Thursday, 8 December 2011

New Age Industrial Energy Audit

Conventionally Energy Audit has been more about Demand Side Management i.e. improvement on Load Side to result in Energy Conservation and enhance Energy Efficiency of the Plant or Facility. However with recent developments and interest in Captive Power Generation Energy - Industrial Audit will not and should not only focus on Demand Side Management but also on Power Generation especially from Green Sources like Solar Energy.

In general Energy Audit as a concept has been more concerned with improvements in existing setup and also a part of it including in retrofits which in most likely scenarios will be additional equipment being installed or replacing outdated plant equipment. There is an interesting shift especially by the Industries in exploring the option for Captive Power generation especially through Green Energy Sources such as Solar Energy.

[Suggested Read - Is Solar Energy really Affordable?]

Industrial Clients are now interested in a more holistic approach to the Energy Solutions and hence look at possible alternative energy. It also makes lot of Commercial Sense to have a Power Portfolio with the right kind of Power Mix. It is quite evident that in such a scenario - Photo Voltaic Solar will play a crucial role in Captive Power Generation thereby reducing some dependence on Grid Power - in whatever small way possible.

Referring to the context in Indian Industries an Energy Audit should adopt a very systematic approach. Primary purpose of Energy Audit is to explore areas and opportunities for Energy Conservation and Energy  Efficiency. However an Energy Audit in itself may save Energy as mentioned in the recent post (Does Energy Audit really save Energy?). Energy Audit should primarily consist of :
  • Detailed understanding and study of existing system and setup and devising ways and means to reduce Specific Power Consumption.
  • Analysis of Power Consumption Trend and suggesting measures for improvement in the same and stabilizing the consumption.
  • Identifying the Present Power Portfolio and Designing the Ideal Power Mix.
  • Exploring possibility of Greener and More Efficient Fuel Alternatives.
  • Identifying Opportunities for Renewable Power Sources - based on Geography.
  • Follow Up visits to ensure that Recommendations schedule is adhered to.
  • Training Session to create awareness regarding Emerging Technologies in Renewtech and EE & EC.
Etc.

From an Industrial point of view Energy Audits should look at more of a comprehensive approach than just as a starting point of reducing Production Cost. Energy Audit Checklist generally forms a good basis for Energy Auditors to carry out Energy Audit.

In the Global context Industries are focusing more on reducing their carbon footprint - necessitated by Governing Environmental Laws. Strict enforcement of such laws postulates that Industrial Energy Audit goes a step beyond the conventional approach and adopts newer technologies for not only Demand Side Management but also for Green Power Generation.

With increased environmental awareness the pressure on Industries is mounting to reduce their Carbon footprint by adopting Greener Methods wherever possible. In such as Scenario Energy Audit would play a crucial role in offering Industries a Comprehensive Approach towards a Greener Plant. Most Frequently asked Questions on Solar Energy can be found on our Post - Solar Energy FAQs.

Monday, 14 November 2011

Industrial Energy Audit - A Perspective

Energy Audit is a very important periodic exercise carried out with the objective of achieving Energy Conservation and improving Energy Efficiency - mainly for Industrial Plants and Commercial Facilities. Some States have a mandate for Energy Audit to be carried out by designated Industries once every 2-3 years. Why is Energy Audit so important and why have a mandate in place for something so useful is a flummoxing question.

As a matter of fact every Industrial Plant or a Commercial Facility - however efficiently run will have scope for Energy Saving. There are various reasons for the same -

