Showing posts with label Thermal Energy Audit. Show all posts
Showing posts with label Thermal Energy Audit. Show all posts

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.

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.

[Can Solar Energy Projects work across India?]

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


[Is Solar Energy really afforable?]

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 !

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