Showing posts with label Energy Efficiency. Show all posts
Showing posts with label Energy Efficiency. Show all posts

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.

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.

Monday, 29 August 2016

Energy Audit - Is it the right time for your plant?

Energy Audit - Is it the right time for your plant?

Energy Audit is a periodic exercise undertaken by a plant to assess it's energy consumption and identify opportunities for Energy Conservation and Energy Efficiency. It also helps a plant personnel in modernizing the plant inline with new technology solutions.

The question is why is it periodic and not a one-time activity. The answer lies in the dynamic nature of manufacturing industry - both internal and external. With the advancement in technology there are better and more energy efficient ways to carry out the same activity. For eg. use of higher efficiency equipment such as Compressors or motors or Boilers. By use of contemporary solutions a company could ensure more bang for the buck. A plant which stays in the status quo mode with the belief that it's performing at it's best would soon witness oblivion.

Additionally a plant undergoes modifications over a period of time which may impact it's energy balance thereby presenting newer opportunities for deployment of Energy Efficiency practices. Modifications may include enhancement of capacity, new product addition, introduction of new equipment or replacement of old or worn out equipment etc.

Increasing competition from the Global and new Local competitors should be one of the major driving forces to achieve optimum energy levels. It is no surprise that plants across the Globe are striving to achieve optimum cost of production to stay ahead of the competition. Energy is indeed one of the most expensive resources which can significantly impact the production cost - both positively and negatively. Energy Efficiency and Energy Conservation should be viewed as a strategic tool to achieve competitive edge.

To understand if this is the right time for your plant to go for Energy Audit we have prepared a check-list. The answers to this checklist would give you a fair idea if Energy Audit is recommended for your plant or not. This is particularly important if you are expecting significant energy saving from the Energy Audit. There are cases wherein a plant carries out Energy Audit to cross-check or verify their correctness of operations as well.

If you are still not sure, you may go for EXPRESS Energy Audit. More details about the same can be found in our blog post - Express Energy Audit and it's benefits.

In any case it would be worthwhile for you to get this FREE analysis done. Simply send a mail to info@econserve.in and we will guide you to the next steps.


Enerco Energy Solutions LLP specializes in Energy Efficiency and Energy Conservation solutions & services including Energy Audit, PV Solar Power Consultancy, Energy Saving Projects, PV Solar Projects, Financing of Energy-related Projects etc. Our key differentiating factor is 100% FINANCING of Energy Saving and Solar Energy Projects.

In the Energy Efficiency space we have carried out assignments for highly reputed Clients from Steel, Cement, Thermal Power Plants, Chemical, Pharma, Glass Manufacturing, FMCG etc.

In the Solar Power space we have advised and executed projects for leading Industrial plants across India (through own financing + Customer financing) rooftop and ground projects ranging from 100 kW to 5000 kW (5 MW).

Monday, 30 March 2015

Can Energy Conservation and Energy Efficiency help in mitigating global warming?

Can Energy Conservation and Energy Efficiency help in reducing global warming?


What is Global Warming?
Global Warming is increase in the earth's atmospheric temperature due to trapping of most of the Sun's heat rather than reflecting from the Earth's surface. Earlier a debatable topic, it is now being accepted for real - thanks to sudden and abrupt weather changes across the Globe.

There is a strong link between Energy Conservation & Energy Efficiency with Global warming. This post attempts to join the dots and answer the query on how Energy Conservation & Energy Efficiency could answer the problem of Global Warming.

How is Global Warming impacting the Earth?
The earth's temperature is steadily rising and the average temperature on earth is expected to rise by about 4 degrees Celsius by the end of this century. The temperature rise is enough to melt down the ice in Antarctica and other areas causing coastal areas to drown.

Earth Atmosphere Temperature

As can be seen in the above graph the earth's temperature has increased significantly mainly attributed to human activities. Historically there have been instances of high temperature on earth but it has never touched the highs that we are currently witnessing.

[Others are reading : ISO 50001 : Energy Management System]

How can Energy Conservation and Energy Efficiency mitigate Global Warming?
With rapid Industrialization and growing population the consumption of all good and materials is significantly increasing. Energy is no exception.

