Friday, 18 October 2019

Express Energy Audit (About & Benefits)

Energy Audit is a periodic exercise carried out once every 2-3 years by Industrial or Manufacturing plants depending on the plant size, Govt. regulations, plant type etc. It definitely results in Energy Conservation & Energy Efficiency for the plant by -

  1. Identifying and plugging energy leakages
  2. Adoption of new technology trends such as IIoT (Industry 4.0)
  3. Improving operational efficiencies
  4. Installing new age technical equipment and retrofits
  5. Using alternative and green sources of energy
The above is carried out in a phase-wise manner with detailed measurements, data collection, team discussions, presentation, RoI & payback calculations. Detailed Energy Audit Report is submitted with all the observed, measured and calculated data along with energy saving recommendations with a payback of typically less than 12 months and in some case more. The obvious benefit of energy audit is cost-saving which consequently results in higher profitability by cost-control.

It is observed that several times Companies or plants would just like to go for a basic check about Energy Saving and may not necessarily wish to go for a comprehensive Energy Audit in such cases an Express Energy Audit is recommended.

What is an Express Energy Audit?
It is an exercise carried out for a plant to identify energy saving potential of the plant. The audit can last for 2-5 days depending on the plant size and includes -
  1. Walk-through of the facility to for visual inspection of the plant setup and the processes.
  2. Identification of visually identifiable energy saving opportunities.
  3. Discussions with the plant team on the various challenges and opportunities.
  4. Understanding the plant energy consumption (Power, Coal, Diesel, LPG, PNG etc.).
  5. Estimating the total energy saving potential of the plant.
  6. Identifying opportunities for captive rooftop and ground-mount Solar potential in the plant with project sizing.
  7. Evaluating the energy saving measures and projects undertaken since the last detailed energy audit.
Benefits of Express Energy Audit
Express Energy Audit is beneficial to a plant in more ways than one. Few of the benefits of Express Energy Audit are -

  1. Carried out by the same team of B.E.E. Certified Energy Auditors (IIT-B alumnus) & Engineers which carry out detailed Energy Audits.
  2. Helps in continuing the momentum of Energy Optimization within the plant.
  3. 3rd party verification of a recently carried out Energy Audit or recommendations made in a detailed Energy Audit.
  4. Costs a fraction of detailed energy audit but can yield good results (Typically around 1% savings straightaway).
  5. Enables a plant to understand if a detailed energy audit would be beneficial at a particular stage or not.
To know more you could download a comparative analysis between Energy Audit and Express Energy Audit

Just drop a mail to info@econserve.in and we will be glad to answer any queries you may have with regards to Energy Audit or Energy Saving in your plant.

Tuesday, 6 August 2019

Energy Audit Planning - Things to know !

Energy Audit Planning - Things to know !

About

Energy Audit is a periodic exercise carried out by Industrial plants and Commercial facilities. This exercise carried out by B.E.E. Certified Energy Auditors and Energy Experts can enable a plant to save 8% to 15% on it's Energy Bills by easy-to-implement and difficult-to-identify energy conservation and energy efficiency measures.
Energy Audit in progress

Based on our experience of 500+ Energy Audits (check out our customer list) we can say that every Industrial plant or manufacturing unit certainly has the potential to save energy. This is due to a variety of factors such as 
  1. Ageing plant equipment / machinery.
  2. Emerging and evolving technologies for better resource optimization.
  3. No dedicated plant team or cell to focus on Energy optimization matters.

Cross-domain B.E.E. Certified Energy Audit team from outside the plant (Enerco) brings in a fresh perspective along with experience of similar and varied types of plants.

Generally an Energy Audit is recommended once every 2 years depending on the size and power + energy consumption of a plant. It is also recommended that a walk-through energy audit be carried out in the plant at least once a year. An annual walk-through energy audit ensures that plant is performing at an optimum level and Energy Conservation and Energy Efficiency becomes a way of life and not just a one time activity.


Things to know at Energy Audit Planning Stage

If you are planning for Energy Audit then you should know a few things before proceeding for Energy Audit. It will help you save time, money and efforts before making the final decision.

Point 1 : Set realistic expectations
Energy saving potential exists in all types of Industrial plants in utilities, processes etc. However the saving for each plant will differ from the other due to the uniqueness of the plant in terms of sector, age, location, manpower etc.

(Others are also reading : Energy Saving = Higher Profitability)

Point 2 : Estimate the Energy Saving potential
A team can be setup to estimate the energy saving potential in the plant before actually assigning the task of Energy Audit to an expert agency. This will help in effective communication during Energy Audit and implementation post audit. An external team can also assist with this exercise through Express Energy Audit (next point).

Point 3 : Express Energy Audit - a starting point
Express Energy Audit is about a walk-through energy audit with certain basic measurements and data analysis. It lasts for a few days (2-5 days) depending on the plant size but gives a good insight into the energy saving potential of the plant and also whether a detailed energy audit would be fruitful at this stage or not. To know more about Express Energy Audit visit our site section on Express Energy Audit. Alternatively you may check out our recent blog post about Benefits of Express Energy Audit.

