TECHNICAL AUDIT IN MURUGAPPA GROUP
Management Audit DivisionE I D PARRY (INDIA) LTD
TECHNICAL AUDIT OBJECTIVES Recommend quantifiable benefits (Cost Savings) and qualitative improvements in various Technical operations (with a Focus on Energy conservation) in the Group Companies through a process of continuously identifying / reviewing such areas, extending implementation facilitation for the agreed proposals, conducting benefit realisation audits and organising awareness creation / knowledge sharing programs in the audited areas for all the Group Company Technical Executives.
AUDIT PROCESSAwareness Creation Process
Awareness creation / Technical Audit Project Identification through a series of internal Workshops among Group Company Executives
Area Identification Process
External search - Attending external knowledge sharing Programs / Seminars with a view to identify new areas for study Association with Energy Conservation Associations
AUDIT PROCESS...Audit Work
Prioritisation and Pilot audits at one plant - Quantification of benefits Replication of systems in other Plants in a phased manner Benefit realisation audits On going reporting on Benefits
Knowledge repository / Transfer process
Audit learnings repository in WEBMARS Organising experience sharing workshops / seminars for Group Company Executives
PAGE
TECHNICAL AUDIT PROCESS FLOW DIAGRAM
PROCESS
TECHNICAL AUDIT MEET
WATER
BOILER
IMPLEMENTATION
FACILITATION
ACTION PLAN
PROJECT IDENTIFICATION
ENERGY INPUT / OUTPUT ANALYSIS
REVIEW / FOLLOW UP
DATABASE
M.I.S.
DATABASE
REPORT BACK TO MANAGEMENT
SUGGESTED MODIFICATION OF PARAMETERS
NO
AUDIT REPORT
PLANT HEAD
CONCURRENCE
WITHIN LIMITS
ENERGY PERFORMANCE MODELS
kWh
PRODUCT
FURNACE OIL
UNITS
DIESEL
STEAM
ELECTIRCAL POWER
WALK THROUGH AUDIT /
DATA COLLECTION
GENSET
STORES
Technical Audit Functional ChartTechnical Audit AreasEnergy & Fuel AuditSHE Audit (Safety, Health & Environment)Factory Assets Management - Maintenance Audit (Civil, Mechanical, Electrical,Instrumentation)Production Process Audit (Input / Output, Mass Balance, etc.)Work done so far in
Steam Power Renewable Energy Electrical Systems Motors Pumps Compressed Air Insulation Dust Collection system Water etc.
ENERGY AUDIT
GOAL:The fundamental goal of energy audit is to provide Value adding services which improves the bottom line.
OBJECTIVESThe objective of Energy Audit is to achieve and maintain optimum energy procurement and utilisation, without affecting the quality of the final product and hence it focuses on .To minimise energy costs & reduce waste without affecting production & qualityTo reduce the effect on environment.
Technical Audit Focus AreasSTEAM
- Generation- Distribution- Condensate Recovery- Steam Traps- Piping Consideration- Flow Measuring Instruments- Insulation- Flash Steam Recovery- Waste Heat Recovery
ELECTRICAL
- Transformer Efficiency- Power Factor Management - Energy Saving in Lighting System- Energy Efficient Tube Lights - Street Light Control - Energy Efficient Motors- Harmonics studyTechnical Audit Focus Areas
COMPRESSED AIR SYSTEM- Compressor Data analysis- Energy Consumption Pattern- Compressed Air Pipeline Layout- Compressor Capacity test- Compressor Efficiency improvementsTechnical Audit Focus Areas
WATERWater conservation in Process AreaWater conservation in Non Process AreaTechnical Audit Focus Areas
INSULATION- Pipe line and Tanks Layout details - Present Energy Loss : Detailed analysis- Efficiency improvements Process with Improved InsulationTechnical Audit Focus Areas
RENEWABLE ENERGY- Locating paces where Renewable Energy can be effectively used- Present Fossil fuel usage and analysing partial utilisation of Renewable Energy - Renewable Energy awareness creation Impact On EnvironmentTechnical Audit Focus Areas
Safety, Health & Environment
- Safety / Environment Policies - Education & Training Efforts - Hazard Identification Process - Statutory Compliance - Accident Statistics, Analysis and Records - Emergency Planning - House Keeping - Work Environment Control - Occupational Health - Fire, Explosion Prevention & ControlTechnical Audit Focus Areas
ENERGY AUDIT SKILLS
Basic qualities of Energy auditor:Energy Auditor should be technically well versed with manufacturing processes, energy utilization technologies, in addition to awareness to statistical techniques of data processing, applied economics and cost accountancy.