World Historical Electricity Consumption
World Historical Electricity Consumption

As can be seen in the above graph the world electricity consumption has been on a consistent rise for a long time now. Power generation or electricity production has been primarily through burning of fossil fuels which releases CO2 into the atmosphere. Carbon dioxide is one of the green house gases which traps the heat within the earth's atmosphere.

Greenhouse Gas Emissions by Gas in U.S.


This is known as Greenhouse Effect which happens when CO2 (main greenhouse gas) along with other green house gases such as Methane form a blanket of cover trapping the heat.

[Other popular article : Energy Audit - Top 5 Reasons to go for it TODAY !]

What can be done?
Every unit (kWh) of electricity produced results in 0.8 to 1.0 kg of CO2 released into the atmosphere. The actual CO2 released into the atmosphere will depend on the type of fuel used i.e. Coal, Lignite, Gas etc. Out of the 2,50,000 + MW of installed capacity in Indian 60% of power generation is through Coal and 10% through other fossil fuels. This shows that fossil fuels still dominate the power scenario in India.

It is expected that power consumption will continue to rise across the Globe especially in developing economies such as India.

Global CO2 Emissions Abatement Energy Conservation, Energy Efficiency and Renewable Energy
Energy Efficiency scores highest on world CO2 emissions abatement Strategy
As can be seen in the above graph Energy Conservation and Energy Efficiency can result in significant CO2 abatement and thereby help in addressing the issues of Global Warming and Climate Change.

While energy consumption for power production cannot be curbed we can certainly adopt energy conservation measures and energy efficient equipment & processes. This would help in bringing down per-capita consumption of energy.

Energy Audit is a step in the direction of Energy Conservation and Energy Efficiency and hence can help in reducing Global Warming to a large extent. This is true for Industrialized Countries as well as developing Countries such as India, China, Middle-East and South East Asia - which are fast becoming a manufacturing hub. Especially for India wherein more than 45% Energy Consumption takes place in Industrial plants, energy conservation and energy efficiency in Industrial plants could certainly help the cause of global warming.

Not just for the planet, Energy Saving makes a strong business case as well. Do check out our blog post on how Energy Saving = Higher Profitability.

We invite your comments to this post with your views, feedback and queries.

Enerco Energy Solutions LLP assists Industrial and Commercial Consumers in reducing their energy usage by adopting energy conservation and energy efficiency measures. This is done by carrying out Energy Audit, System Audit, Site Survey and then executing Energy Saving and Solar Energy projects on BOOT Basis and ESCO basis with 100% Investment.

Wednesday, 21 January 2015

Energy Audit - What Next?

Energy Audit - What Next?
(Updates of 01st August 2016 - below)

International Energy Agency (IEA) estimates that Energy Conservation and Energy Efficiency can alone result in more than 60% of CO2 Abatement by 2020.

Energy Efficiency IEA Chart
CO2 Abatement IEA Chart

As can be seen above Energy Efficiency sits on top of all other initiatives for CO2 abatement and thereby controlling global warming. Interestingly the investment required to achieve 60% of CO2 abatement during the period 2010-2020 is 70% of the total investment required for all the initiatives during the period.

Energy Audit is the first step towards Energy Conservation in an Industrial plant or a Commercial facility. In India Energy Audit, although quite popular with Industrial plants, is yet to take off in a very big way. Many Companies have realized the potential of energy saving in their plant and have also carried out energy audit. However one must realize that Energy Audit is only the first step in the direction of energy efficiency and energy conservation. The recommendations made as part of the energy audit have to be implemented to achieve the energy saving targets.

The energy saving recommendations may require little or no investment and in some cases high investments as well. The investments are then taken up by the plant in a phase-wise manner, which result in delayed energy saving for the plant. In fact some of the recommendations may never be taken up by the plant. This renders the entire energy audit exercise futile.

