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PEDOMAN TEKNIS
AUDIT ENERGI
DALAM
IMPLEMENTASI KONSERVASI ENERGI DAN
PENGURANGAN EMISI
CO2 DI SEKTOR INDUSTRI (FASE 1)
PEDOMAN TEKNIS
AUDIT ENERGI DALAM
IMPLEMENTASI KONSERVASI ENERGI DAN PENGURANGAN
EMISI CO2 DI SEKTOR INDUSTRI (FASE 1)
PEMBINA
Menteri Perindustrian
M.S Hidayat
PENANGGUNG JAWAB
Arryanto Sagala
TIM PENGARAH
Tri Reni Budiharti
Shinta D. Sirait
TIM PENYUSUN
Rafles Simatupang
Muhammad Hafiz
Nugroho Adi Sasongko
TIM EDITOR
Sangapan
Denny Noviansyah
Yuni Herlina Harahap
Juwarso Gading
Budiando Panggaribuan
Wiwiek Sari Wijiastuti
DITERBITKAN OLEH
Pusat Pengkajian Industri Hijau dan Lingkungan Hidup
Badan Pengkajian Kebijakan, Iklim, dan Mutu Industri
DICETAK OLEH
KEMENTERIAN PERINDUSTRIAN
ii
PEDOMAN TEKNIS
AUDIT ENERGI Dalam IMPLEMENTASI KONSERVASI ENERGI
Dan PENGURANGAN EMISI CO2 Di SEKTOR INDUSTRI (FASE
1)
Alamat Penerbit:
Kementerian Perindustrian
Jl. Gatot Subroto Kav. 52-53
Jakarta Selatan 12950
ISBN:.................................
iii
KATA PENGANTAR
Puji dan syukur kami panjatkan kehadirat Tuhan
Yang Maha Esa yang telah memberikan rahmat dan
karunia-Nya sehingga Pedoman Teknis Audit Energi di
Industri dalam rangka Implementasi Konservasi Energi dan
Pengurangan Emisi CO2 di Sektor Industri (Fase 1) ini
dapat diselesaikan pada waktunya.
Pedoman Teknis ini disusun untuk meningkatkan
pengetahuan dalam pelaksanaan konservasi energi dan
pengurangan emisi CO2 di sektor industri yang telah
dibahas oleh. unsur pemerintah, tenaga ahli dan praktisi.
Diharapkan Pedoman Teknis ini bermanfaat bagi
para pihak yang berkepentingan dalam menerapkan
konservasi energi dan pengurangan emisi CO2 di sektor
industri. Akhir kata kami mengucapkan terimakasih kepada
semua pihak yang telah membantu dalam penyusunan
Pedoman ini.
Arryanto Sagala
iv
DAFTAR ISI
KATA PENGANTAR ........................................................
DAFTAR ISI .......................................................................
BAB I
PENDAHULUAN ..............................................
iv
v
1
1.1.
...
1.2.
7
7
8
9
10
3.1.
Prosedur ...........................................................
10
3.2.
14
3.2.1.
3.2.2.
3.2.3.
3.2.4.
17
17
18
3.2.5.
3.2.6.
3.2.7.
BAB IV
PEMBANGUNAN BASELINE...
24
BAB V
26
BAB VI
28
BAB II
2.1.
2.2.
2.3.
2.4.
BAB III
21
22
23
23
29
30
BAB I
PENDAHULUAN
Halaman 3 dari 32
Halaman 5 dari 32
BAB II
METODOLOGI PELAKSANAAN
Halaman 6 dari 32
2.1.
Intensitas
Konsumsi
Energi
(IKE),
merupakan parameter utama yang harus dicari dan
ditentukan, baik pada sistem proses produksi
maupun pada peralatan utility (boiler, chiller,
compressor, pompa, dll). Dengan besaran/nilai IKE
tersebut dapat dikembangkan menjadi formulasi dan
simulasi analisis peluang penghematan energi.
2.2.
Pareto Chart;
Halaman 7 dari 32
2.3.
Metode 5W + 1H
2.4.