ENERGY AUDIT SKILLS
Technical skills are a pre requisite in improving the energy efficiency of a process or equipment such as boilers, furnaces etc. For example, to improve the boiler efficiency oneneed to know the principles of combustion, heat transfer and steam generation.
ENERGY AUDIT SKILLS
Managerial skills which includes bringing about awareness, motivating people at all levels,recommending for the structure & procedure, reviewing the energy consumption, norms target setting, etc. Both the organizational and people changes are required. For example, a mere awareness campaign in an industry for switching off lights, fans and air conditioners brought about a significant reduction in energy consumption.
ENERGY AUDIT STRATEGY
Energy Audit should be seen as a continuous process. Key activities are outlined below; strategies should be reviewed annually, and revised as necessary.
1. Identify a Strategic Corporate Approach2. Appoint Energy Auditor3. Set up an Energy Monitoring and Reporting System4.Conduct Energy Audit5. Formalize an Energy Management Policy Statement6. Prepare and Undertake a Detailed Project Implementation Plan7. Implement a Staff Awareness and Training Program8. Annual Review
ENERGY AUDIT - METHODOLOGY
Energy Audit is the key to a systematic approach for decision-making in the area of energy management.
As per the Energy Conservation Act, 2001 Energy Audit is defined as the verification, monitoring and analysis of use of energy including submission of technical report containingrecommendations for improving energy efficiency with cost benefit analysis and an action plan to reduce energy consumption.
ENERGY AUDIT - METHODOLOGY
Type of Energy Audit
The type of Energy Audit to be performed depends on.
- the function and type of industry- the depth to which final audit is needed, and- the potential and magnitude of cost reduction desired
Thus Energy Audit can be classified into the following two types.
i) Preliminary Audit
ii) Detailed Audit
ENERGY AUDIT - METHODOLOGY
Preliminary energy audit is a relatively quick exercise to:
Establish energy consumption in the Unit
Identify the most likely (and the easiest areas for attention)
Identify immediate (especially no-/ low-cost) improvements/ savings
Set a reference point
Identify areas for more detailed study/measurement
Preliminary energy audit uses existing, or easily obtained, data
Estimate the scope for saving
ENERGY AUDIT - METHODOLOGY
Steps in Conducting a Preliminary Energy Audit
1. Plan how to obtain useful data Plan how to win the involvement/Commitment of others
2. Collect data Collect the existing data e.g., a energy bills(volume/cost) Collect the Production output/records plant layouts using checklists
ENERGY AUDIT - METHODOLOGY
3. Analyse data: Find unit cost of energy (Rs./ kWh for all types) Find fixed and variable energy element Derive energy Index: energy cost/unit output ,energy cost/floor area
ENERGY AUDIT - METHODOLOGY
4. Formulate plan: Formulate Immediate energy-saving actions: Where? How ? How much? Areas to investigate further Resources required for more detailed study
5. Actions and monitoring
6. Next steps (e.g. detailed audits), where needed
ENERGY AUDIT - METHODOLOGY
Detailed energy auditing is carried out in three phases, namely
1. Pre Audit Phase
2. Audit Phase
3. Post Audit Phase
ENERGY AUDIT - METHODOLOGY
Phase I Pre Audit Phase
Step 1
Planing and organising Walk through Audit Data collection using the checklist Familiarization of process/plant activities
Step 2
Conducting brief meeting awareness programme with all divisional heads and persons concerned
ENERGY AUDIT - METHODOLOGY
Phase II Audit Phase
Step 3
Primary data gathering, process flow diagram, &Energy Utility Diagram
Preparation of process flow charts [All service utilities system diagram (Ex.Single line power distribution diagram, water, compressed air & steam distribution.]
