Baseline Energy

Format for Baseline Energy Audit

Bureau of Energy Efficiency



[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 / co-operative sector)b. Present Installed capacity and stages of capacity addition (if any)c. Trend of capacity utilization in last 5 yearsd. Trend of monthly production and capacity utilization of last one yeare. Review of process flow diagram

2. Give the energy scenario of the planta. Different types of energy sources being used and their % share of contributioni. Primary Energy (Solid Fuel, Liquid fuel, gaseous fuel etc.)ii. Secondary Energy (Electricity)1. Purchased from grid2. Self-generated (CPP/DG sets/Co-Generation)iii. Energy from internally generated by-products or waste heativ. Renewable energyb. Establish the trend of following of last 3 years i. % share purchaged electricity from grid to that of total electricity consumedii. % share of self generated electricity to that of total electricity consumediii. % share of internally generated thermal energy from waste-heat, co-generation or by-product of total consumed energyiv. % Cost of energy to that of total production costv. % share of renewable energy to that of total energy consumedc. Trend of monthly production and energy consumption (Electrical & thermal) of last one yeard. 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) concepta. 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 yearsc. 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.

ItemUnitSource of DataFrequency 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 observationsd. 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 Flow Diagram and Present Metering System

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 stageb. Divide the entire process into key sub-processes or sub-systems. The typical sub-process of the sectors are given below (but not limited).

SectorSub-Processes

Thermal Power Plant (coal)Coal handling Plant, Ash Handling System, Steam Generation System, Turbo-Generator system, CW system, ESP, Compressed Air System

Thermal Power Plant (Gas)Turbo-Compressor System, Waste Heat Recovery Boiler, CW system, Compressed Air System

Aluminium (Smelter)Rectiformer, Pot-Lines, Carbon Plant (Green Anode Plant, Bake Oven, Rodding Shop), Cast-House, Compressed Air System, Fume Treatment Plant

Aluminium (Refinery)Digester system, Cleaning & Refining System, Calcinations System, Steam Generation System, Co-Gen System

CementRaw Material Preparation System, Cement Kiln, Grinding Section, Captive Power Plant(CPP)

Iron & Steel (Integrated)Coke oven, Sintering Plant, Blast Furnace, BOF, Casting Section, Rolling Mills, CPP

Iron & Steel (Sponge Iron)Sintering Plant, DRI section, EAF section / IF Section, Casting section, Rolling Mill, CPP

FertilizerNitrogen Plant, Urea Plant, Steam Generation System, CPP

Pulp & PaperRaw Material Preparation, Pulping Section, Paper Machine Section, CPP, Co-Gen Plant

TextileSpinning 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 sub-process, 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

ParametersWhat to look forValue

Brief Description of the Sub-Process

Material FlowName

Flow RateDesignoperating

Energy InputElectricity

Solid Fuel (Coal/Lignite)

Liquid Fuel (FO/HSD/LHHS...)

Gaseous Fuel (NG/LPG...)

Others

Major EquipmentName

Technology

Numbers InstalledOperating

Technical Specifications

Specific Energy ConsumptionDesignOperating

Factors Affecting Energy EfficiencyTechnical ParametersDesignOperating

Operating ParametersDesignOperating

Major Auxiliaries Associated (Pumps, Fans, Compressors, Furnaces, HVAC system etc.)Numbers Operating

Technical Specifications

% Loading or Capacity UtilizationDesignOperating

Efficiency (%)DesignOperating

Specific Energy ConsumptionDesignOperating

Technology Up gradation in Last 3 Years Technology Change Process Modification O & M Practice Resulting Energy Saving Approx. Investment done

[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 Possible Energy Efficiency Improvement Option

a. Waste Heat Recovery Optionsi. Sourceii. Comment on Feasibility iii. Quantum of Possible Extracted Energyb. Co-Generation Optioni. Comment on Feasibility ii. Approximate Thermal & Electrical Energy outputc. Fuel Switch Optionsd. Retrofit Optionse. Use of Energy Efficient Equipmenti. Energy efficient drives, Pumps, Fans, Compressors, Lighting system etc.ii. Variable Frequency Drives / Variable Speed Drivesiii. Any otherf. O & M Practices i. Waste minimization (Reuse, Recycle, Resizing)ii. Control Mechanismiii. Data Monitoring & Accountingg. Cost-Benefit Option in all possible optionsi. Simple Pay Back Period

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

Sub-ProcessAction TakenCategory*Year of ImplementationResulted SavingInvestment Done

* 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. Specific Projects to be undertakenb. Investment Planc. Human Resource Planning in Energy Managementd. Any target fixed by management as per their policy

10. Prepare the Audit Report with Following Structure/Formata. Acknowledgementb. Study Team Membersc. Executive Summary

SlRecommendationsAnnual Potential SavingApprox. Investment Simple Pay-Back PeriodRemark

d. Introductione. Methodology Adopted f. Instruments Used for Energy auditg. Brief Description about the plant (Process Flow Diagram)h. Energy Scenario & Usage patterni. Description about Sub-Process (As per Point # 6)j. Identifying ENCON Options (As per Point # 7)k. Description about Past ENCON activitiesl. Description about future ENCON strategym. Conclusion & Critical Commentn. 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.GarnaikEnergy EconomistBureau of Energy EfficiencyMinistry of Power, GOI4th Floor, Sewa Bhawan, R.K.Puram, New Delhi-66Ph: 011-26178352 email: [email protected]

Annexure-ADifferent Case Situations in Estimating Total Energy Consumption and Specific Energy Consumption in Gate-to-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.

CASE -I : All Energy Purchased and Consumed

Electricity is purchased from the Grid

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

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

Electricity is purchased from the Grid & generated by DG set

A (Ltr)Others (KG or Ltr)Coal (KG)NG (SCM)Electricity (KWH)FO (Liter)

X ( kwh)DG Set

SFC (kwh/ltr)Product (Kg)

Process

(a) If X is known and A is known, SFC = ( X / A) kwh/ltr(b) If A is known X = ( A x SFC ) kwh where SFC = 3.0 to 3.5 kwh/ltr(c) If X is known 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


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

Y (KWH) to GridElectricity is generated by Coal Based CPP, partially sold to grid

A (KG)Others (KG or Ltr)FO (Ltr)NG (SCM)Coal (KG)

X ( kwh)CPP

Heat Rate (Kcal/Kwh)Product (Kg)

Process

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


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

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

G (KWH)B

Coal (KG)Y (KWH) to GridCPP

Others (KG or Ltr)Aux P (a%)X (KWH)

FO (Liter)Product (Kg)APROCESS

NG (SCM)

Coal (KG)

Others (KG or Ltr)

Here, in case of two separate boundaries, two different Norms / Targets to be established1. 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


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.

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

Electricity & Heat are generated by Co-Gen Plant

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

Co-Gen

Y (Kcal)Plant Eff. (%)Product (Kg)

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) =(Elect + X) KWH

Total Thermal Energy Consumption (THtotal) =[FO x GCVfo + Coal x GCVcoal + NG x GCVng + Others x GCVeach + Y] Kcal


CASE -VI : Energy Purchased & Consumed, Heat energy partially met by waste / by-product of the Process

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

Product (Kg)

By-Product (X KG)Z Kcal

Heat Content of By-Product = Y Kcal / KgSo, 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


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