Halaman 9 dari 32
BAB III
PROSEDUR DAN TEKNIS PELAKSANAAN
3.1 Prosedur
Pelaksanaan audit energi merupakan gabungan
interaksi antara tim auditor dan obyek audit. Agar
interaksi berjalan dengan baik dan efektif, langkahlangkah yang perlu dilakukan adalah:
- Inisiasi kegiatan audit;
- Penyiapan/preparasi pelaksanaan audit;
- Pelaksanaan audit;
- Evaluasi dan Pelaporan
Gambar 1 merupakan bagan alir pelaksanaan
audit yang menggambarkan berbagai kegiatan awal
calon pelaksana sampai ke kegiatan akhir audit energi.
Tahap 1 dan Tahap 2 merupakan tahapan yang
dilakukan oleh calon auditor sampai pada kesimpulan
apakah audit dapat dilakukan secara keseluruhan atau
hanya dilakukan pada beberapa bagian berdasarkan
evaluasi awal yang dilakukan.
Halaman 10 dari 32
Halaman 11 dari 32
Halaman 13 dari 32
Halaman 14 dari 32
Halaman 15 dari 32
Halaman 16 dari 32
Halaman 17 dari 32
Halaman 18 dari 32
i.
(load
survey)
dan
parameter-parameter
pengoperasian seperti: tekanan, suhu, laju alir
(flow rate) yang diukur dengan menggunakan alat
ukur portable.
Pengukuran dilakukan pada kondisi beban
operasi normal dengan memperhatikan prosedur
operasi yang dijalankan, meliputi:
pengukuran temperatur, kelembaban, tekanan,
flow rate, kondisi kelistrikan (tegangan, arus, daya,
faktor daya, dan lain-lain), serta parameterparameter lainnya yang diperlukan untuk
dianalisis.
3.2.4. Analisis Data dan Peluang Penghematan Energi
Dari hasil pengumpulan data, selanjutnya
dilakukan analisis data.
Analisis tersebut
dimaksudkan untuk mengetahui secara rinci
besarnya potensi penghematan energi yang dapat
dilakukan dan menyusun rekomendasi langkahIangkah penghematan energi berdasarkan kriteria;
tanpa biaya, biaya rendah, biaya sedang dan biaya
tinggi yang dapat ditindaklanjuti oleh pihak industri.
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
Halaman 22 dari 32
Halaman 23 dari 32
BAB IV
PEMBANGUNAN BASELINE
y = a + bx
2500
kWh
2000
Slope
1500
1000
Intercept
2500
3000
3500
4000
4500
5000
ton
Halaman 24 dari 32
Halaman 25 dari 32
BAB V
PERANGKAT PENGUKURAN ENERGI
Halaman 26 dari 32
Manometer
Manometer adalah alat audit energi yang digunakan
untuk mengukur perbedaan tekanan antara dua titik
pengukuran. Manometer biasa digunakan dalam
pipa distribusi (udara, air dan gas), peralatan seperti
kompresor dan pompa.
Sound meter
Sound meter adalah alat yang digunakan untuk
mengukur tingkat kebisingan dalam desibel (dB).
Sound meter digunakan pada hampir semua
peralatan industri, seperti memutar mesin dan pipa
distribusi.
Sound
meter
dapat
membantu
memberikan diagnosis dini kebocoran dan
menentukan tingkat kesehatan kerja.
Pengukuran Putaran
Kecepatan pengukuran yang digunakan untuk
mengukur kecepatan rotasi objek dengan rotasi unit
per menit (RPM).
Analyzer Gas Buang
Audit energi instrumen yang digunakan untuk
mengukur gas buang untuk mendapatkan efisiensi
pembakaran bahan bakar.
Meter Aliran Air
Instrumen audit energi yang digunakan untuk
mengukur aliran air.
Detektor Kebocoran
Instrumen audit energi yang digunakan untuk
mendeteksi lokasi kebocoran dari sistem distribusi
gas.
