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Bureau of Energy Efficiency Format for Baseline Energy Audit

Renewable energy b. Lighting etc. ownership (public / private / cooperative sector) b.) ii.) e. Energy from internally generated by-products or waste heat iv. Trend of monthly production and capacity utilization of last one year e. History of establishment. Different types of energy sources being used and their % share of contribution i. Any other as may be deemed fit 3. % share of renewable energy to that of total energy consumed c. % share of internally generated thermal energy from waste-heat. co-generation or by-product of total consumed energy iv. Review of process flow diagram 2. Give the energy scenario of the plant a. % Cost of energy to that of total production cost v. gaseous fuel etc. Share of Energy in various Purposes ( Process. % share of self generated electricity to that of total electricity consumed iii.Format for Baseline Energy Audit [Adopt the following methodology for conducting baseline energy audit in Designated Consumers industries. Give brief description about the plant . Liquid fuel. auxiliaries. Establish the trend of following of last 3 years i. Present Installed capacity and stages of capacity addition (if any) c. Trend of capacity utilization in last 5 years d. Primary Energy (Solid Fuel. Establish the energy scenario in gate-to-gate (GtG) concept 2 | Page . Self-generated (CPP/DG sets/Co-Generation) iii. Additional information may be obtained. if required and found appropriate. a. Trend of monthly production and energy consumption (Electrical & thermal) of last one year d. % share purchaged electricity from grid to that of total electricity consumed ii. Secondary Energy (Electricity) 1.] 1. Purchased from grid 2.

Clearly define the inclusions / exclusions of the energy consumption of colony power. in the reported data. 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. internally generated energy and the product output (Please refer to the case situations in Annexure-A) b. typical parameters like heat rate. Divide the entire process into key sub-processes or sub-systems. temporary constructions. Review of Reported Data of DCs a. Establish the Specific Energy Consumption (SEC) in GtG concept 4. at each input-output stage b. Study and review the process flow diagram (PFD). 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. installed meters and gadgets etc. records. pressure etc. The typical sub-process of the sectors are given below (but not limited). log books. temperature. Develop the gate-to-gate schematic of the plant depicting the energy input to the plant boundary. Reconcile the data with respect to production. Sector Thermal Power Plant (coal) 3 | Page Sub-Processes Coal handling Plant. internal transportations etc. The data source may be documents. Trend the energy consumption in GtG concept of last 5 years c. 5. Find out the source of each data which has been reported by DC.a. Review the Process Metering System Flow Diagram and Present a. b. specific fuel consumption or any other observations d. Ash Handling . Develop the schematic of the PFD depicting the operating parameters like flow.

b. Rodding Shop). Carbon Plant (Green Anode Plant. The auditor may suitably select the sub-process depending upon the material & energy flow and quantum of energy consumed] 6. Casting section.Thermal Power Plant (Gas) Aluminium (Smelter) Aluminium (Refinery) Cement Iron & Steel (Integrated) Iron & Steel (Sponge Iron) Fertilizer Pulp & Paper Textile System. 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 . EAF section / IF Section. Rolling Mills. Rolling Mill. Turbo-Generator system. Drying Section. CPP Chlor-Alakali [The above sub-processes are indicative only. Steam Generation System. Co-Gen System Raw Material Preparation System. Urea Plant. CPP Sintering Plant. Steam Generation System. CPP. Cement Kiln. Compressed Air System Turbo-Compressor System. Cleaning & Refining System. Co-Gen Plant Spinning section. Steam Generation System. Pulping Section. Fume Treatment Plant Digester system. Paper Machine Section. Study of Sub-Processes a. process parameters and present metering system for all energy sources in the sub-process under study. Sintering Plant. Compressed Air System Rectiformer. Blast Furnace. Grinding Section. CPP Nitrogen Plant. CPP Raw Material Preparation. Cast-House. Compressed Air System. Pot-Lines. CW system. DRI section. BOF. (This should be in the form of Block Diagrams). Steam Generation System. Bake Oven. Waste Heat Recovery Boiler. Calcinations System. ESP. Define the energy & material flow into and out of each subprocess. Captive Power Plant(CPP) Coke oven. Casting Section. CW system.