In addition to the technical expertise required for Energy Audit the need of the hour is to have mutually beneficial business models such as ESCO and RESCO. 
Energy Audit - ESCO Approach

In case of ESCO the service provider (Energy Audit Company) invests in the energy saving projects identified in the plant or commercial facility (Target Company). The benefits of the savings achieved are then shared by the service provider and the plant.

The benefits of this approach to a plant :

  1. Energy Audit enables to assess the true potential of energy saving in the plant. Typically this can range from 5% to 12% of Specific Energy Consumption (SEC).
  2. The service provider (Energy Audit Company) has the responsibility to identify truly feasible projects after mutual discussions and an in-depth analysis.
  3. The responsibility of service provider does not end with submission of energy audit report.
  4. Financing for the identified energy saving projects would also be undertaken by the service provider and hence no investment to be done by the plant once the energy audit is completed.
  5. The plant would start saving from the first day of implementation of project without investing in the project.
Updates of 01st Aug 2016
In addition to above mentioned benefits it is also prudent to note that Energy Efficiency and Energy Conservation is an ongoing exercise. This means fresh influx of investments are required from time to time.

In most of the cases any Industrial plant or manufacturing unit wishes to focus it's major resources - money, time and work-force - on it's core activities. For example a Steel plant would want to focus it's entire work force on quality, timely and cost-efficient way of manufacturing Steel. In such a 

[Other Popular Article : Energy Audit - Is it the right time for your plant?]

scenario a holistic approach by a dedicated Energy Saving company could reap results and benefits in the short to long term. While the Energy Saving Company resources work independently (under the leadership guidance of a Energy Manager) there are various improvement suggested over a period of time (as against a one-time Energy Audit activity) :
  1. Brainstorming sessions : Prepare a list of all identifiable Energy Saving opportunities - including the ones suggested by in-house team. Evaluate all the opportunities and come up with a final list of practically possible Energy Saving measures. This is supported by data.
  2. Expert Consultancy under ESCO : Visit by a process expert under ESCO model wherein the said Company does not pay for consultancy charges but the charges for consultancy are linked to actual energy saving achieved.
  3. Contemporary Solutions : As the approach is cyclical and ongoing in nature it ensures that the most contemporary solutions are being suggested and implemented in the plant.
  4. 360 Degree view : All the critical touch-points including all equipment, machinery, logistics (if applicable) from gate-to-gate are covered and explored for Energy Saving opportunities.
Many plants wish to go for an Express Energy Audit after a detailed Energy Audit for 3rd party verification of energy saving recommendations and to continue the momentum of energy saving within the plant. This could be a good next step after a detailed or Comprehensive Energy Audit.

At Enerco Energy Solutions LLP we partner with your Company for Technical Consultancy but also Financial Consultancy as well as fund Energy Saving Projects and Solar Energy Projects. There are various financing models including (but not limited to) -
  1. 100% investment in Energy Saving / Solar Power under ESCO / RESCO model.
  2. Low-cost Debt financing of Energy-related projects.
  3. Performance-linked financing of Energy-related projects etc.

If you wish to know more about how Enerco Energy Solutions LLP could partner with you in bringing down your energy costs - under ESCO and RESCO (or other financing) models - please write into us on info@econserve.in . To know more about our Energy Audit related services please visit our website section dedicated on the same - Energy Saving Audit.

Thursday, 10 October 2013

ISO 50001 : 2011 Energy Management Systems Overview & Benefits

ISO 50001 : 2011 Energy Management Systems Overview & Benefits

ISO 50001 : 2011 Energy Management Systems was released by International Organization for Standardization in June 2011. It specifies a standard for improving energy efficiency of an Organization by achieving continual improvement in it's energy usage.

[Our latest post - Can Energy Conservation help in mitigating Global Warming?]

ISO 50001 offers a systematic approach for Energy management within an Organization. While Energy Audit which is certainly beneficial to a single unit or plant or office in saving energy, the ISO 50001 framework works across the Organization. It may still be required to audit individual plants or facilities as part of the policy framework developed for an Organization.

