Preview Energy Manager Issue 34 Apr-Jun 2016

April - June | 2016 | Vol :: 09 | No :: 02

ISSN 0974 - 0996

energy audits: state of the art energy audit: an essential step for an enterprise quality of energy audits: an SDA perspective

enhancing quality of energy audits: suggestions

six energy audit case studies

Editorial Consultant Prof. (Dr.) K K Sasi |Amrita University, India Guest Editor Mr. Sanjay Seth | BEE, India Editor K Madhusoodanan|SEEM, India Co-ordinating Editor Sonia Jose | Energy Press, India Book Design Badusha Creatives Translation Coordinator R Sudhir Kumar|CPRI, Bangalore Financial Controller K K Babu | Energy Press, India Printed and Published by G Krishnakumar, Energy Press for the Society of Energy Engineers and Managers and printed at St Francis Press, Ernakulam, India Disclaimer : The views expressed in the magazine are those of the authors and the Editorial team | SEEM | energy press | energyη manager does not take responsibility for the contents and opinions. η energy manager will not be responsible for errors, omissions or comments made by writers, interviewers or advertisers. Any part of this publication may be reproduced with acknowledgement to the author and magazine.

April - June 2016 | Volume: 09 | Number: 02 ISSN 0974 - 0996 Supported by::

Registered Office : Energy Press | SEEM Bhavan | KRA-A79 Kannammoola | Thiruvananthapuram | Kerala | India Tel : +91 - 471 - 2557607 | 3242323 E : energymanagerhq@gmail.com Web: www.energyprofessional.in

contents energy audit: an essential step for an enterprise ADEME

06

quality of energy audits: an SDA perspective Narayanan A M

13

enhancing quality of energy audits: suggestions Upendra Pratap Singh

18

Opinion acting on energy conservation: a collective responsibility Ashok Sethuraman

23

Energy Audit energy audit & benchmarking of hotels : an experience from Thailand's Chiang Mai municipality Soumya P Garnaik and Mrinal S Bhaskar

26

energy audit of sponge iron plant- a case study Mool Chand Jain

34

design of waste heat recovery system in a cement plant - a comprehensive case study Prahlad Chandra Tiwari

41

coal blending and its effects on boiler performance Vijay Bansal and Sudarshan Goyal

54

saving fuel by increasing boiler efficiency the case study of Arvind Ltd Vinay Singhal and Mukesh Patel

60

ओ रएंट सीमट म ऊजा बचत प रयोजनाएं

62

आर वी आर मू त

03 a quarterly magazine of the society of energy engineers and managers / India

Editorial Board Prof. Ahamed Galal Abdo | Advisor Minister of Higher Education, Egypt Darshan Goswami | US Dept. of Energy, USA Prof. (Dr.) Hab Jurgis Staniskis | Director, Institute of Environmental Engg., Lithuania Dr. R Harikumar | Immediate Past General Secretary, SEEM, India Prof. P A Onwualu | DG, RMR&D Council, Nigeria R Paraman |Devki Energy Consultancy,India Ramesh Babu Gupta | India Dr. Rwaichi J A Minja | University of Dar Es Salaam, Tanzania Prof. (Dr.) R Sethumadhavan | Anna University, India Prof. Sujay Basu | CEEM, India

Cover Feature

April - June 2016

Advisory Board Dr. Bhaskar Natarajan | India Binu Parthan | REEEP, Vienna Dr. Brahmanand Mohanty | Advisor, ADEME Dr. P P Mittal | Immediate Past President, SEEM, India Dr. B G Desai | Energy Expert, India C. Jayaraman | General Secretary SEEM, India Dr. Kinsuk Mitra | Winrock International, India Dr. G M Pillai| WISE, India Dr. N P Singh | Advisor MNRE, India Prof. P R Shukla | IIM Ahmedabad, India

editor's note

quality audits for smart energy choices

With a more broad perspective being added to facility process /process energy analyses, the increasing complexities of today's audit may recur more demands from the auditor. It is, therefore, important that we should not lose sight of the fact that really good auditors have

In conclusion, if audits can come closer to the prediction of actual savings over the life of a contract, the advantages include larger projects which are better for the client, more satisfying to the engineer, and more profitable for the ESCO. Consistency in audit predictions and results would also provide an increased level of confidence to financial houses asked to provide funding for energy efficiency improvement. Basic understanding of an investment grade audit (IGA) is the realization that the traditional audit must serve as a starting point.

In our first cover feature, ADEME gives us an insight into the importance of energy management for small and medium enterprises, and focuses on the analysis of energy consumption of utilities and manufacturing equipment. The second article by Mr. A.M. Narayanan highlights areas that need improvement giving suggestions for the same based on previous energy audit reports. Further ahead, Mr. Upendra Pratap from Schneider India, enlightens us on the importance of choosing well experienced energy auditors in order to achieve the full potential regarding energy savings.