Halaman 27 dari 32
BAB VI
LAPORAN AUDIT
Halaman 28 dari 32
DAFTAR PUSTAKA
Pemerintah Indonesia.(2010). PP No.70, 2009,
Peraturan Pemerintah Republik Indonesia tentang
Konservasi Energi. Jakarta
BSNI. (2000). SNI 03 - 6196 - 2000 tentang
Prosedur Audit Energi pada Bangunan Gedung.
Jakarta.
PT KONEBA (Persero). (1995). Manual Audit Energi
di Sektor Industri. Jakarta.
CIPEC.(2002). Energi Efficiency Planning and
Management Guide, Natural Resource Canada,
Ottawa.
Bureau of Energi Efficiency (BEE). (2004). General
Aspect of Energi Management and Audit Energi.
New Delhi.
PT. EMI (Persero). (2008). Prosedur dan Instruksi
kerja audit energi. Jakarta.
Halaman 29 dari 32
LAMPIRAN
Outline Contoh susunan pelaporan audit energi di
industri
RINGKASAN EKSEKUTIF
BAB I PENDAHULUAN
1.1 Latar Belakang
1.2 Target Pencapaian
1.3 Lingkup Audit
1.4 Metodologi dan Teknis Pelaksanaan Audit
BAB II
DESKRIPSI PABRIK
2.1 UMUM
2.1.1 Informasi Umum Pabrik
2.1.2 Layout dan Deskripsi Proses
2.1.3 Plant Layout
2.2 DESKRIPSI PROSES UTAMA
2.2.1 Process #1 (SEBUTKAN), dst
2.2.2 Faktor-Faktor Pengaruh Proses
2.3 POTRET DAN POLA PENGGUNAAN ENERGI
2.3.1 Sumber-Sumber Energi
2.3.2 Distribusi Energi
- Bahan Bakar
Referensi energi
- Energi Listrik
Referensi energi
- Energi Panas (Uap)
Referensi energi
2.3.3 Profile Konsumsi dan Intensitas Energi
Halaman 30 dari 32
2.4
BAB
3.1
3.2
3.3
3.4
3.5
- Total Pabrik
- Proses Utama
- Fasilitas Pendukung
SISTEM MONITORING ENERGI
2.4.1 Sensors dan Peralatan Ukur
2.4.2 Monitoring & Reporting
2.4.3 Organisasi Energi
2.4.4 Histori Pelaksanaan Konservasi Energi
III IDENTIFIKASI PELUANG PENGHEMATAN
ENERGI
PROSES UTAMA 1,2,3 DST.
UTILITAS
- Pembangkit listrik
- Pembangkit Uap
- Sistem Refrigerasi dan AC
- Pompa dan Kompresor
- Lainnya (sebutkan)
SISTEM PENERANGAN
SISTEM DISTRIBUSI LISTRIK
LAINNYA (SEBUTKAN)
e. LAINNYA (SEBUTKAN)
BAB V KESIMPULAN DAN REKOMENDASI
5.1 KESIMPULAN
5.2 REKOMENDASI
Halaman 32 dari 32
MINISTRY OF INDUSTRY
Jln. Jenderal Gatot Subroto Kav 52-53,
Telp/fax: 021 - 5252746, Jakarta Selatan 12950
ADVISOR
Arryanto Sagala
STEERING COMMITTEE
Tri Reni Budiharti
Shinta D. Sirait
AUTHORS
Rafles Simatupang
Muhammad Hafiz
Nugroho Adi Sasongko
EDITORS
Sangapan
Denny Noviansyah
Yuni Herlina Harahap
Juwarso Gading
Budiando Pangaribuan
Wiwiek Sari Wijiastuti
PUBLISHED BY
Center for Green Industry and Environment Assessment
Agency for Industrial Policy, Climate and Quality Assessment
PRINTED BY
MINISTRY OF INDUSTRY
ii
Publisher Address:
Ministry of Industry
Jl. Gatot Subroto Kav. 52-53
Jakarta Selatan 12950
ISBN: ...................
iii
FOREWORD
Praise the Lord giving us His mercy and grace so
this Technical Guideline for Audit Energy within the
framework of Implementation of Energy Conservation and
CO2 Emission Reduction in Industrial Sector (Phase 1) can
be finalized in time.