  1. Dynamic Changes - every plant / facility undergoes some changes (expansion / addition / removal) over a period of time and the overall energy consumption and trends may change because of this.
  2. Emergence of Advanced Technology Equipment and Retrofit which save significant energy due to efficient running.
  3. Critical Assessment including Advanced Thermography for Thermal Energy Audit and Power Quality Check (especially for Harmonics) for Electrical Energy Audit.
  4. Not having a dedicated Energy Cell to monitor and report Energy usage and suggest corrective actions for the same. Many Industrial Plants still rely on Production or Maintenance Teams for the same. Energy Cell is especially recommended for Industrial Plants and specifically for Energy-intensive Industries.
  5. Ageing of Equipment.
  6. Lack of awareness regarding energy saving potential of the plant or about Energy Audit in general with specific plant related inputs.
  7. Not undergoing an Energy Audit. Even for the plants having a dedicated Energy Cell or a Energy Manager - an Energy Audit will prove fruitful. This is because an Energy Audit from a vendor brings in experts from diverse Industries who are dedicated towards achieving results in this domain.
  8. Plant People focus on their primary responsibility. For instance a department HOD may focus only on the domain maintenance and improvements in the particular domain which maybe viewed in isolation. An Energy Audit looks at holistic picture to suggest improvements in the plant.
  9. Although plant people are highly capable there might be times that simpler measures such as operational efficiency may be overlooked- which may deteriorate over a period of time.
  10. Improper maintenance for short-term gains.
  11. Cross-Industrial and Cross-Domain Experience which may not be found within any single plant but may certainly be found in a single Service Provider.
So why despite the ever-rising running costs and Energy Costs are Indian Industries not carrying out Energy Audit on a bigger scale? The answers could be many but the primary reason is the Myths surrounding the Audit. For instance many consider Energy Audit to be the Energy Saver exerciser without any further investment. However the fact remains that Energy Audit is the first step in the direction of Energy Optimization of a Plant. The exercise begins with initial visit or collection of data in the Energy Audit Questionnaire. The Questionnaire is generally filled up by the Plant team and submitted back to the Service Provider / Energy Auditor. On receiving the same the Service Provider proceeds with preparing a Comprehensive and Customized Scope of Work for the Plant. The primary objective of Energy Audit is to explore potential areas for Energy Conservation and Energy Efficiency including the ones which require No Investment. So in some sense Energy Audit in itself can also save energy. Although there are recommendations in the Energy Audit Report which indicate retrofits which require investment. However with the due care that the Investments are justified.

It has also been observed that in some few cases Energy Audit is carried out by inexperienced and un-certified engineers who may have no previous experience in this. This impacts the overall outcome and may not actually meet the primary objective of Energy Audit. In such cases an Organizations which are not satisfied with the past Energy Audit are discouraged from carrying out future Energy Audits as well. As a practice Organizations should duly check the experience and expertise of the Vendor. In general Energy Audit is carried out of Electrical and Thermal Utilities and as such a similar Industry experience may prove to be beneficial but may not be deemed necessary. This is because more or less the composition of Electrical and Thermal Utilities remain the same - irrespective of the type of Industry. If however a Process Audit needs to be done then a Domain expert can add value to the exercise.

Energy Audit is the beginning of Energy Saving in a plant and is recommended for almost all the Industries - irrespective of size and type. In the Indian Context Energy Audit has a special role to play as India faces tremendous power shortage (about 10% Peak Deficit) and also the potential for Energy Conservation is estimated at a mind-boggling 25,000 MW.

It may be worthwhile to mention that the exercise bears results for Industries having either a load of above 400 kVA or good Steam Consumption & Boilers. In case a Plant or Facility has both - then a periodic Energy Audit is highly recommended. The frequency of audit may differ from plant to plant and is typically once in 2 years for detailed energy audit. In addition to this a walk-through audit twice a year ensures that Recommendations are implemented and momentum is kept strong. This also ensures that Energy Conservation and Energy Efficiency becomes a way of life in the plant and taps the potentials at grass-root level.

For any further information on Energy Audit or Energy Optimization Exercise you may contact us. We have an excellent experience in Energy Audit across various diverse Industries including Steel, Cement, Thermal Power Plant, Chemical, FMCG, Edible Oil etc. Contact Details below. We have had the opportunity to serve Industry Leaders across various Industries. If you are interested in receiving our Client Testimonial and Feedback please do contact us today.


Enerco Energy Solutions LLP 
Email - info [@] econserve [dot] in
Website - www.econserve.in 

Thursday, 3 November 2011

Energy Audit - Checklist

Energy Audit Quick Checklist


(Recent Updates of 06th April 2015 - below)

Energy Audit Checklist gives an overview of Preliminary Energy Audit of a Facility. This refers to the basic data capturing for assessing the present status of Energy Efficiency. This Energy Audit checklist is only for a quick assessment and not a detailed Energy Audit. For a detailed study Our Energy Audit experts from this field who are IIT-B alumnus and B.E.E. Certified need to make a comprehensive Energy Saving Plan for Energy Optimization.

