payback on any capital investment needed.
• 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 investments.
27. The information to be collected 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).
28. 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.
29. • 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
30. • - Other inputs such as compressed air, cooling
water etc
• - Quantity & type of wastes generated
• - Percentage rejection / reprocessing
• - Efficiencies / yield
31. Detailed Energy Survey
Detailed evaluation of energy use pattern
• By processes and equipment
• Measurement of energy use parameters
• Review of equipment operating
characteristics
• Evaluation of efficiencies
• Identify DSM options and measures
• Recommendation for implementation
32. Identification of Energy Conservation
Opportunities
• Fuel substitution: Identifying the appropriate fuel
for efficient energy conversion
• Energy generation :Identifying Efficiency
opportunities in energy conversion
equipment/utility such as captive power
generation, steam generation in boilers, thermic
fluid heating, minimum excess air combustion with
boilers/thermic fluid heating, optimising existing
efficiencies, efficienct energy conversion
equipment, biomass gasifiers, Cogeneration etc.
33. • Energy distribution: Identifying Efficiency
opportunities network 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 and many of
them are hidden. Process analysis is useful tool
for process integration measures.
34. Technical and Economic feasibility
The technical feasibility should address the
following issues
• Technology availability, space, skilled
manpower, reliability, service etc
• The impact of energy efficiency measure on
safety, quality, production or process.
• The maintenance requirements and spares
availability
35. • The Economic viability often becomes the key
parameter for the management acceptance.
• The economic analysis can be conducted by
using a variety of methods.
• Example: Pay back method, Internal Rate of
Return method, Net Present Value method etc.
• For low investment short duration measures,
which have attractive economic viability,
simplest of the methods, payback is usually
sufficient.
36. Energy Audit Report
• After successfully carried out energy audit energy
manager/energy auditor should report to the top
management for effective communication and
implementation.
• A typical energy audit reporting contents and
format are given below.
• The following format is applicable for most of the
industries.
• However the format can be suitably modified for
specific requirement applicable for a particular
type of industry.
38. ELECTRICAL ENERGY
AUDIT
Areas covered under Electrical audit are
1. Electrical System :
• Electrical Distribution system (substation &
feeders study)
• PF Improvement study
• Capacitor performance
• Transformer optimization
• Cable sizing & loss reduction
• Motor loading survey
• Lighting system
• Electrical heating & melting furnaces
• Electric ovens
39. 2. Mechanical System :
• Fans & Blowers
• Exhaust & ventilation
System
• Pumps and pumping
System
• Compressed air System
• Air Conditioning &
Refrigeration System
• Cooling Tower System
40. THERMAL ENERGY AUDIT
Areas covered under Electrical audit are
• Steam Generation Boilers
• Steam Audit and Conversation
• Steam Trap Survey
• Condensate Recovery System
• Insulation Survey
• Energy and Material Balance for Unit operation
• Heat Exchanger
• Waste Heat Recovery System
41. WATER AUDIT & CONSERVATION
Industry has recognized 'Water Audit' as a important tool for
water resource management
Water Audit study is a qualitative and quantitative analysis of
water consumption to identify means of reuse and recycling of
water.
This study includes segregation of effluent streams and
schemes for effectively treating them to enable byproduct
recovery.
Water Audits encourage social responsibility by identifying
wasteful use, enables estimation of the saving potential they
not only promote water conservation but also deliver cost
savings, but also companies to safeguard public health and
property, improve external relations and reduce legal liability.
42. Benefits of energy audit
There is a lot of potential for energy savings from
energy audits.Technical solutions proposed in the
energy audits show massive potential for energy
savings in every sub-sector with an average of
almost ten percent of the energy usage. However,
this can only materialize through replication at
other factories within the respective sub-sector.
43. Benefits of an industrial energy audit include:
•Energy savings
•Avoiding power factor penalties and environmental compliance
costs
•Quality improvements
•Productivity improvements
•Reduced maintenance
•Fewer breakdowns
•Better safety and protection
•A process for repeatable improvements
45. Bureau of Energy Efficiency
Certification
• The Government of India (GoI) established Bureau
of Energy Efficiency (BEE) on 1st March 2002 under
the provisions of Energy Conservation Act, 2001.
• BEE was started to develop policies and build
strategies with a push towards self-regulation to
achieve energy efficiency.
• BEE will be monitored by the Ministry of Power to
enhance delivery mechanisms, provide leadership
and create conservation policies leading to
efficient energy preservation.
46. Objective of BEE
• Frame policy at the national level for energy
conservation
• Measure, monitor and verify the results of the
energy conservation
• Help SMEs and MSMEs to establish and
implement energy consumption
47. Regulatory activities by BEE
• Creating a standard for appliances and design
scheme for the products through star ratings in
various appliances like refrigerators, water
heaters, AC, fans, pump, etc.
• Regulating the star ratings
• BEE develops energy efficiency code for
industries and buildings
• Development of norms for the consumption of
energy
• Certification for Energy Managers and Energy
Auditors who can perform energy audits
48. Promotional activities by BEE
• BEE develops promotional programs for star rating,
energy efficiency and awareness
• Organizes training for members involved in handling
energy efficiency projects
• Development of testing and certification procedures
and promotion of testing facilities
• Promotion of innovative financing of energy
efficiency projects
• Preparation of educational curriculum on the
efficient use of energy and ways to conserve
• Provides financial assistance to institutions for the
promotion of efficient use of energy
49. Standards and Labeling Program
• BEE establishes the standards and star rating for
different appliances.