This Technical Guideline is structured to enhance
knowledge in implementation of energy conservation and
reduction of CO2 emission and have been discussed by
governments, experts and practitioners.
It is expected that this Technical Guideline is useful
for the related parties to implement energy conservation
and reduction of CO2 emission. Finally, we would like to
thank all those who have participated in the preparation of
this guideline.
Jakarta,
January 2011
Head of
Agency for Industrial Policy,
Climate and Quality Assessment
Arryanto Sagala
iv
TABLE OF CONTENTS
FOREWORD .....................................................................
RABLE OF CONTENTS ...................................................
CHAPTER I
INTRODUCTION ......................................
iv
v
1
1.1.
1.2.
5
6
6
7
3.1.
Procedure ................................................
3.2.
12
3.2.1.
3.2.2.
3.2.3.
3.2.4.
15
15
16
CHAPTER IV
BASELINE DEVELOPMENT .
22
CHAPTER V
24
CHAPTER VI
26
CHAPTER II
2.1.
2.2.
2.3.
2.4.
CHAPTER III
3.2.5.
3.2.6.
3.2.7.
REFERENCE ..................................................................
APPENDIX
19
20
20
21
27
28
CHAPTER I
INTRODUCTION
factory
installation
entirely. From
the energy
balance, it can be determined the efficiency of
equipment and the presence or absence of
energy cost savings opportunities. After that, a more
detail test on each opportunity, estimated costs
and benefits of those choices that have been
determined is conducted.
In some cases, the energy auditor cannot
provide recommendations regarding a particular
investment, due to the risks or because the total
of investment is too large. In such cases, the energy
auditor will provide a recommendation regarding the
feasibility study (e.g. replacement of boilers,
furnaces, water vapor system and the process
changing).
The final DEA result will be a detail report
containing recommnedation along with benefits and
related costs and implementation program.
In general, it is quite difficult to deduce the
amount of savings that can be identified through the
energy audits. However, savings are usually close
to significant numbers, even through the simplest
energy
audit. As
a rough
guide, the
initial
energy audits are expected to identify savings
of 10 percent, which generally can be achieved
through
house-keeping
action at
the factory
installation, or other actions that require little capital
investment.
Detailed energy audits
can
often achieved savings of 20 percent or more
for medium and long term period.
Page 4 of 30
CHAPTER II
IMPLEMENTATION METHODOLOGY
Page 5 of 30
Pareto Chart;
5W + 1H Method.
Page 6 of 30
2.4.
Page 7 of 30
Page 8 of 30
CHAPTER III
PROCEDURE AND TECHNICAL IMPLEMENTATION
3.1 Procedure
Implementation of energy audit is combined of
interaction between the audit team and audit object. In
order that the interaction is going well and effectively,
the steps that need to be addressed:
- Initiation of audit activities;
- Preparation of audit;
- Conducting an audit;
- Evaluation and Reporting
Figure 1 is a flow chart illustrating the
implementation of audit beginning from implementing
various
candidate
activities
until
the energy
audit activities end.
Step 1 and Step 2 are steps that being taken by
the prospective auditors until the audit can be done as
whole or only done in some part based on initial
evaluation.
After getting conclusion that the audit will be
conducted, it is necessary to determine the various
steps or procedures to be performed. The procedures
that been used will be vary according to the
proposed scope of audit as well as by size and type
of facility. The following procedure is generally used
for the implementation / execution of energy audits.
Page 9 of 30
Page 10 of 30
Step 1:
Planning the overall audit activities that to be
performed. This includes determining the audit
objectives, division of plant facilities to be part of
execution or cost center. The selection of audit team
members and giving responsibilities, and the selection
of the necessary instruments.
Step 2:
Initiation of meetings and technical discussions with
the assistancy team of industry object.
Step 3:
Brief observation of the field (walk through surveys)
that at once can be done also in-house training to
assistancy team of industry object.
Step 4:
Data collection of energy consumption and production
data are taken from a part or a particular cost center
(data sheet form, historical data, etc.). If necessary,
conduct testing system / equipment to obtain
additional data of performance from the specific
equipment and the units or a specific cost center.