This is NOT a Energy Audit Questionnaire. To download Energy Audit Questionnaire please Click Here.

a)         Lighting:-

♦    Is your facility using the most energy efficient lighting options (fluorescent mercury vapor, etc.)?
♦    Are there areas that have excessive or unneeded lighting?
♦    Are you making effective use of available lighting, such as natural sunlight?
♦    Have you installed lighting management equipment such as dimmers, timers and sensors?

b)         Building Envelope:-
♦    Is the building well insulated?
♦    Does weather stripping around doors and windows need to be replaced?
♦    Are cracks around doors, windows and foundations properly sealed?
♦    Are there open doors around loading docks or other frequently accessed areas?

c)         Heating and Cooling:-

♦    Arc   furnaces,   boilers   and   air conditioning systems   operating efficiently?
♦    Is there a regular maintenance and update schedule for these systems?
♦    Are filters replaced regularly?
♦    Is the building properly ventilated?

d)         Motors and Equipment:-

♦     Is your equipment maintained so that it is operating at maximum efficiency?
♦     Is equipment load compatible with manufacturer specifications?
♦     Are machines shut down when not in use?
♦     Are fan belts at the proper tension and in good condition?

e)  Energy Behavior:-
♦     Are   lights, fans   and   equipment (computer, printers, etc.) turned off when not in use?
♦     Are building temperatures set back when not in use?
♦     Are thermostats set to higher or Lower than necessary in summer and winter?
♦     After finding answers to the check list   and   identifying areas   of improvement, following possibilities maybe   explored   as   energy conservation measures.


f) Lighting-:
♦     Reduce Hours of Operation.
       -    Occupancy Sensors, Photocells,
                        Central Control.
♦     Reduce Capacity of Equipment.
                   -    Delamping, Reflectors.

♦     Reduce Load or Equipment Capacity.       
                   Requirements.
                   -    Day lighting.

♦     Reduce Energy Cost.
                   -    Base demand load reduction.

♦     Increase Efficiency
                   -    T-12 to T-8
                   -    Incandescent to Fluorescent
                   -    Reflectors
                   -    Dimmers          

g) Building envelope:-
♦     Insulation
                   -    Insulation of roof & walls.

♦     Glass modifications-:
                   -    Use of permanent/movable shading on glass
                   -    Changing to low solar heat gain glass, insulating (low U-value) glass

♦     Reduce air Leakage-:
-    air lock entry
-    plugging all leakages

[Others are also reading - Top 5 Reasons to carry out Energy Audit]


h) Heating-:
♦     Reduce Hours of Operation-:
                   -    Automated Controls.
♦     Reduce Capacity of Equipment-:
-    Size to meet actual load
      ♦     Reduce Load or Equipment Capacity-:
                   Requirements
                        - Insulation
                        - Infiltration reduction
♦     Reduce Energy Cost-:
                        - Fuel Switch
                        - Rate Switch
                        - Direct Purchase Gas
♦     Increase Efficiency-:
                        - High Efficiency Boilers           
                        - High Efficiency Furnaces

i) Air Conditioning
                   ♦   Reduce Hours of Operation-:
                        - Automated Controls
                        -  Economizer
                  
                   ♦   Reduce Capacity of Equipment-:
                        - Size to meet actual load
                        - Chiller Loop

                   ♦   Reduce Load or Equipment Capacity-:
                   Requirements.
                        -           Insulation.
                        -           Infiltration reduction.
                  
                   ♦   Reduce Energy Cost-:
                        -           Rate Switch.
                        -           Thermal Storage.
                  
                   ♦   Increase Efficiency-:
                        -           High Efficiency Chillers.
                        -           Variable speed tower fans.
                        -           Geothermal Heat pumps.

[Recent popular article - Can Energy Conservation help fight Global Warming?]

j) Fans and Pumps-:
                  
                   ♦   Reduce Hours of Operation-:
                        -           Automated Controls.
                  
                   ♦   Reduce Capacity of Equipment-:
                        -           Size to meet actual load requirements.
                  
                   ♦   Reduce Load or Equipment Capacity-:
                        Requirements.
                        -           Insulation.
                        -           Infiltration reduction.
                  
                   ♦   Reduce Energy Cost-:
                        -           Reduce base demand load through right sizing fans and pumps.
                  
                   ♦   Increase Efficiency-:
                        -           CAV to VAV conversion.       
                        -           CP to VP conversion.


k) Renewable Energy Potential

Evaluating potential for Renewable Energy especially Solar Energy for Power generation. This is because of immense benefits of PV Solar over other technologies, especially modular and scalable nature.


Updates on 06th April 2015
While energy-intensive Industrial plants are taking all possible steps to improve on Energy Conservation and Energy Efficiency one point worth mentioning is that the Energy Audit concludes with the Energy Audit Report submission.The end-user is left to implement the energy conservation and energy efficiency measures on their own., which is the general practice.