It provides a framework of requirements for Organizations to :
  1. Develop a policy to improve energy efficiency
  2. Set targets and objectives
  3. Carry out energy audit
  4. Measure results
  5. Review policy
  6. Ensure continual improvement in energy efficiency
In the present scenario where the energy costs are at an all time high ISO 50001 provides the necessary approach path to achieve energy conservation and energy efficiency goals of a Company in a systematic manner. It offers a blueprint for energy management policy and a universal process that can be applied across Organization including factories, offices, commercial facilities etc.


Energy Efficiency by ISO 50001 Energy Management System


The most important aspect of ISO 50001 is continuous improvement in energy efficiency through Action => Data collection => Data Analysis => Further Action. Energy Audit forms a critical part of the ISO 50001 framework implementation as it calls for performance review at critical points and enables a strong feedback based system. It may be noted that it is advisable for a plant to undergo an Energy Audit at periodic interval for achieving optimum level of energy usage.

The benefits of ISO 50001 to an Organization are as follows :
  1. Ensure optimum energy usage and thereby reduce cost across its manufacturing facilities, offices, warehouses etc.
  2. Improve its competitiveness by ensuring optimum cost of production as energy forms a sizable part of input cost.
  3. Improve it's image by projecting itself as an environmental conscious Company.
  4. Ensures uniformity in approach and better output through individual contribution for Energy Efficiency.
If you would like to know more about this, please get in touch with us today.

Enerco Energy Solutions LLP offers variety of solutions and services mainly in the Energy and Safety domain for Industrial plants. Our latest offering is 100% Funded Solar Energy and Energy Conservation projects on BOOT and ESCO basis.

Services include Energy Audit (Electrical and Thermal), ISO 50001 - Consulting, Implementation and Training, Solar Power - Consulting, Training and Project Execution., please drop us a mail to info@econserve.in or get in touch with us through our Contact Us form.

Tuesday, 3 September 2013

Energy Audit - How much energy can your plant save?

Energy Audit is an important Energy Conservation and Energy Efficiency exercise carried out annually or biennially by Industrial plants and Commercial facilities. The obvious reason for a plant to go for an Energy Audit is the saving of energy through Energy Conservation and Energy Efficiency measures. This saving translates into monetary saving and hence can have a direct impact on profitability of a Company. It is also an obvious step towards sustainability.

Although Energy Audit in itself can result in saving of Energy the recommendations made post complete survey, study and analysis as part of Energy Audit results in far more savings. The typical savings for a plant can range from 7% to 15% or more, the savings vary from plant to plant as there are various factors that can impact the same :
  1. Age and type of the plant.
  2. Time since last energy audit.
  3. Plant load composition.
  4. Modifications in the plant.
  5. Energy saving measures undertaken.
  6. Plant / Company Policies.
  7. Types of fuel used in the Plant.
  8. Energy billing type.
  9. Plant location.
And many such factors.

There is, thus no specific answer, as to how much energy a plant could save post an Energy Audit. An estimate could certainly be provided and in all cases, based on our experience with various Clients across India and overseas, Energy Audit could prove to be useful and economically viable. This is especially true in the present day scenario when Energy costs are ever-rising and are expected to rise further.

If you are still not sure the best approach is to go for Express Energy Audit which would help you in estimating the energy saving potential of your plant. You may then decide whether to go for a detailed or Comprehensive Energy Audit post the express energy audit.

Enerco Energy Solutions LLP has been at the forefront of advising Industrial Plants on Green Energy initiatives such as Energy Optimization, Energy Audit, Solar Power, PV Solar etc. If you wish to carry out Energy Audit of your plant please send us the details in the Energy Audit Questionnaire.

Monday, 14 January 2013

Energy Audit - Top 5 Reasons to go for it TODAY !

Energy Audit – Top 5 Reasons to go for it TODAY !

