Bureau of Energy Efficiency Format for Baseline Energy Audit

Format for Baseline Energy Audit

[Adopt the following methodology for conducting baseline energy audit in Designated Consumers industries. Additional information may be obtained, if required and found appropriate.]

1. Give brief description about the plant .

a. History of establishment, ownership (public / private / cooperative sector) b. Present Installed capacity and stages of capacity addition (if any) c. Trend of capacity utilization in last 5 years d. Trend of monthly production and capacity utilization of last one year e. Review of process flow diagram

2. Give the energy scenario of the plant

a. Different types of energy sources being used and their % share of contribution i. Primary Energy (Solid Fuel, Liquid fuel, gaseous fuel etc.) ii. Secondary Energy (Electricity) 1. Purchased from grid 2. Self-generated (CPP/DG sets/Co-Generation) iii. Energy from internally generated by-products or waste heat iv. Renewable energy b. Establish the trend of following of last 3 years i. % share purchaged electricity from grid to that of total electricity consumed ii. % share of self generated electricity to that of total electricity consumed iii. % share of internally generated thermal energy from waste-heat, co-generation or by-product of total consumed energy iv. % Cost of energy to that of total production cost v. % share of renewable energy to that of total energy consumed c. Trend of monthly production and energy consumption (Electrical & thermal) of last one year d. Share of Energy in various Purposes ( Process, auxiliaries, Lighting etc.) e. Any other as may be deemed fit

3. Establish the energy scenario in gate-to-gate (GtG) concept

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a. Develop the gate-to-gate schematic of the plant depicting the energy input to the plant boundary, internally generated energy and the product output (Please refer to the case situations in Annexure-A) b. Trend the energy consumption in GtG concept of last 5 years c. Establish the Specific Energy Consumption (SEC) in GtG concept

4. Review of Reported Data of DCs

a. Complete review of reported data of DCs through notified format (BEE will provide the data sheet of the DC ), the summary sheet of each DC. b. Find out the source of each data which has been reported by DC. The data source may be documents, records, log books, installed meters and gadgets etc.
Item Unit Source of Data Frequency of data recording* Method of Data Recording**

Production Purchased Electricity All Energy Sources

* instantaneous/hourly/daily/monthly/yearly ** manual reading or recording /scada/Automatic MIS c. Reconcile the data with respect to production, typical parameters like heat rate, specific fuel consumption or any other observations d. Clearly define the inclusions / exclusions of the energy consumption of colony power, temporary constructions, internal transportations etc. in the reported data.

5. Review the Process Metering System

Flow

Diagram

and

Present

a. Study and review the process flow diagram (PFD). Develop the schematic of the PFD depicting the operating parameters like flow, temperature, pressure etc. at each input-output stage b. Divide the entire process into key sub-processes or sub-systems. The typical sub-process of the sectors are given below (but not limited).
Sector Thermal Power Plant (coal) 3 | Page Sub-Processes Coal handling Plant, Ash Handling

Thermal Power Plant (Gas) Aluminium (Smelter)

Aluminium (Refinery)

Cement Iron & Steel (Integrated) Iron & Steel (Sponge Iron) Fertilizer Pulp & Paper Textile

System, Steam Generation System, Turbo-Generator system, CW system, ESP, Compressed Air System Turbo-Compressor System, Waste Heat Recovery Boiler, CW system, Compressed Air System Rectiformer, Pot-Lines, Carbon Plant (Green Anode Plant, Bake Oven, Rodding Shop), Cast-House, Compressed Air System, Fume Treatment Plant Digester system, Cleaning & Refining System, Calcinations System, Steam Generation System, Co-Gen System Raw Material Preparation System, Cement Kiln, Grinding Section, Captive Power Plant(CPP) Coke oven, Sintering Plant, Blast Furnace, BOF, Casting Section, Rolling Mills, CPP Sintering Plant, DRI section, EAF section / IF Section, Casting section, Rolling Mill, CPP Nitrogen Plant, Urea Plant, Steam Generation System, CPP Raw Material Preparation, Pulping Section, Paper Machine Section, CPP, Co-Gen Plant Spinning section, Drying Section, Steam Generation System, CPP

Chlor-Alakali [The above sub-processes are indicative only. The auditor may suitably select the sub-process depending upon the material & energy flow and quantum of energy consumed]

6. Study of Sub-Processes
a. Define the energy & material flow into and out of each subprocess, process parameters and present metering system for all energy sources in the sub-process under study. (This should be in the form of Block Diagrams). b. Investigate the following in each sub-process
Parameters Brief Description of the Sub-Process Material Flow Energy Input 4 | Page What to look for Name Flow Rate Electricity Value

Design

operating

Major Equipment

Solid Fuel (Coal/Lignite) Liquid Fuel (FO/HSD/LHHS...) Gaseous Fuel (NG/LPG...) Others Name Technology Numbers Technical Specifications Specific Energy Consumption Technical Parameters Operating Parameters Numbers Operating Technical Specifications % Loading or Capacity Utilization Efficiency (%) Specific Energy Consumption Technology Change Process Modification O & M Practice Resulting Energy Saving Approx. Investment done

Installe d Design Design Design

Operating

Operating Operating Operating

Factors Affecting Energy Efficiency Major Auxiliaries Associated (Pumps, Fans, Compressors, Furnaces, HVAC system etc.)