Step 5:
Data processing and initial evaluation to obtain the
energy balance, mass balance, energy intensity and to
identify energy saving opportunities (ESO). ESO
identification results is then analyzed to produce a list
of energy saving opportunities (ESO) based on the
amount of savings that might be obtained.
Page 11 of 30
Step 6:
Presentation and discussion with the assistancy team
of industry object on the initial ESO lists for findings
and the results obtained. Those steps are done at the
same time to clarify the various data and information
so that at the time of execution of a detailed analysis
is conducted on the correct data basis and information
and also it can be accepted by both parties.
Step 7:
Conduct detailed evaluation and analysis on the
provided ESO.
Step 8:
Develop energy audit report includes a numbers of
recommendation of ESO and management of energy
that delivered to industrial objects.
3.2 Activity Implementation Techniques
Energy audit is a systematic activity / technical
activities, aimed to explore the potential / energy saving
opportunities in the energy consuming facilities
(machinery / equipment contained in a plant). Energy
audit output is energy saving opportunities in the form of
reports on a cost center (centers of energy costs) that
can be achieved after the observation, measurement,
and analysis of energy (energy calculation and
consideration).
Focus of energy audits is to identify, measure
and calculate the deviations / anomalies of energy use,
Page 12 of 30
Page 13 of 30
Page 14 of 30
Page 15 of 30
General
information
of
industry,
process description, plot plan, plant layout
Design data of major equipment ;
Information on the
data
modification
activity ever undertaken, both in order to
increase efficiency,
reliability,
capacity
and energy conservation;
Supply and distribution of energy use (Energy
Reference and
Energy Balance) for the
whole plant and each
process / major
equipment.
Energy consumption profile. Historical data of
energy use (daily, monthly and yearly) for the
whole plant and each process / major
equipment.
Material consumption, production and waste
profile. Historical data of process material
used, products
and waste
generated
production (daily, monthly and yearly) for the
whole plant and each
process / major
equipment.
ii. Primary Data Collection
The primary data is collected through surveys
and field measurements in order to
obtain
information and technical data and specifications
of the actual operation of equipment related to the
operation of energy user equipment in industry.
Primary data collection has started with a walktrough the pitch, knowing energy user equipment
Page 17 of 30
operating conditions
and determination the
measurement points that are required.
Actual operating data on each unit includes:
input & output, specification of equipment, energy
consumption, operating conditions (temperature,
pressure, flowrate) and other factor or parameters
that contribute in determining the operations that to
be compiled based on data logsheet energy user
equipment.
In primary data collection was carried out also
interview with
management, operators and or
persons who responsible in the energy sector
related to activity patterns of plant operations,
modifications or retrofitting / revamping has ever
done,
both in order to increase efficiency,
reliability, capacity and energy conservation. To
facilitate the collection of primary data, the field
survey was conducted using the questionnaire in
which filling will be guided by the consultant so
that all applicable questions on the questionnaire
can be answered by respondents.
Data and process
parameters on the
actual
operating conditions that are not recorded from
logsheet plant or control room but required in the
evaluation, can be
obtained
by
direct
measurement
(load
survey)
and
operating parameters such
as
pressure,
temperature, flow rate were measured using a
portable measuring instrument.
Measurements were taken at normal operating
load conditions due to the operating/running
procedures, including:
Page 18 of 30
3.2.4. Data
Analysis
and
Energy
Savings
Opportunities
From the results of data collection, data analysis
is then performed. The analysis was intended to
find out in detail the amount of potential energy
savings that can be done and make
recommendation steps for energy savings based on
the criteria, no cost, low-cost, medium cost and
high cost that can be performed upon by the
industry.
Data analysis activities include:
i. Analyze
energy
sources
and
energy
consumption in energy consuming equipment;
ii. Mass and Heat Balance; to calculate how much
the utility of energy use and energy losses in a
system of processes and each energyconsuming equipment; Energy Losses is then
analyzed to consider how much it costs (the
special character of the medium and high cost of
implementation) to be issued to convert losses
into potential energy saving.
iii. Analyze / inventory of energy consumption of
products produced or the intensity of energy on
process flow and process energy user
equipment as a parameter to determine the level
of effectiveness and efficiency of energy use;
Page 19 of 30
iv.
v.
vi.
vii.
viii.