About Express Energy Audit


Point 4 : Brainstorming of plant people
Brainstorming sessions help in identifying improvement points within the plant before going for an energy audit. Ideally cross-functional teams work the best during such sessions.


A good starting point for Energy Audit planning is the Express Energy Audit. This exercise is recommended for a plant -
  1. Which is considering a detailed energy audit but would like to know if the detailed exercise would be useful at this stage.
  2. Which has never carried out energy audit but wants to estimate the energy saving potential.
  3. Interested in Energy Conservation and Energy Efficiency but does not know where to begin.
You can also download the FREE comparative analysis between Energy Audit and Express Energy Audit from our website section on Whitepapers and Case-Studies. Alternatively contact us to know more about how we could partner with your Company and assist you in saving energy NOW !

Enerco Energy Solutions LLP is India's most experienced Energy Consulting Company with a dedicated team of B.E.E. Certified Energy Auditors (IIT-B Alumnus), Energy Managers, Engineers and Solar Energy Experts. We can be reached on our website - www.econserve.in by mail on info@econserve.in by phone / whatsapp on +91 9890737447.

Thursday, 11 July 2019

Energy Saving = Higher Profitability?

Energy Saving = Higher Profitability?

Energy forms one of the largest components in production costs for majority of the manufacturing units. This is true whether a manufacturing process is energy-intensive or not. The energy costs have been consistently rising and the trend is likely to continue in the foreseeable future as India continues to grow. 

Make-in-India and Chinese slowdown are other factors which are seen as contributors to rising energy demand in India. The demand-supply gap will keep on rising especially in the power space as could be seen in the figure below.
Historic Power Generation Demand-Supply
                    Fig. 1 - Energy Cost Trend & Supply-demand Gap in India
In the current situation of intense competition cost control is one of the comparatively easier routes to improve profitability. In fact majority of the well-known Companies consider cost control as central objective of the finance department and purchase department. Market-driven factors aside, Companies are focused to improve the internal efficiency at all levels such as manpower efficiency, energy efficiency, equipment efficiency, procurement efficiency etc. With appropriate management processes in places the non-technical efficiency can be achieved.

With regards to technical efficiency it is mandatory for Companies to rely upon one of the easier routes of energy which forms a significant component (as high as 20% in some cases) of the overall cost of manufacturing. The good news, however, is that the energy can be controlled by implementing Energy Efficiency and Energy Conservation measures.
Energy Cost as part of Production Cost in Manufacturing

   Fig. 2 – Energy Cost as part of overall Production Cost
So are Energy Conservation and Energy Efficiency different? While both contribute to the same goal i.e. reducing overall energy consumption in the facility without hampering productivity, quality and output., the 2 are different in terms of the path taken to achieve that goal.
Basically they are defined as -

Energy Conservation - To arrest leakages within the existing systems through plugging the leakages, altering operations and changing human behavior.

Energy Efficiency - Implementation of new-age equipment through retrofitting or replacement of existing systems which improves overall system efficiency thereby giving more output per unit of energy consumption. 

Sometimes the above two terms are used interchangeably which, as you could see, is not correct. Both the measures should be used collectively and not in isolation. Energy Optimization is a joint term to indicate both the above. For a plant to have optimum energy levels both Energy Conservation and Energy Efficiency are necessary. Not just for saving on production cost but also as a sustainability measure.

Majority of the plants where we have conducted Energy Audit have had energy as a significant cost component in the range of 10% to 30% with a median of 17%. So any reduction in energy through Energy Audit or going for Renewable energy has a significant and direct impact on Company's profitability. Even assuming a basic 7% reduction in energy bills (power, fuel, gas, coal etc.) can result in a saving of 1.20% in the total cost of production.
Energy Audit Saving Calculations
           Fig. 3 – Energy Saving Calculations and Impact on Cost of Production
As can be seen in Fig. 3 above savings on energy can have a positive and direct impact on a Company's profitability through cost control. It is thus a mandate now for Energy-intensive Industries to carry out frequent Energy Audits. Irrespective of the type of industry a plant should carry out Energy Audit at frequent intervals. Ideally once every 2-3 years is a good time for Energy Audit to reveal good opportunities for Energy Saving.
To know more or to enquire about Energy Audit, contact us at Enerco Energy Solutions LLP through -
Our website : www.econserve.in
Email id : info@econserve.in
Whatsapp / Phone : +91 9890737447  

Monday, 20 May 2019

Energy Audit - Energy Saving Guide for Industries

Energy Audit - Energy Saving Guide for Industries 

Energy Audit certainly benefits all types of plants - irrespective of size or type or age. While the energy saving opportunities might differ., there is no doubt that energy audit does result in energy saving.

Each Industrial plant is unique and has it’s own opportunities and challenges., although there are some common areas wherein a plant could benefit from implementing most common Energy Conservation and Energy Efficiency measures. It is observed that majority of the Industrial plants (nearly 80%) can save good amount of energy by focusing on below areas. Of course these are only general guidelines and exact savings, investments, payback would be plant specific and is understood better during detailed energy audit.

