1. Energy Audit Definition:Energy audit Types of energy audit, Understanding energy costs Bench marking Energy performance Fuel and energy substitution Energy audit instruments

2. Conversion Factors for MTOE 1 Kwh = 860 Kcal 1 kg of coal/coke = GCV in Latest Certificates 1 kg FO/LSHS/Naptha = 10500 Kcal/kg (density = 0.93) 1 kg HSD = 11840 Kcal (density = 0.82) 1 kg Petrol = 11200 Kcal (density = 0.708) 1 kg Kerosene = 11110 Kcal (density = 0.778) 1 kg LPG = 12500 Kcal 1 m3 of Natural gas = 8000-10500Kcal (actual as per certificate) 1 kg of oil equivalent = 10,000 Kcal

3. Energy Conservation Act Designated consumers :Central Govt. specify the following criteria for energy Intensive Industries and other establishments. (As per EC Act 2001, Section 14(e) For Industries Electrical connected load -5000 KW and above or Annual energy consumption - 30,000 MTOE For Commercial Buildings Connected Load - 500 KW or 600 KVA

4. ELECTRICITY ACT 2001 MAIN FEATURES 1. Replaced all the previous three Electricity Laws: –Indian Electricity Act 1910, Electricity Supply Act 1948 –Electricity Regulatory Commission Act 1998 as amended from time to time 2. 100% metering is mandatory for 11 KV feeder 3. 100% Rural Electrification – Accelerated Rural electrification Program, AREP) – PRIs & NGOs can be participated) –80,000 villages yet to be electrified

5. ELECTRICITY ACT 2001(Contd..) 4. Private sector Investments is allowed in Renewable Energy Sources (Generation, Distribution, Supply area) –No license is required for generation and distribution of power in Rural areas. 5. Participation in power transmission sector 6. More stringent provision for theft of electricity

6. ELECTRICITY ACT 2001(Contd..) 7. Delicensed for Captive power generation, Thermal power generation, Hydro power generation –can be sold directly to other consumers by wheeling through the grid under open access –Banking facility is provided to captive power plants 8. State Electricity Regulatory Commission is mandatory for all States

7. Definition of Energy Audit As per the Energy Conservation Act, 2001, Energy Audit is defined as “the verification, monitoring and analysis of use of energy including submission of technical report containing recommendations for improving energy efficiency with cost benefit analysis and an action plan to reduce energy consumption “

8. Objective of Energy Management To achieve and maintain optimum energy procurement and utilisation, throughout the organization To minimise energy costs / waste without affecting production & quality To minimise environmental effects. TO KNOW TECHNICAL PERFORMANCE OF MAJOR EQUIPTMENT / SYSTEMS TO IDENTIFY LOSS AREAS TO ASSESS TECHNO ECONOMIC FEASIBILITY OF ENCON OPTIONS.

9. ENERGY AUDIT….. It’s a tech.Survey to analyze existing energy utilisation practice, pinpoint areas of wastage and to evolve energy saving schemes. It is an organised and systematic exercise with top management support Energy audit addresses House keeping Operational improvement/retrofits Capital projects requiring investment New technology Energy audit helps to achieve “savings through invisibles”.

10. Types of Energy Audit 1.Preliminary energy audit 2.Detailed energy audit

11. Safety Considerations The audit person or team should be thoroughly briefed on safety equipment and procedures Adequate safety equipment should be worn at all appropriate times. Auditors should be extremely careful making any measurements on electrical systems/on high temperature devices.

12. Preliminary Audit Site Survey: Take a walk through survey /Observations Collection of existing energy and production records of the entire plant and major energy consuming facilities and departments. Brief data analysis and preparation of documentation. Identification of preliminary energy saving measures, including an estimation of saving potentials and economic aspects

13. INDUSTRIAL ACTIVITIES Final Product Raw Materials Fluids Raw Materials Fluids Manpower Energy Industrial Wastes LIQUID toxic, inorganic and organic wastewaters GASEOUS Emissions SO 2, NO x, CO, etc. SOLID WASTES wasted raw material or product, sludge from ETP DISCHARGE ENERGY heated fluids, steam, hot emissions etc.