1.     Energy Audit which results in Energy Saving for a Plant translates into Significant Saving on Production Costs which can be anywhere from 5% to 10% depending on size of the plant and various other factors.
C  Energy is the 2nd largest component in the Production Cost. In 2012 - almost all the States of India hiked power prices with hike ranging from 5% to 30%. With ever-rising cost of Energy – Energy Conservation and Energy Efficiency can directly impact P&L Statement. Energy Audit will thus result in significant Energy Saving - as mentioned in this post - Does Energy Audit really save Energy? [link]

2.    Energy Audit works for every single Plant or Commercial Facility as there is always scope for Energy Optimization through Energy Conservation & Energy Efficiency.
C  Every plant goes through some changes over a period of time. Moreover an external Energy Audit team works across departments and brings in rich experience gained from Energy Audit of several plants. This not only results in gaining fresh perspective of Energy saving possibility by an external team also results in bench-marking based on similar parameters.

3.  Energy Audit gives a positive orientation to Preventive Maintenance, Safety and Quality Control programs thereby improving the overall efficiency and output of existing system.
C  Energy Audit does not mean only studying the energy aspects but also a comprehensive study of the plant with respect to performance and output. As mentioned in the New Age Industrial Energy Audit [link] post - an Energy Audit includes several aspects of improvement in output at an Industrial plant with Energy Conservation and Energy Efficiency as the central theme.
   
4.  Nearly all the Industrial Units and Commercial Complexes have a potential to save 10-15% on Energy Bills (in Electrical Power alone) and additional savings in Thermal Energy.
C  Verified by Government Agencies and hence BEE has selected Designated Consumers to carry out periodic Energy Audit. In any case an Industrial Plant or Commercial Facility is certain to gain from an Energy Audit which gives them an opportunity to periodically review their Energy goals and ensure optimum energy levels for the plant.
 
5.     Many of the Energy Saving measures recommended as part of an Energy Audit may require little or no investment but results in significant savings.
C  Energy Audit Report [link] - submitted at the end of the Energy Audit - consists of several recommendations including many which may require negligible or no investment – but can result in savings of 5 – 8%. Further savings possible through implementation of additional recommendations in the report.


To know more please read - Energy Audit : Why Should a Plant go for it [link].

If you are interested in a FREE Assessment of Potential Energy Saving in your plant and a Quote for Energy Audit - please download the questionnaire [link] and mail us the details on info@econserve.in

Wednesday, 17 October 2012

Energy Audit :: Why should a Plant go for it?

Energy Audit :: Why should a Plant go for it?

Energy Audit is an exercise carried out for an Industrial Plant, Thermal Power Plant or a Commercial Facility as a first step towards achieving Energy Conservation and Energy Efficiency. As mentioned in one of our previous posts it is a complex technical assessment which results in achieving optimum energy level. 

More often this crucial exercise is carried out for Industrial Plants or Thermal Power Plants as Energy forms a greater component in the production cost. With the ever-rising cost of Energy (Fuel, Coal etc.) and Grid Electrical Power it is a necessary step towards achieving optimum Energy level. The term Specific Energy Consumption (SEC) is commonly used to determine the energy required to manufacture or process a particular unit of plant output (eg. kWh / T for a Steel plant or litres / kWh for a D.G. Set etc.). For an Industrial Plant SEC may include all possible energy that has been used in the product manufacturing or processing and not just electrical power.