Design Design Design

Operating Operating Operating

Technology Up gradation in Last 3 Years

[In order to get the operating values suitable measurements to be done by energy auditing gadgets or observation from installed gadgets]

7. Investigate the All Improvement Option

Possible

Energy

Efficiency

a. Waste Heat Recovery Options i. Source ii. Comment on Feasibility iii. Quantum of Possible Extracted Energy b. Co-Generation Option i. Comment on Feasibility ii. Approximate Thermal & Electrical Energy output c. Fuel Switch Options d. Retrofit Options e. Use of Energy Efficient Equipment i. Energy efficient drives, Pumps, Fans, Compressors, Lighting system etc.
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ii. Variable Frequency Drives / Variable Speed Drives iii. Any other f. O & M Practices i. Waste minimization (Reuse, Recycle, Resizing) ii. Control Mechanism iii. Data Monitoring & Accounting g. Cost-Benefit Option in all possible options i. Simple Pay Back Period

8. Review the Past Energy Strategies (Last 3 years)

SubProcess Action Taken Category*

Efficiency

Improvement
Investment Done

Year of Implementat ion

Resulted Saving

* Technology Upgradation / Process Modification/ O&M Practice / Retrofit/ Others

9. Review the Future Energy Efficiency Improvement Strategy

[Discuss with Plant Management to get the future energy efficiency improvement strategies] a. b. c. d. Specific Projects to be undertaken Investment Plan Human Resource Planning in Energy Management Any target fixed by management as per their policy

10. Prepare the Structure/Format

Audit

Report

with

Following

a. Acknowledgement b. Study Team Members c. Executive Summary

Sl Recommendations Annual Potential Saving Approx. Investment Simple PayBack Period Remark

d. Introduction e. Methodology Adopted

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f. Instruments Used for Energy audit g. Brief Description about the plant (Process Flow Diagram) h. Energy Scenario & Usage pattern i. Description about Sub-Process (As per Point # 6) j. Identifying ENCON Options (As per Point # 7) k. Description about Past ENCON activities l. Description about future ENCON strategy m.Conclusion & Critical Comment n. Annexure [The report must be equipped with tables, graphs, sample calculation sheet, assumptions (if any) at suitable places ]

For any clarification Please Contact :

S.P.Garnaik
Energy Economist Bureau of Energy Efficiency Ministry of Power, GOI 4th Floor, Sewa Bhawan, R.K.Puram, New Delhi-66 Ph: 011-26178352 email: sgarnaik@beenet.in

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Annexure-A Different Case Situations in Estimating Total Energy Consumption and Specific Energy Consumption in Gateto-Gate Concept

The following are the explanations on estimating the total energy consumption and specific energy consumption in various case situations as encountered in Designated Consumer industries.

Pre-Consideration: 1. The plant boundary has already been defined. 2. There is a single product at the output which has been defined. In case of multiple products, the major product to be considered. 3. The energy consumption is to be considered only for plant process operations to produce the 'defined product'. So, the energy consumed in internal transportation, residential colony etc. have been excluded. 4. The primary energies actually consumed for producing the product are considered. Any primary energy purchased and stored inside the system boundary is excluded.

The cases have been prepared based on prevailing scenario of energy usage in the energy intensive sectors like Power Plant, Iron & Steel, cement, Fertilizer, Aluminium, pulp & paper, Textile, Chlor-Alkali etc.

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CASE -I : All Energy Purchased and Consumed

Electricity is purchased from the Grid

Electricity FO (Liter) Product (Kg) NG (SCM) Coal (KG) Others (KG or

PROCESS

Total Energy Consumption (Etotal) = [Elect x 860 + FO x GCVfo + Coal x GCVcoal + NG x GCVng + Others x GCVeach] Kcal Total Electrical Energy Consumption (ELtotal) = Electricity KWH

Total Thermal Energy Consumption (THtotal) = [FO x GCVfo + Coal x GCVcoal + NG x GCVng + Others x GCVeach] Kcal Gate to-Gate SEC = [Etotal /kg of product] Kcal/kg

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CASE -II : Electricity Partially Generated by DG Sets, other Energy Purchased and Consumed

Electricity is purchased from the Grid & generated by DG set

Electricity A FO (Liter) NG (SCM) Coal (KG) Others (KG or DG Set SFC X Product

Process

(a) If X is known and A is known, SFC = ( X / A) (b) If A is known (c) If X is known

kwh/ltr

X = ( A x SFC ) kwh where SFC = 3.0 to 3.5 kwh/ltr A = ( X / SFC) kwh where SFC = 3.0 to 3.5 kwh/ltr