However the key to complete the cycle of Energy Audit is to implement the solutions and recommendations made in the Energy Audit Report. Without which the entire exercise of Energy Audit is rendered futile. There could be 2 possible scenarios under this -
  1. The plant / end-user Company may invest in the energy saving recommendations on their own. This is the general practice all across India in 99% of the cases.
  2. The energy audit Company invests in these recommendations and shares the benefits of Energy saving with the plant on ESCO basis.
The advantage of ESCO model is immense and it can enable a plant to save on energy immediately without any investment. We invite your comments / queries / feedback below this article.

Enerco Energy Solutions LLP offers ESCO based Energy Audit primarily for Industrial plants across sectors. This includes B.E.E. PAT Energy Audit, Periodic Energy Audit, B.E.E. PAT M&V assignments. Similarly we also offer 100% funded Solar Energy projects on BOOT basis.

To know more you may simply send a mail to info@econserve.in

Wednesday, 2 November 2011

What is Energy Audit?

                                                    What is Energy Audit


We frequently encounter this question - What is an Energy Audit? Energy Audit is a complex technical assessment of present energy consumption of an Industrial Unit or a Commercial Facility or a Community Complex for the purpose of reduction in wasteful consumption and improvement in efficiency. Reduction in wasteful consumption is done by implementing energy conservation technologies. Improvement in energy efficiency can be done either through operational improvements, implementation of retrofit solutions etc.

Objectives of Energy Audit (Why Energy Audit)
  • Accumulating data at various energy points
  • Identifying energy losses and critical junctions
  • Enabling energy conservation and cost savings
  • Understanding overall efficiency and suggesting improvements.
  • Recommendations of Solutions to achieve Energy Optimization.

The Methodology (How Energy Audit)
  • Analyzing the performance of each equipment by Certified B.E.E. Experts using most advanced instruments and equipment
  • Collating the parameter data with benchmarks
  • Manifesting and implementing corrective measures

What does Energy Audit Cover (Scope of Energy Audit)
  • All operations, processes, products and departments in the organization
  • All forms of energy – specifically electrical + thermal
  • Operational efficiency of equipment like diesel generator sets, turbo generator sets and utilization of power from the electricity supply authority
  • Evaluation of different components of the electrical network like transformers, lighting, motors, capacitors and the distribution network
  • Study of utility equipment like air compressors, fans, pumps, blowers, air-conditioning and refrigeration, evaporative cooling, cooling towers, boilers, furnaces, thermal fluid heaters


What are the various phases of Enerco Energy Audit

Although there are various phases of an Energy Audit most of the firms in India rely only on Onsite Phase i.e. Measurement phase. However we at Enerco Energy Solutions LLP offer a Comprehensive package as part of Energy Audit which we refer to as Energy Optimization Exercise which consists of :

The visits are customized depending on Plant size, type, energy trend, consumption pattern etc. The customized package for a plant is prepared after the data captured in the Energy Audit Questionnaire is furnished by the Client. The Questionnaire link is given above.



What does Energy Audit lead to (Outcome of Energy Audit)
  • Energy balance
  • Heat and mass balance
  • Establishing specific energy consumption
  • Identifying opportunities for energy efficiency

 What does Energy Audit help achieve ?
  • Compliance with Government regulations
  • Lower energy costs
  • Enable faster recovery of investments
  • Achieve better performance and lower downtime
  • Enhanced power quality and productivity
  • Reduced emission levels
  • Improved Age of Equipment and complete system
  • Reducing Global Warming
There are some startling and interesting Facts about how Energy Conservation & Energy Efficiency can help us overcome the Power Problems.



Areas of Energy Audit
  • Industrial Units – Manufacturing Units – Steel, Metal, Ceramic, Cement, Chemicals, Edible Oil, Fertilizer, Paper, Textiles etc., Processing Units, Foundries, Cold Storages etc. and several other similar units definitely benefit from an Energy Audit.

  • Commercial Facilities Corporate Houses, Offices, Educational Institutes, Multi-Storeyed Complexes, Commercial Complexes, Hotels, Shopping Malls, Hospitals, Airports etc. definitely benefit from an Energy Audit.

Types of Energy Audit
  • Thermal Energy Audit: energy balancing, waste heat recovery, thermal control systems and energy savings study
  • Electrical Energy Audit: distribution system study, energy balancing, power factor study, electrical loads, loss estimation, and methods for loss elimination
  • Energy Intensive Equipment Study
  • Power Quality Analysis

For any further information on Energy Audit or Energy Optimization Exercise you may contact us. We have an excellent experience in Energy Audit across various diverse Industries including Steel, Cement, Thermal Power Plant, Chemical, FMCG, Edible Oil etc. Contact Details below.

Enerco Energy Solutions LLP
Email - info [@] econserve [dot] in
Website - www.econserve.in