There are several reasons why a Plant should ensure a periodic and comprehensive Energy Audit (Thermal + Electrical)., majority of them are :
  1. Energy forms a major component in Production Cost and will continue to increase its share for an Industrial Plant as Energy costs are rising every day. In many cases it is the 2nd largest component in Production cost next only to Labor. Thus an Energy Audit can significantly and positively impact a Plant's Profit & Loss Statement.
  2. Any Industrial Plant undergoes a change due to expansion or modification or modernization - always presenting an opportunity for Energy Optimization. An Energy Audit will thus reveal potential areas to save energy and improve efficiency.
  3. Energy being a topic of high interest - constant innovation takes place with regards to modernization of equipment and retrofits for existing equipment. Energy Audit enables a plant to understand about continuous opportunities in a plant to achieve energy optimization. In fact our post on New Age Industrial Energy Audit focuses on this point.
  4. Several Energy-intensive plants may have a permanent Energy Auditor or Energy Manager. However there are several benefits of an external Energy Audit team which works across various departments - Electrical, Mechanical, Maintenance, Production etc. of a plant. Moreover an external team is better equipped to achieve Energy Conservation and Energy Efficiency through energy audit as it brings a focused approach and past experience of several plants which enables in bench-marking including successful case-studies of past implementations.
  5. Contrary to the popular belief an Energy Audit in itself can actually save Energy (Does Energy Audit really save Energy?) without further investments as well. This is the case because the Energy Audit report which is submitted after the Energy Audit contains several key information about the plant such as energy consumption trend, energy calculations, areas for improvement etc. and of course the recommendations. 
  6. The Energy Audit report submitted at the end of the site visit phase (for measurement, collection of data, interaction with plant people etc.). The recommendations in the Energy Audit Report are not always requiring high investment and are in any case having a payback of less than 18 months or in some cases 24 months - which is generally acceptable to the Management. They are categorized into 3 types -
    • ZERO / Low investment recommendations - mainly related to operational changes or utilizing existing resources to optimize energy consumption.
    • Medium investment recommendations - typically the ones with requiring mid-size investments in retrofits or modifications in the existing system for Energy optimization.
    • High investment recommendations - the ones requiring larger investments. (The categorization value is specific to a plant based on various factor such as size, energy consumption, SEC etc.)
  7. Energy Audit in a Plant creates an awareness and a sense of urgency among the Plant personnels which in turn translates into further energy saving. It is established that simple methods of saving energy (such as manually Switching off an equipment when not in use) can be achieved through human intervention. Thus Energy Audit helps a plant to achieve further savings - however small without any investments !
  8. It gives a positive orientation to Preventive Maintenance. This is mainly because although Energy Audit focuses primarily on Energy optimization it also points out areas which can perform better with timely maintenance - thereby enhancing reduced downtime and improved output.
It is thus no surprise that several Plants opt for a periodic Energy Audit to keep a check on the overall Energy consumption and continually achieve Energy Conservation and Energy Efficiency. Energy Audit is also a step towards green initiative as it results in achieving Energy Conservation and Energy Efficiency. At a higher level an Energy Audit can go a long way in optimizing the consumption of Nation's natural resources. At the Global level an Energy Audit can be a small step towards reducing GHG levels.

Tuesday, 3 April 2012

Does Energy Audit really save energy?


Energy Audit is the first step towards Energy Conservation & Energy Efficiency. In fact Energy Audit itself may consist of 3 steps i.e. Preliminary Analysis, Walk-through Energy Audit (aka Express Energy Audit) and Detailed or Comprehensive Energy Audit.

The steps may sometimes be combined but some Companies may skip a step or in some cases combine them as well. Express Energy Audit is used by Companies to only estimate the potential energy saving in the plant. Although finding out visible areas of savings are possible through Express Energy Audit. With regards to Detailed Energy Audit., it definitely digs in deeper to identify all possible energy saving opportunities within the plant. A well-documented report with recommendations backed by data is the outcome of detailed Energy Audit. Do visit our website to know more about each type of Energy Audit.

There are definite reasons that Energy Audit is not viewed as a wholesome exercise by many. The variety of reasons are at operational level as well as based on past experience by a few of the decision makers who have been involved in previous such exercises -

  1. Misconception that Energy Audit in itself would save a lot of Energy.
  2. Energy Audit being carried out by inexperienced and incompetent teams.
  3. Recommendation implementations not taking place resulting in no conclusive outcome of Energy Audit.
  4. Recommendation implementations not approved despite good savings potential.

Etc. Etc.

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With various factors considered it is sensible to assume that an Energy Audit in itself will not save significant energy. Although Energy Audit itself does save some energy and the savings can be in the range of 6-8% achieved by changing certain operational parameters, visible areas of saving by bench-marking, ergonomic factors, enhanced awareness etc.. In case of purely Electrical Energy Audit the savings can be on the higher side of range band through the Energy Audit itself. To achieve significant saving retrofits and equipment replacements are needed as per the recommendations mentioned in the Energy Audit Report. However to obtain appropriate recommendations for operational changes, retrofits and replacements inline with the process and operational requirements is what Energy Audit is all about.