Total Energy Consumption (Etotal) = [Elect x 860 + A x GCVa + FO x GCVfo + Coal x GCVcoal + NG x GCVng + Others x GCVeach] Kcal Total Electrical Energy Consumption (ELtotal) = (Purchased Electricity + X) KWH

Total Thermal Energy Consumption (THtotal) = [(FO-A) x GCVfo + Coal x GCVcoal + NG x GCVng + Others x GCVeach] Kcal Gate to-Gate SEC = [Etotal /kg of product] Kcal/kg

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CASE -III : Electricity Generated by CPP, other Energy Purchased & Consumed, Electricity partially sold to grid

Electricity is generated by Coal Based CPP, partially sold to grid

Y (KWH) to Grid A Coal (KG) NG (SCM) FO (Ltr) Others (KG or CPP X Product Heat Rate Process

(a) If X is known and A is known, Heat Rate (HR) = [( A x GCVcoal ) / X] Kcal/kwh (b) If A is known Heat Rate (c) If X is known Heat Rate X = [( A x GCVcoal ) / HR ] kwh where HR = Avg. Plant A =[ ( X * HR)/ GCVcoal]

KG where HR= Avg. Plant

* If plant HR is not available, then National Avg. HR i.e. 2717 Kcal/kg may be considered * The total electricity consumption also includes the auxiliary power consumption of CPP

Total Energy Consumption (Etotal) = [FO x GCVfo + Coal x GCVcoal + NG x GCVng + Others x GCVeach] Kcal Total Electrical Energy Consumption (ELtotal) = (X - Y) KWH

Total Thermal Energy Consumption (THtotal) = [FO x GCVfo + (Coal-A) x GCVcoal + NG x GCVng + Others x GCVeach] Kcal
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Gate to-Gate SEC =

CASE -IV : Electricity Generated by CPP, other Energy Purchased & Consumed, Electricity partially sold to grid from CPP.

[Etotal /kg of product]

Kcal/kg

Electricity is generated by Coal Based CPP, partially sold to grid. CPP is in separate Boundary

Coal

B
CPP

G Y (KWH) to

Others (KG or

Aux P (a

X (KWH)

FO (Liter) NG (SCM) Coal (KG) Others (KG or

A
Product (Kg)

PROCESS

Here, in case of two separate boundaries, two different Norms / Targets to be established 1. For the Production Plant Boundary (A):

Total Energy Consumption (Etotal) = [X *860 + FO x GCVfo + Coal x GCVcoal + NG x GCVng + Others x GCVeach] Kcal Total Electrical Energy Consumption (ELtotal) = X kwh Total Thermal Energy Consumption (THtotal) = [FO x GCVfo + Coal x GCVcoal + NG x GCVng + Others x GCVeach] Kcal
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Gate to-Gate SEC = [Etotal /kg of product] Kcal/kg

2. For the Captive Power Plant Boundary (B):

Total Energy Consumption (Etotal) = [FO x GCVfo + Coal x GCVcoal + Others x GCVeach] Kcal Total Electrical Energy Consumption (ELtotal) = ( G ) x (a/100) kwh

Gate to-Gate SEC ( i.e Net Heat Rate) = Etotal / (G - ELtotal) Kcal / kwh

Here, the target setting criteria of Power Plant should be adopted which is based on Net Heat Rate.

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CASE -V : Energy Purchased & Consumed, Electricity & Heat partially Generated through Co-Gen plant

Electricity & Heat are generated by Co-Gen Plant

Elect (KWH) Coal (KG) NG (SCM) FO (Ltr) Others (KG or

X CoGe Y (Kcal) n Plant Eff. (%) Process

Product

Total Energy Consumption (Etotal) = [Elect x 860 +FO x GCVfo + Coal x GCVcoal + NG x GCVng + Others x GCVeach] Kcal Total Electrical Energy Consumption (ELtotal) = (Elect + X) KWH

Total Thermal Energy Consumption (THtotal) = [FO x GCVfo + Coal x GCVcoal + NG x GCVng + Others x GCVeach + Y] Kcal Gate to-Gate SEC = [Etotal /kg of product] Kcal/kg

CASE -VI : Energy Purchased & Consumed, Heat energy partially met by waste / 14 | Page

by-product of the Process

Elect (KWH) Coal (KG) NG (SCM) FO (Ltr) Others (KG or Z Kcal By-Product (X KG)

PROCESS

Product

Heat Content of By-Product = Y Kcal / Kg So, Energy Available Z = X * Y Kcal

Total Energy Consumption (Etotal) = [Elect x 860 +FO x GCVfo + Coal x GCVcoal + NG x GCVng + Others x GCVeach] Kcal Total Electrical Energy Consumption (ELtotal) = (Elect) KWH

Total Thermal Energy Consumption (THtotal) = [FO x GCVfo + Coal x GCVcoal + NG x GCVng + Others x GCVeach + Z] Kcal Gate to-Gate SEC = [Etotal /kg of product] Kcal/kg

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