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INDUSTRIAL ENERGY AUDITING
AND REPORTING
VIGNESH S
BTG-12-037
INDUSTRIAL ENERGY AUDITING & REPORTING
08/12/15 – 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 situation
Recommendations for improving energy efficiency
Cost-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

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Industrial energy auditing and reporting

  • 1. INDUSTRIAL ENERGY AUDITING AND REPORTING VIGNESH S BTG-12-037
  • 2. INDUSTRIAL ENERGY AUDITING & REPORTING 08/12/15 – TUESDAY  Introduction to Industrial Energy Efficiency Assessments  Types of Energy Audits  Comprehensive Approaches  Process flow diagrams  Energy Audit Feasibilities  Energy Audit Report  Conclusion  References
  • 3. 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.
  • 4. 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
  • 5. 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 situation Recommendations for improving energy efficiency Cost-benefit analysis of recommended options an action plan
  • 6. 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
  • 7. 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.
  • 8. 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
  • 9. 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
  • 10. 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.
  • 11. 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.
  • 12.
  • 13. 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.
  • 14. 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.
  • 15. 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.
  • 16. 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
  • 17. 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
  • 18. 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