A few energy audit case studies have also been included and we hope you find this issue of energy manager informative. Please feel free to let us know your comments and suggestions.

K. Madhusoodanan Editor

(Please contribute your articles and case studies to reach the editor at madhukoovaprath@gmail.com or energymanagerhq@gmail.com)

05 a quarterly magazine of the society of energy engineers and managers / India

Demand, in time, creates supply. Historically, the auditor's involvement ended with the delivery of a report to the owner and the collection of a fee which did not carry any assurance of predictive consistency. Engineers are becoming more deliberate in their efforts to gradually modify audits in order to reflect the human element and operational concerns. More engineering firms are incorporating risk assessment procedures in their auditing protocol. It is the owner's right to demand that an energy audit be a sound guide to investment, whether guarantees are involved or not. The Investment Grade Audit (IGA) is destined to become increasingly popular among more knowledgeable energy efficient consumers, but it will take some time before it is a standard in the industry. This is due to the difficulty of finding those capable of performing real IGAs outside the ESCO industry.

been gradually incorporating many of these broader concerns into their work. It has, however, been on a rather ad hoc basis. The time has arrived to systematically weigh these issues with respect to each client's needs and incorporate them into an investment grade audit. The cost/benefit analysis presented in the audit report should offer the investor a reliable guide to the investment potential of the recommended measuresa guide that recognizes the impact to the organization's bottom line.

April - June 2016

W

ith regard to technology, energy audits have been constantly evolving. More sincere effort is being made into the data which is gathered as engineers learned to interpret what they observed in terms of energy efficiency possibilities. However, despite all the improvements, it still adheres to the basic technical study of conditions as they exist at the time of the audit and the analysis is limited to implementing specific measures encapsulated in existing conditions. As the energy efficiency industry matures, projects become more complex and the risk analysis more sophisticated.

Hence the need for information becomes beyond what regular audits produce. Financiers were asking more sophisticated questions about risk and basing interest rates more closely on the answers. The "snap shot" approach was the foremost limitation of the traditional energy audit and this does not necessarily meet the owner's energy efficiency needs. Today those needs also require attention to unique process requirements, supply availability, energy security and information systems

April - June 2016

a quarterly magazine of the society of energy engineers and managers / India

06

energy audit: an essential step for an enterprise

ADEME

recent study by the French Environment and Energy Management Agency (ADEME) on the prospective evolution of energy demand highlights potential energy efficiency gains of nearly 20% on average in industries by 2030. The organizational measures alone represent between 10 and 25% of savings in question according to the sectors concerned. Faced with the inevitable increase in energy costs in the future, energy management thus represents for enterprises a "competitive resource",

which is essential to exploit right from now. w

Mandatory energy audits

Under the EU directive on energy efficiency, energy audits have become mandatory for large companies from December 5, 2015. It should be noted that a certified energy management system meeting the requirements of the ISO 50001 Standard also helps satisfy this new obligation.

energy audit: an essential step for an enterprise a quarterly magazine of the society of energy engineers and managers / India

A

07

April - June 2016

A recent study by ADEME highlights potential energy efficiency gains of nearly 20% on average in industries by 2030.

Energy audits are an essential step for appropriate energy management actions in the future and it has become mandatory for all large companies. This article emphasizes that the successful implementation of energy audit recommendations depends on certain key aspects like scope of study, internal organization set up, selection of the service provider and a clear picture of the process in advance. An energy audit that provides the basis for an Energy Management System (EMS) gives the company more gain in terms of energy efficiency.

Narayanan A M

Impact of quality of energy audit in energy management has a strong bearing in realizing substantial energy efficiency enhancement opportunities. Although many facilitation measures prevail for quality assurance of energy audits, salient areas for improvement based on observations made on energy audit reports are discussed here.

E

nergy Audit forms an integral part of Energy Management, as it is an effective tool for evaluation of energy efficiency, identification of energy saving projects and setting benchmarks and targets for energy efficiency. Energy Audit is an innovative and challenging exercise, as much as an activity to be carried out in compliance with relevant technical codes, standards, basic energy technology and engineering, operation and maintenance practices, principles of techno-economics analysis and project

April - June 2016

quality of energy audits: an SDA perspective

a quarterly magazine of the society of energy engineers and managers / India

13

enhancing quality of energy audits: suggestions Upendra Pratap Singh

April - June 2016

a quarterly magazine of the society of energy engineers and managers / India

18

If you are serious about energy efficiency, it is shortsighted to select inexperienced energy audit providers. Often the low cost providers charge very little because they have little experience and they may provide a poor quality audit. In the long run, a poor quality energy audit can hinder the energy efficiency success, and end up costing owner many times more than cost of the audit. A poor quality energy audit can prevent owner from achieving the full potential of energy cost savings. Some of the ways in which energy audits lead to less than desirable results include: missing the most beneficial energy efficiency measures, suggesting measures that do not save energy, and not including a scope of work.