14. TYPICAL PLANT UTILITIES & SCOPE AREAS BOILERS/FURNACES PUMPS FANS AIR COMPRESSORS A/C PLANTS COOLING TOWER TRANSFORMERS MOTORS DG SETS LIGHTING ELECTRIC HEATERS

15. Process Flow Diagram Spinning Mils Raw Cotton Blow room Carding Drawing Combing Simplex Ring frame spinning Cheese Winding Doubling Cone winding Utility Electricity Humidifin.. Comp.air Lighting Production Yarn

16. Power Consumption Pattern in Spinning Mills

17. Typical Specific Energy Consumption Norms in Textile Industry COMPOSITE MILLS Thermal Energy = 19.0 Kg Steam /Kg of cloth Electrical Energy = 2.2 Kwh /Kg of cloth SPINNING MILLS Electrical Energy = 3.6 Kwh /Kg of yarn (UKG adjusted to 40 counts)

18. Preliminary Energy Audit Methodology It uses existing and easily obtained data Establish energy consumption pattern Establishes base line data Identify the most likely areas for attention/savings Identify immediate(no/low-cost) improvements Identify areas for more detailed study/measurement Helps in planning for Detailed audit(Team/instrument/Duration required)

19. Detailed Energy Audit Evaluates all energy using system, equipment and include detailed energy savings and costs Different phases of Detailed Audit –Pre-audit Phase (Preliminary audit) –Audit Phase (Instrumented/Comprehensive) –Brief presentation,Report Preparation/Vendor details collection –Draft Report presentation and Final Presentation –Post-Audit

20. PLANT ENERGY AUDIT COVERS ENERGY GENERATING EQUIPMENTS ENERGY DISTRIBUTION NETWORK END USE EQUIPMENTS. OPERATIONAL FEATURES PLANT. 1.CONTINUOUS PROCESS PLANT 2.ONE/TWO SHIFT OPERATION 3.INTERMITTENT.

21. ????????????????? l What type of energy used l How much energy is used? l How much does it cost? l Where it is used? l How efficiently it is used? l How can it be managed more efficiently and effectively? This is identified through carrying out ENERGY AUDITs

22. STEPS INVOLVED IN ENERGY AUDIT. 1.Data Collection 2.Efficiency Evaluation 3.Loss Quantification 4.Operational Improvement Measures 5.Techno Economic Evaluation of Projects. 6.Designing Energy Data Report System 7.Instrumentation Requirement 8.Action Plan For ENCON Implementation 9.Review --Setting Up of Target

23. SCOPE OF “DEA” TO INDICATE  CAPABILITIES & EFFICIENCY OF EQUIPMENT  NEED FOR AUTOMATIC CONTROLS  ADEQUACY OF MAINTENANCE  NEED FOR IMPROVED INSTRUMENTATION  SCOPE AREAS FOR ENERGY SAVING  COST BENEFITS OF SPECIFIC MEASURES IN SHORT / MEDIUM / LONG TERM  MECHANISM OF MONITORING  VENDOR INFORMATION  INCENTIVE SCHEMES / PROVISIONS

24. Detailed Energy audit tasks:- 1.Elaboration and discussion of audit methodology. 2.Selection of plants items to be audited. 3.Collection of more detailed energy and production data. 4.Comprehensive measurements at selected plants items. Process flow and utility diagram Measurement survey/performance trials 5.Data analysis and calculations 6.Elaboration of energy and material balance for the audited plant items.

25. 7. Investigation of energy saving options (improved maintenance of equipment, improved energy management, modification or rationalization of process configuration, improved insulation/ control of refrigeration, etc.) 8. Recommendation of feasible energy efficiency measures. 9.Financial analysis of recommended measures, including cost benefit calculation. 10.Ranking of measures and elaboration of an energy saving action plant 11.Reporting 12.Presentation to plant management

26. DATA COLLECTION How Much Data ? What Data ? Data Availability –Plant Records-metering How To Proceed In Case Of Data Not Available To Know Source of Information Experience To Device Data From Secondary Information Planning For Field Trials And Observation

27. Plant data Present landed cost of all types of energy used in the plant. Types of energy used :Electricity, Fuel oil, Coal, Gas Annual energy consumption and cost for all purchased and internal fuel.(3 years) Monthly purchased electricity & self generated. Month,kva,kwh,PF,bill amount. (Grid Power) Month,kva,kwh,PF,fuel cons.(Captive power plant) Annual Production for Past 3 Financial Year To know seasonal variation to know production and energy trend

28. Electricity Tariff Structure What are the elements of Electricity Bill ? Elements TNEB APSEB KEB Gujarat / Maharashtra MD Charge Rs.300/KVA RS.117/KVA <1000 kw Minimum 90% of CMD RS.116/KVA 1000-3000 Rs.115/kva > 3000 Kw MD Penalty Rs 600/Kva Rs. 225/Kva Energy 3.5.00 P/Unit Rs.1.8 <400 kwh charges Rs.1.6 >400 kwh TOD Tariff 6 - 9 AM/PM 10AM-6PM Oct-Feb 20% more 2 PM-10PM Mar- Sep 20paise /unit more PF minimum 0.9 0.85 PF Penalty <.9 2P unit for each 1% decrease in PF below.85