• The star ratings define the standard of energy
efficiency where it helps the people an informed
choice of energy performance and cost.
• For certification, the manufactured products will
be subjected to the tests as designed by BEE.
• As the certification helps to gain trust from a
consumer, BEE constantly refines the standards
and certification procedures to improve energy
efficiency.
50. BEE Rating Certification
• The Bureau of Energy Efficiency rating
certificate is issued by the BEE indicating the
level of compliance done by an organisation
about the standards and guidelines issued by
the bureau.
• The certificate is framed to regulate, audit the
time intervals, monitor and improve energy
efficiency.
51. Types of Certification
• Accredited Energy Auditors
• Energy Auditors/Managers
• Refresher Course
52. Types of Certificate Labels
• There are two types of labels on products
manufactured in India.
• Endorsement label
• Under this label, the products are labelled as per
their minimum performance criteria to become a
BEE certified company.
• Comparative label
• Under this label, the products are labelled as
per the star rating (scale of 1 to 5) which includes
BEE logo and license number on the product. This
rating helps consumers choose the right product.
53. • Bachat Lamp Yojana
• Standard and Labeling
• ECBC
• CDM
• Operationalization of SDAs
• ADSMs
• MDSMs
• SMEs
• CECF scheme
• Institutional strengthening of Bureau
54. BLY scheme : to promote energy efficient and high quality
CFLs as replacement for Incandescent bulb in household
Standard & labelling scheme :target high energy end
equipment and appliance to lay down minimum energy
performance standards
ECBC: that sets minimum energy performance standards for
new commercial buildings
Agricultural and Municipal DSM: targeting replacement
inefficient pump sets and street lights
Oct2013
55. BLY scheme : to promote energy efficient and high quality
CFLs as replacement for Incandescent bulb in household
Standard & labelling scheme :target high energy end
equipment and appliance to lay down minimum energy
performance standards
ECBC: that sets minimum energy performance standards for
new commercial buildings
Agricultural and Municipal DSM: targeting replacement
inefficient pump sets and street lights
56. Institutional strengthen of BEE
the proposed scheme seeks to provide resource allocation during the
XI plan : a. setting up Energy conservation information center (ECIC)
for online data collection
Infra and resource augmentation of BEE /other Energy efficiency
institution
Support for R&D in energy management in IITs ,and policy research
from ASCI ,IIPA etc
Professional certification and accreditation
Bureau is conducting national energy manager and auditor
examination every year
Prepared guide books for professionals
Manuals and code
The energy performance code provides the field testing of utility
equipment in DC premises
BEE developed for 7 technology i.e.,lighting ,dryer cogeneration plant ,transformer
,fluid piping system ,insulation and air conditioner system (HVAC)
57. Awareness and outreach
The govt. has launched a National campaign on Energy conservation
on 14th dec 2004 for spreading awareness among society for EC
Postal stamp on EC were also released by Hon’ble PM ,multimedia for
awareness campaigns
Spreading awareness about energy situation ,and saving in daily life
Present a wider variety of energy conservation method to improve energy
consumption behavior
Information about power and oil situation of country
Involvement of SDAs in outreach program
National Energy Conservation awards - one of the innovative scheme
initiated by
country ,
the govt. of India .MoP over the last decade to promote EC in
award for instutionilization the energy efficiency movement in
country by identifying and giving recognition to the energy conservation effort
by different firm
58.
59. • SDA’s are statutory bodies set up under section 15 of the Energy
Conservation Act, 2001; at the state level to implement theAct , in 33 states
• They are the nodal agencies at state level and need to coordinate and
cooperate with BEE at the central level to ensure a smooth and speedy
implementation of the Act in the country
• SDA’s have an important role to play particularly in creating public
awareness and enforcement of the EC Act,2001 at the grass rootlevel.
• These agencies are different in state to state with renewable energy
development agency ,electrical inspectorate and distributioncompanies
• Responsible for capacity building ,enhancing the knowledge about EC
,preparing action plan and project implementation
60. Role and responsibility of SDAs
• Prepare Annual Action Plan
• Organize meetings and workshops
• Capacity building of various stakeholders
• Support during implementation of Energy Conservation
Activities in the states
• Identify and implement demonstration projects with high
impact value
61. Role and responsibility of SDAs
Oct2013
• Strengthening the SDAs which would enable them to implement
• various programs and activities initiated by BEE or
SDAs themselves
• Institutionalization of the enforcement machinery
at the Statelevel
• Implementation of various EE demonstration
projects in the states to showcase the
effectiveness of the most advanced energy efficient
technology and pursue state governments to
replicate the project in other parts of the state.
62. • LED village campaign in the villages and
pursue state governments to replicate the
project in other parts of the state.
• Continued engagement of SDAs with energy
efficiency professionals like energy auditors,
energy managers, DCs and ESCOs
• Publicity /awareness on EE in the states
• Workshops/ training programmes for all the
stakeholders
