Energy Audit Process
Usually walk-throughs are conducted.
1. During off period
(a) Layout building Name plate details, input energy sources, output loads, energy routes from inlet,
Off period walk through goes without disturbing the operating personnel and without disturbance from the working shift.
2. During working shift walk through audit, the actual process is closely observed with focus on various electrical, thermal, chemical, physical energy inputs and outputs. The obvious energy wastage locations, waste energy/material objects are spotted.
Discussions with Line supervisors and Brain storming :
- During the walk through energy audit, discussions with line supervisors and line technicians and joint brain storming may be necessary to acquire creative ideas and to know the practical difficulties in carrying out the proposed ECMS.
- The prevailing process may have some salient features beyond energy consideration, for example, increased production and in given period by using excess energy.
- There is a trade off between Energy Conservation Measure and higher production by overloading.
- These considerations must be brought out in the report.
Observations during Walk Through Energy Audit Report :
- Various types of energy and material inputs and various types of energy outputs. For example, (a) Inputs : Electricity, Petrol, Diesel, Furance oil, Lubricating oil, Chemical, Metals, Consumables (graphite, electrodes, reagents etc.), Coal, Fire wood/other fuels, biomasses, (b) Outputs : Finished products, byproducts, waste, scrap, heating/air conditioning/ventilation, lighting.
- Spots for reducing influx, exflux in thermal systems. Heat flows from high temperature to low temperature. Thermal systems have tendency to loose energy continuously by either inlet of cold media or outlet of hot media.
- Opportunities for waste reduction and waste recycling.
- Optimizing operating cycle to reduce energy consumption.
- Substituting the prevailing energy form by more economical one e.g. heating by using renewable energy rather than costlier petrol or electricity. Use of diesel instead of petrol.
- Electricity : power factor and its improvement MVA – max demand and its reduction.
Check list is filled during the walk through energy audits.
Typical check list is given below :
Check List for Walk Through Energy Audit
Project No. :
EA No. :
Title of Energy Audit :
Team members :
Date of Audit :
Remarks :
|
1.Data Regarding Plant/Process and Identification Numbers 101 Main Plants 102 Auxiliary Plant |
1011…………………………… 1012…………………………… 1013…………………………… 10111…………………………. 10112…………………………. 10113…………………………. 10121…………………………. 10122…………………………. |
|
2. Buildings |
2001…………………………… 2002…………………………… |
|
3. Other zones e.g. Store, Recreation Club, Swimming Pool |
3001…………………………… 3002…………………………… 3003…………………………… |
|
Ctg. (as example) |
Elect. A |
Petrol Nil |
Diesel Nil |
Fuel A |
Lub. B |
Heat B |
Coal C |
Wood Nil |
|
Main Plant No. |
|
|
|
|
|
|
|
|
1011……………………………..
1012……………………………..
1013……………………………..
2. Input to Each Auxiliary (Yes or No) :
|
Ctg. (as example) |
Elect. A |
Petrol Nil |
Diesel Nil |
Fuel A |
Lub. B |
Heat B |
Coal C |
Wood Nil |
Auxiliary Plant No.
10111……………………………
10112……………………………
10113……………………………
3. Input Energy to Others Zones :
|
Ctg. (as example) |
Elect. A |
Petrol Nil |
Diesel Nil |
Fuel A |
Lub. B |
Heat B |
Coal C |
Wood Nil |
Zone No.
3001…………………………….
3002…………………………….
C. OUTPUTS
4. Input Energy to Each Main Plant (Yes or No) :
|
Ctg. (as example) |
Elect. A |
Petrol Nil |
Diesel Nil |
Fuel A |
Lub. B |
Heat B |
Coal C |
Wood Nil |
Plant No.
|
Ctg.(example) |
Elect |
Petrol |
Diesel |
Fuel |
Lub |
Heat |
Coal |
Wood |
Consumption |
|
Ctg.(example) |
Elect |
Petrol |
Diesel |
Fuel |
Lub |
Heat |
Coal |
Wood |
Zone No.
|
Energy Type |
Main Plant |
Auxiliary Plant |
Other Zones |
|
1. Cold influx 2. Heat outflux 3. Thermal losses 4. Waste 5. Electricity 5.1 Power factor 5.2 Peak demand 5.3 Consumption 6. Operating cycle 7. Revised energy source 8. Waste recycling 9. Waste reuse 10. Reduced setting 11. Introduced automation 12. Creative suggestions |
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- Meetings are arranged with Plant Manager Energy Manager and the O & M Manager to decide the action plan for executing energy conservation measures.
- Management must give directives and financial approval to decide and implement the Energy Conservation Projects recommended by the Walk Through Energy Audit.