Page 20 of 30
Page 21 of 30
CHAPTER IV
BASELINE DEVELOPMENT
y = a + bx
kWh
2500
2000
Slope
1500
1000
Intercept
2500
3000
3500
4000
4500
5000
ton
Page 22 of 30
Page 23 of 30
CHAPTER V
ENERGY MEASUREMENT DEVICES
Power Analyzer
In general, power analysis is used to explain kVA
fluctuations load which connected with the actual
load.
Lux meter
Lux meter is
used to measure
the level
illumination / strong level of light illumination.
of
Humidity Measurement
Moisture meter is a type of energy audit
instruments used to measure the humidity level.
Anemometers
Anemometers are the type of energy audit
instruments used to measure air flow velocity.
Page 24 of 30
Manometers
Manometer is a tool used to measure the pressure
difference
between
two
measuring
points. Manometer is used in the distribution pipes
(air, water and gas), equipment such as
compressors and pumps.
Sound meter
Sound meter is a tool used to measure the noise
level in decibels (dB). Sound meters are used in
almost all industrial equipment, such as rotating
machinery and pipe distribution. Sound meters can
help to provide early diagnosis and determine the
level of leakage occupational health.
Rotation Measurement
The used speed of measurement for measuring
the rotation speed of the object is the rotation
of units per minute (RPM).
to measure
Leak Detector
Energy audit instrument used to detect the location
of leaks from gas distribution system.
Page 25 of 30
CHAPTER VI
AUDIT REPORT
Page 26 of 30
REFERENCE
Indonesian Government. (2010). PP No.70, 2009, the
Indonesian Government Regulation on the Energy
Conservation;
BSNI. (2000). SNI 03 - 6196-2000 about Energy Audit
Procedures in Buildings
KONEBA PT (Persero). (1995). Manual of Energy
Audits in Industrial Sector, Jakarta.
CIPEC. (2002). Energy Efficiency Planning and
Management Guide, Natural Resource Canada,
Ottawa.
Bureau of Energy Efficiency (BEE). (2004). General
Aspect of Energy Management and Energy
Audits, New Delhi.
PT. EMI (Persero). (2008). Procedures and Work
Instructions of Energy Audits, Jakarta.
Page 27 of 30
APPENDIX
Table of content of example of energy audit reporting in
Industry
EXECUTIVE SUMMARY
CHAPTER I INTRODUCTION
1.1 Background
1.2 Target Achievement
1.3 Scope of Audit
1.4 Methodology and Technical Implementation of
Audit
CHAPTER II FACTORY DESCRIPTION
2.1 GENERAL
2.1.1 Factory General Information
2.1.2 Layout and Process Description
2.1.3 Plant Layout
2.2 DESCRIPTION OF MAIN PROCESS
2.2.1 Process #1 (LISTED), etc
2.2.2 Influenced Factors on Process
2.3 PORTRAIT AND PATTERNS OF ENERGY USE
2.3.1 Energy Sources
2.3.2 Energy Distribution
- Fuel
Energi Reference
- Electrical Energy
Energy References
- Thermal Energy (Steam)
Energy Reference
2.3.3 Consumptionand Energy Intensity Profile
Page 28 of 30
Total Plant
Main Process
Support Facilities
IV
ANALYSIS
ON
ENERGY
CONSERVATION OPPORTUNITIES
4.1. MAIN PROCESS 1,2,3 ETC.
4.2. UTILITY
- Electrical Generator
- Steam Generator
- Refrigeration and Air Conditioning Systems
- Pump and Compressors
Page 29 of 30
- Other (specify)
4.3. LIGHTING SYSTEM
4.4.ELECTRICAL DISTRIBUTION SYSTEM
4.5. OTHER (SPECIFY)
CHAPTER V. CONCLUSIONS AND
RECOMMENDATIONS
5.1 CONCLUSION
5.2 RECOMMENDATIONS
Page 30 of 30