29. SPECIFICATION OF MAJOR ENERGY CONVERSION EQUPT. BOILERS HEATERS FURNACES THERMIC FLUID HEATER POWER GENERATING UNITS DETAILS OF MAJOR UTILITIES(PUMPS/FANS/COMPRESSORS) MAKE TYPE CAPACITY SINGLE STAGE/MULTISTAGE FLOW, HEAD DESIGN KW – EFFICIENCY CAPACITY CONTROL METHOD ACTUAL REQUIREMENTS ANNUAL OPERATING HOURS Operating Schedule(Design and Operating parameters)

31. Benchmarking Internal Benchmarking Historical and trend analysis External Benchmarking  Across similar industries kWh/MT Cement produced (Cement Industry) kWh/MT Paper produced (Paper Industry) kWh/ton of refrigeration (AC&R PLANT) /kWh /litre (DG Sets)  Energy cost as a percentage of total manufacturing cost - 30 to 60 %  Generally a decreasing trend in specific energy consumption  Specific power consumption varies from 66 to 127 kWh per tonne of cement  Specific thermal energy consumption varies from 692 to 879 kCal/kg clinker

32. Energy Conversion Boiler efficiency, Quality of Fuel used, Maintenance Energy Transfer Insulation of Steam piping, Jackets for hot fluid pipes to prevent losses Energy Utilization Equipment efficiency, Maintenance, Energy Recovery Waste heat exchangers, Energy Conservation

33. Product Waste Raw materials Separation Equipment Heat Recovery Heat Recovery By Product Material balance Cause and Effect Analysis Cost-benefit analysis Brainstorming Process 2 Process 1 Recovery Recycle, Reuse and Recovery

34. Fuel and Energy Substitution Fuel substitution Replacement of coal by Agro fuels Replacement of LDO by LSHS Energy substitution Electric heaters by steam heaters Steam based hot water by solar systems

35. ENERGY AUDIT REPORT 1.ACKNOWLEDGEMENT 2.CONTENTS 3.EXECUTIVE SUMMARY 4.SUMMARY OF SAVINGS 5.INTRODUCTION 6.PLANT ENERGY SYSTEM 7.ENERGY USAGE PATTERN 8.ENERGY INDICATORS 9.ENERGY SAVING OPTIONS/RECOMMENDATIONS 10.ANNEXURE/PLANT BASE LINE DATA Filed observation and savings calculations. List of suppliers. Action plan for ENCON implementation

37. Technical and Economic feasibility

38. Energy Audit Instruments POWER ANALYSERS

39. Measurement Technology -Measures @256 samples/cycle for better accuracy even on non-linear waveforms -Continuous & simultaneous sampling on all 6 channels for accurate readings on dynamic loads Accuracy far superior when compared to conventional analyzers with low sampling rate New Generation Measurement Techniques

40. Application – Textile Mill Study Readings of KRYKARD Load Manager ALM 30 Readings of Low & non- continuous sampling meter THD in %P.FTHD in % KWh (% error) P.F 8%0.882 15%0.837 36%0.86436%-1.2%0.82 52%0.88146%-2.77%0.74 74%0.88081%-8.2%0.68 This picture is taken using the Screen shot feature of ALM/3032. You can see that the ALM 30/32 is highly accurate even on non-linear loads thanks to the new generation measuring techniques used by it.

41. FLUE GAS ANALYSERS

42. TEMPERATURE MEASURMENTS

43. FLOW MEASURMENTS – AIR,WATER

45. Portable InstrumentsBudget Price (Rs) 1 Three phase Power Analyzer. (V, A, KW, KVA, KVAR, PF, HZ and THD) 2,60,000 2Single Phase Power Analyzer with THD 90,000 3Megger & Resistance Meter50,000 4Lux Meter (Digital)7,000 5Ultrasonic Flow Meter4,00,000 6Pitot Tube & Monometer60,000 7Digital Animometer15,000 8Hot Wire Animometer7,000 9Contact & Non-Contact Tachometer (Speed) 5,000

46. 10 Thermal : Flue Gas Analyzer (O 2, CO and Template) 1,50,0 00 11Humidity Meter (Digital) - For Aircondition Space Survey 12,000 12Leaf Probe Surface Temp. Indicator 6,000 13Stroboscope5,000 14Thermocouple for Liquid Gas and High Temp.(0-100 o C, 0- 500 o C, 2000 o C) 30,000