Fuel Switch Options d.. Use of Energy Efficient Equipment i. Quantum of Possible Extracted Energy b. Compressors. Investment done Installe d Design Design Design Operating Operating Operating Operating Factors Affecting Energy Efficiency Major Auxiliaries Associated (Pumps. Source ii. Energy efficient drives.) 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. Lighting system etc.... Waste Heat Recovery Options i. Comment on Feasibility ii. Comment on Feasibility iii. Retrofit Options e. Furnaces.Major Equipment Solid Fuel (Coal/Lignite) Liquid Fuel (FO/HSD/LHHS. Co-Generation Option i. HVAC system etc. Fans. Investigate the All Improvement Option Possible Energy Efficiency a. Compressors. 5 | Page . Pumps. Fans. Approximate Thermal & Electrical Energy output c.) 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.) Gaseous Fuel (NG/LPG.

Introduction e. Review the Future Energy Efficiency Improvement Strategy [Discuss with Plant Management to get the future energy efficiency improvement strategies] a. Data Monitoring & Accounting g. Investment Simple PayBack Period Remark d. Control Mechanism iii. 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. Study Team Members c. 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. Resizing) ii.ii. Recycle. Executive Summary Sl Recommendations Annual Potential Saving Approx. b. Any other f. Simple Pay Back Period 8. O & M Practices i. Cost-Benefit Option in all possible options i. c. Methodology Adopted 6 | Page . Waste minimization (Reuse. Variable Frequency Drives / Variable Speed Drives iii. Acknowledgement b. d.

GOI 4th Floor. assumptions (if any) at suitable places ] For any clarification Please Contact : S. Brief Description about the plant (Process Flow Diagram) h. Energy Scenario & Usage pattern i. graphs. Identifying ENCON Options (As per Point # 7) k. Description about Past ENCON activities l.P.K.Puram.Garnaik Energy Economist Bureau of Energy Efficiency Ministry of Power. sample calculation sheet. Instruments Used for Energy audit g. New Delhi-66 Ph: 011-26178352 email: sgarnaik@beenet. Description about future ENCON strategy m. Annexure [The report must be equipped with tables.in 7 | Page . R.Conclusion & Critical Comment n. Description about Sub-Process (As per Point # 6) j. Sewa Bhawan.f.

cement.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. 2. 4. The primary energies actually consumed for producing the product are considered. In case of multiple products. So. Fertilizer. have been excluded. There is a single product at the output which has been defined. Any primary energy purchased and stored inside the system boundary is excluded. 8 | Page . residential colony etc. Pre-Consideration: 1. pulp & paper. The energy consumption is to be considered only for plant process operations to produce the 'defined product'. Aluminium. Textile. The cases have been prepared based on prevailing scenario of energy usage in the energy intensive sectors like Power Plant. the major product to be considered. The plant boundary has already been defined. the energy consumed in internal transportation. Iron & Steel. 3. Chlor-Alkali etc.

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 9 | Page .

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 10 | Page .5 kwh/ltr A = ( X / SFC) kwh where SFC = 3.0 to 3.CASE -II : Electricity Partially Generated by DG Sets. 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. 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.

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.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 .CASE -III : Electricity Generated by CPP. Plant * If plant HR is not available. Electricity partially sold to grid • Electricity is generated by Coal Based CPP.Y) KWH Total Thermal Energy Consumption (THtotal) = [FO x GCVfo + (Coal-A) x GCVcoal + NG x GCVng + Others x GCVeach] Kcal 11 | Page . other Energy Purchased & Consumed. 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. Plant A =[ ( X * HR)/ GCVcoal] KG where HR= Avg. then National Avg. HR i.

Gate –to-Gate SEC = CASE -IV : Electricity Generated by CPP. other Energy Purchased & Consumed. 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 12 | Page . [Etotal /kg of product] Kcal/kg • Electricity is generated by Coal Based CPP. two different Norms / Targets to be established 1. Electricity partially sold to grid from 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.

the target setting criteria of ‘Power Plant’ should be adopted which is based on ‘Net Heat Rate’. 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.Gate –to-Gate SEC = [Etotal /kg of product] Kcal/kg 2.ELtotal) Kcal / kwh Here. 13 | Page .e Net Heat Rate) = Etotal / (G .

Heat energy partially met by waste / 14 | Page . (%) 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.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 A X CoGe Y (Kcal) n Plant Eff.

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 15 | Page .