It is important when selecting an auditor that we select a skilled professional to do the job. Facility owners should take responsibility for getting a quality job done.

Ashok Sethuraman

Energy conservation initiatives and implementation measures are the collective responsibility of the government and the industry. The need of the hour is to promote energy conservation initiatives among industry and society through regulatory measures by the government.

Governments shall encourage industry to carry out systematic and periodic energy audits to achieve the results. Industry shall showcase in detail, the value added through encon measures in their annual reports.

April - June 2016

acting on energy conservation: a collective responsibility

a quarterly magazine of the society of energy engineers and managers / India

23

SEEM Technical Sessions on

Demystifying PAT & Energy Efciency Bhopal | Raipur | Mumbai | Bangalore

Inauguration of SEEM Bhopal Chapter. L to R: Mr. Gyanendra Saxena, Mr. R.C. Shrivastav – Chairman Institute of Engineers, Mr. M.C Jain – CEA – MCJ Associates, Dr. R.M Sarviya – Head of Energy Centre, MANIT – Chief Guest, Mr. M. Mohtasib – APQI, Mr. Ashish Pandit – ICAI

April - June 2016

a quarterly magazine of the society of energy engineers and managers / India

52

Bhopal team with delegates

April - June 2016

a quarterly magazine of the society of energy engineers and managers / India

26

energy audit & benchmarking of hotels

an experience from Thailand's Chiang Mai municipality

T

Soumya P Garnaik and Mrinal S Bhaskar

he hospitality sector in Chiang Mai, Thailand uses different forms of primary and secondary energy i.e. electricity, LPG, steam, fuel oil, etc. to cater to the needs of end-use applications. The energy cost is about 6-10% of total operating cost in this sector.

Moreover, the energy performance of hotels varies widely due to various factors like operation and maintenance practices, selection of end-use

energy audit & benchmarking of hotels - an experience from Thailand's Chiang Mai municipality a quarterly magazine of the society of energy engineers and managers / India

27

April - June 2016

Energy audit is a tool to identify energy saving potential and avenues through a structured, scientific and logical approach. Various energy audit studies have revealed that commercial building sector (including hospitality sector) can save up to 2030% of their energy consumption.

The Municipality of Chiang Mai, Chamber of Commerce, University of Chiang Mai, and the Thai Hotel Association, among other relevant institutions, recognize the importance of this tool in order to become competitive and environment-friendly on sustainable basis. Moreover, under Energy Conservation Law of Thailand, hotels (under commercial building sector) have been identified as "Designated Buildings" which have the responsibility of ensuring efficient use of energy. Energy audit will certainly serve a first-step approach in this requirement. This paper describes the experience of a successful program implemented in Chiang Mai's hotel sector to improve the energy performance on a sustainable basis.

April - June 2016

a quarterly magazine of the society of energy engineers and managers / India

34

energy audit of sponge iron plant a case study

Mool Chand Jain

Prahlad Chandra Tiwari

April - June 2016

design of waste heat recovery system in a cement plant a comprehensive case study

a quarterly magazine of the society of energy engineers and managers / India

41

April - June 2016

a quarterly magazine of the society of energy engineers and managers / India

coal blending and its effects on boiler performance Vijay Bansal and Sudarshan Goyal

54

oal blending is required as the quality of Indian coal is progressively degrading. It also aids in mixing of low grade coal with a better grade, meeting the short supply, improvement of boiler performance and reduction of power generation cost.

coal blending and its effects on boiler performance

C

Since coal is not homogenous, its quality varies and depends on the content of several properties, like origin, combustion properties, ash content variation and burning profile analysis. Blending of coals should be done judiciously taking into consideration the properties of the individual blend components.

w The origin of coal w Chemistry of inorganic, organic part and the combustion properties w The grindability of coal w The variation in ash content w

Burning profile analysis -Differential Thermo gravimetric (DTG) & Differential Scanning Colorimetric (DSC) are used for pre blend analysis

w Slagging, fouling and emission characteristics like NOx, SOx and particulate.

55 a quarterly magazine of the society of energy engineers and managers / India

Things to understand before blending of coals

April - June 2016

Coal blending in power plants is mainly adopted to reduce power generation cost and to increase availability of coal. Low grade coals can be mixed with imported or higher grade coal without deterioration in thermal performance of the boiler. The authors of this article aim to give the readers an understanding of the implication of coal blending on boiler performance by explaining the effect on various coal properties on blended coal combustion as well as various techniques for the process.

April - June 2016

a quarterly magazine of the society of energy engineers and managers / India

60

saving fuel by increasing boiler efficiency – the case study of Arvind Ltd Vinay Singhal and Mukesh Patel

ओ रएंट सीमट म ऊजा बचत प रयोजनाएं आर वी आर मू त

April - June 2016

a quarterly magazine of the society of energy engineers and managers / India

62

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