In a nutshell Energy Audit is the first crucial step in the direction of Energy Conservation & Energy Efficiency Project. If carried out in a systematic approach by experts in this field - energy saving can be expected as an outcome of the exercise. The other outcome of course is the report which lists out the recommendations. With ever-rising Energy Costs it is imperative for Industrial Plants to carry out periodic Energy Audit and implement the solution as well to achieve greater results.

Energy Conservation Project generally follows the below cycle -

Energy Audit, Energy Conservation, Energy Efficiency


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Another interesting point is about measuring the savings and if savings have actually been achieved in a plant after an Energy Audit. In general a comparative analysis of energy consumption before and after audit will not reveal true results as energy consumption generally is not constant for any given plant due to seasonal changes, market demand for the product (being manufactured), internal factors etc. Specific Energy Consumption is the term which is used to denote the Energy required or Energy invested (Electricity, Coal, Diesel, Fuel etc.) in producing one unit of a product. With a setup having more than one product the SEC for each of the product needs to be calculated and will give a true indication whether an Energy Conservation and Energy Efficiency has been achieved or not.

With an aim to reduce Specific Energy Consumption an Energy Audit should not be carried out in isolation but should be looked at as part of an overall Energy Conservation Project and hence Specific Energy Consumption (SEC) or Specific Power Consumption (SPC) should be closely monitored as an ongoing practice to achieve good results. It is known fact that energy saving is not a destination but a journey.

Updates of Oct 2019
Based on our past experience a Company can save anywhere between 5% to 12% on Energy Bills. This includes - Electricity Bill, Fuel Bill (Diesel, F.O., Coal, LPG etc.). For a typical plant this could mean savings of 2% to 5% on it's production costs.

The range of energy saving is based on our past experience of 300+ Energy Audits and is based on practically implementable solutions. We are in the process of documenting energy savings achieved through energy audit assignments by preparation of a Comprehensive Report with data for a variety of Industries. For now you might find it useful to download our Energy Audit Case-Study for a recent assignment. The customer was able to save 10% Energy and consequently 2.5% on production costs.

Download the Energy Audit Case-Study to know more about details of the Energy Audit, our approach, findings, recommendations etc. for this plant.

If you are planning for Energy Audit, there are certain things that you should be aware of. Why not check our blog post on the subject - Energy Audit planning - things to know !

Saturday, 18 February 2012

Energy Optimization - here to stay....

Energy Optimization is here to stay and there are reasons to believe it - atleast in India. With 15% peak deficit which is expected to widen further with rapid growth and Industrialization. Well this is just not the reason but one of the most startling facts that should ensure that Energy Optimization becomes a routine rather than a specialized exercise.

Reason # 1 : India continues to grow rapidly with several expansions and new Industries seeing the light of the day. To support these Industries by relying only on power generation will not be possible and we can certainly see renewed and long-term interest in Energy Optimization. Perhaps it will result in further interest in the form of Government initiatives.

Reason # 2 : With nearly 70% of power from Fossil fuels there is a huge dependence on the same. It has been witnessed in the past (Gulf War etc.) that certain instances can certainly influence the pricing and availability of fossil fuels. There is a gradual shift in focus from reducing dependence on fossil fuels by going for alternative options like Solar Power. However without Energy Optimization a holistic approach to solving the power problem may not be seen. It therefore makes considerable sense to adopt Energy Efficient approach by initiating an Energy Audit.

[Suggested Read - Does Energy Audit really Save Energy?]

Reason # 3 : Large-scale initiatives require Government support. Energy Saving Certificates or E-Certs are Government initiatives to encourage Industrial Plants (especially Energy intensive Industries) to opt for Energy Optimization. This is just the beginning and hence we expect greater action going forward. Moreover there is already a Government directive to penalize Industrial plants which are not adopting energy efficient means of operation.

Reason # 4 : Power deficit and increased demand translates into increased prices. The power prices have already risen several times in the past. This will continue to rise further thanks to coal shortage and freeing up of Coal prices. In a nutshell there would be no option but to go in for comprehensive measures to optimize energy usage and most of it would be outsourced to experts.

There are other reasons which shall be discussed in the next posts.....