A FORMAT OF ENERGY AUDIT REPORT

As required under clause-5 of Govt. order No GHU/99/31/GUE/1196/9018/KI.

Dated : 5^th October 1999.Energy audit report should include a work schedule sheet duly signed by energy auditor and concerned consumer

Points listed below can be separate sections of the report. An Executive Summary may be provided at the beginning of the report.

(A) GENERAL :

(1) Introduction :Background of the plant manufacturing activities and major electricity consuming areas.

(2) Electricity Consumption and Bills :Summary for the past year’s monthly electricity

               consumption and production data. Calculation of specific Energy Consumption 

               (KWH/TON of materials produced. KWH/M²etc.) and comments on the same.

               Calculation of Load Factor and methods to reduce Maximum Demand.

               Comments on Average Power Factor and methods to improve power factor. Explore

possibility of better use of Time of use tariff.

(B) PERFORMANCE EVALUTION OF MAJOR UTILITIES AND PROCESS

      EQUIPMENTS :

(1) Electrical Distribution Networks:

Transformers :Performance evaluation through simultaneous measurements of major electrical parameters on H.T. & L.T. side and rationalization of transformers, if needed.

Power Factor :Measurement of distortion & displacement power factor at various points viz. PCC, MCC, load centres etc. and analysis of the same for optimizing the network losses.

Metering and Monitoring Status :Review of existing meters for adequate monitoring requirements.

               (2) Electrical Equipment : Measurements of all major electrical parameters viz. Voltage, current,

                    power factor, KW, frequency etc. of important equipments (motors, furnaces, electrolysis,  

                    lighting, etc.) with significant energy consumption. Loads susceptible to generation of

                    harmonics should be checked for present harmonics level. System unbalance with respect to

                    voltage and current shall be checked.

(3) C.P.P./D.G. Sets :Review of performance including major auxiliaries and suggestions for

        optimization.

(4) Pumps & Blowers :Measurements of Head/Pressure, Flow, Power of pumps and blowers.

      Determination of Pump/blower efficiencies based on measured parameters and critical study of

      piping/ducting/valve/damper pressure losses, system layout etc.

(5) Compressors :Determination of compressor capacities, specific power consumption (KWH/

      CFM) , leakage detection and quantification, pressure losses in auxiliary equipments / piping,

       identify points using unnecessary high pressures and identify applications with wasteful use.

(6) Refrigeration & Air-conditioning systems :Determination of refrigeration system cooling

      capacity through measured operating parameters viz., flow ,inlet/outlet temperature of cooling          

      media, specific power consumption (KW/TR) review temperatures maintained, explore

      possibility of thermal storage to take advantage of Time of use tariff, Critical examination of

      coils, filters, AIIU’s duets etc.

(7) Cooling Towers :Evaluation of Cooling performance by measurements of cooling water flow,

      inlet/outlet temperatures and ambient air DBT/WBT, air flow, fan power etc. Co-relation of

      cooling tower performance with due consideration of cooling water system as a whole.

(8) Furnaces :Determination of specific power consumption (KWH/TON) based on

      measurements, work out heat balance to identify major factors contributing to

      energy loss. Explore possibility of alternate mode of heating.

(9) Electrolysis :Determination of specific power consumption, estimation, of heat losses of hot

      water baths and hot air dryers etc.

(10) Process Equipments : (e.g. extruders, grinders, mixers etc.) Determination of specific power

        consumption for every major process step through measurements. Review of data with

        process personnel.

(11) Lightings :Measurement of light intensity and all major electrical parameters viz., Voltage,

        amp, p.f., KW, etc. Study of type of lamps used, type of chockes used, day and night time

        lighting etc.

Findings :

·        The reportwill provide existing Energy Profile of the unit with percentage share of major equipment processes, utilities etc., so that it becomes a basic document for future monitoring.

·        Detail of measures to be taken to improve Energy Efficiency and reduce losses for all above areas. Estimation of energy and monitory servings, investments requirement and simple payback periods. The measures shall be categorized into operational changes, minor modifications and retrofits(negligible & moderate investment) and use of more efficient equipment/process (major investment). The investment proposals should be backed up with quotations received from vendors.