1.  Compressed Air System
Observations :
a.   Manual loading and unloading
b.  Idle running
c.   Obsolete starting methods
d.  Manual intervention
e.   Leakages in Compressed Air System
f.    Maintenance

Recommendations :
a.   Automation for synchronization
b.  Adoption of advanced starting methods
c.   Arresting leakages in compressed air system
       
2.  Pumps
Observations :
a.   Efficiency deviation from design
b.  Damages to pump internals – impeller or casing
c.   Malfunctioning valves
d.  Ageing
e.   Maintenance
Recommendations :
a.   Impeller re-sizing
b.  Higher maintenance focus
c.   Replacement of ageing pumps (can payback within months)
3.  Fans & Blowers
Observations :
a.   Impeller sizing issues
b.  Obsolete control mechanisms
c.   Maintenance
d.  Throttled Dampers
e.   Efficiency deviation from design

Recommendations :
a. Automation for fan speed adjustment.
b. Repair of internal damages.
c. Higher focus on maintenance.
d. Better damper control.

It is observed that above 3 areas contribute to nearly 10% to 20% of total energy saving opportunity in a typical plant. In majority of the cases minor tweaks in operational practices can lead to huge savings i.e. zero investment recommendation with immediate payback.

Some of the cases include incorporation of newer technologies which help in better control of energy usage. In a few of the observed cases it was recommended to adopt newer technologies for improved energy performance. Any cost implications of new technologies was suitably supported with quick RoI / payback of 9-12 months. In all cases the recommendations had a payback of lesser than 24 months as is accepted by majority of the Companies.

There are other common areas within every plant which could be explored for further energy saving which are as below.

Other common areas for Energy Saving –
A. Using Rooftop Solar for captive use (significant savings)
Ø  Variety of financial models including ZERO upfront payment under BOOT / RESCO
Ø  Power cheaper than Electricity Board / DISCOM / Utility
Ø  Can result in 10% to 30% saving on Electricity Bill per month
Ø  Simple payback of 3-5 years for self-financed project which is attractive considering 20+ years of PV Solar life.

(Check out : How Solar Energy can boost your Company's Profits)

B. Replacing lighting with higher efficiency lights (miniscule savings)
Ø  Newer and evolving technologies such as LED, Sky lamp etc.
Ø  Can result in 1% to 2% saving on Electricity Bill per month.
Ø  Simple payback is less than 1 year for majority of the replacements.


Conclusion
Energy Audit is a highly customized exercise carried out for plants and can result in SEC (Specific Energy Consumption) reduction of anywhere between 2% to 7%. The actual saving depends on a variety of factors but overall it is almost always possible to identify areas for energy saving.
The savings can have a huge impact on a plant’s revenue and profitability based on the actual cost composition in overall plant manufacturing. 

With ever-rising grid tariffs, cost of basic energy (coal, oil, gas etc.) it definitely makes a strong business case for a plant to carry out Energy Audit. For plants which have never carried out energy audit there could be shocking revelations on this front. For plants which periodically carry out energy audit, this exercise helps in identifying niche areas for energy saving as well as keeping up the momentum.

While major energy saving lies in the process specific to a particular unit, the utilities present a generic energy saving opportunity for a plant. These energy saving opportunities are basically “low-hanging” fruits that can be used to capitalize on energy optimization by any plant – irrespective of it’s process or age or composition. By adopting few simple methods as outlined in the observations in the previous section, a plant can certainly expect to save some amount of energy., which is a welcome positive step. With additional measures the energy saving initiative could be taken up further.

Moreover a detailed energy audit reveals far more opportunities which can have a significant impact on a Company’s profit margins. Many companies are waking up to this fact and are adopting energy saving measures as a Company wide policy and not just as a one-time exercise. ISO 50001 is another step in that direction which indicates how well a Company is using it’s energy resources. Customers are satisfied in more than 90% of the cases wherein Energy Audit was carried out for the 1st time. Majority of these customers have vowed to carry out frequent and periodic energy audit to ensure maximum benefits and for maintaining continual momentum for energy saving within the plant.


(Enerco Energy Solutions LLP cannot be held liable for the outcome of the recommendations mentioned herein. Any recommendation mentioned herein should be carried out post verification by a Certified Energy Auditor)

About Us –
ENERCO ENERGY SOLUTIONS LLP (estd. 2009) is one of the oldest Energy Consultancy Companies with highly experienced team of Solar Consultants, Energy Auditors and Energy Managers led by IIT-B alumnus. We have had the pleasure and privilege to work with some of the top names across India and overseas and assisted them in adopting energy efficiency and Solar Power for their Company.

In case you are interested in carrying our Energy Audit of your plant., simply send us a mail on info@econserve.in / info@enercoenergy.in and we would be glad to assist you. You can even whatsapp or call on +91 9890737447.