Annual Energy Bill and energy consumption pattern (Refer manual, log sheet, name plate,interview)
Design and operating data and schedule of operation
ENERGY AUDIT - METHODOLOGY
Step 4
Conducting survey and monitoringMeasurements :Motor survey, Insulation, and lighting survey with portable instruments for collection of more and accurate data. Confirm and compare operating data with design data.
Step 5
Conduct of detailed trials /experiments for selected equipments Few hours power monitoring (MD, PF, kWh etc.) . Load variations trends in pumps, fan, compressors etc.
ENERGY AUDIT - METHODOLOGY
Step6
Analysis of energy use: Energy and Material balance & energy loss/waste analysis
Step 7
Identification and development of ENCON opportunities Conceive, develop, refine ideas Review the previous ideas suggested by unit personal Review the previous ideas suggested by energy audit if any Use brainstorming and value analysis techniques Contact vendors for new/efficient technology
ENERGY AUDIT - METHODOLOGY
Step 8Cost benefit analysis Assess technical feasibility, economic viability and prioritization of ENCON options for implementation Select the most promising projects Prioritise by low, medium, long term measures
Step9
Reporting & Presentation to the Top Management Documentation, Report Presentation to the top Management.
ENERGY AUDIT - METHODOLOGY
Step10
Phase III Post Audit phase
Implementation and Follow up
Assist and Implement ENCON recommendation measures and Monitor the performance
Action plan, Schedule for implementation Follow-up and periodic review
ENERGY AUDIT - METHODOLOGY
The instrumentation required to carry out the audit.
Electrical Measuring Instruments:These are instruments for measuring majorelectrical parameters such as kVA, kW, PF,Hertz, kvar, Amps and Volts. In additionsome of these instruments also measureharmonics.These instruments are applied on-line i.e onrunning motors without any need to stop themotor.
ENERGY AUDIT - METHODOLOGY
Combustion analyzer:This instrument has in-built chemical cells which measure various gases such as CO2, CO, NOX, SOX etcFuel Efficiency Monitor:This measures Oxygen and temperature of the flue gas.Contact thermometer:These are thermocouples which measures for example flue gas, hot air, hot water temperatures by insertion of probe into the stream.Infrared Pyrometer:This is a non-contact type measurement which when directed at a heat source directly gives the temperature read out. Can be useful for measuring hot jobs in furnaces, surface temperatures etc.
ENERGY AUDIT - METHODOLOGY
Pitot Tube and manometer:Air velocity in ducts can be measured using a pitot tube and inclined manometer for further calculation of flows.Speed Measurements:In any audit exercise speed measurements are critical as thay may change with frequency, belt slip and loading.A simple tachometer is a contact type instrument which can be used where direct access is possible.More sophisticated and safer ones are non contact instruments such as stroboscopes.
ENERGY AUDIT - METHODOLOGY
Leak Detectors:Ultrasonic instruments are available which can be used to detect leaks of compressed air and other gases which are normally not possible with human abilities.Lux meters:Illumination levels are measured with a lux meter. It consists of a photo cell which senses the light output, converts to electrical impulses which are calibrated as lux.
AUDIT - TOOLS
WEBMARS
ENERGY AUDITING SYSTEM
DOWNLOADED SOFTWARES [DEMO VERSION]
METHODWARE - PRO AUDIT
AUDIT - TOOLS
ENERGY AUDITING SYSTEM
Environment: VB, MS Access / SQL Server
Application Software for Monitoring Process Equipment Efficiency and Energy Conserve Measures Reporting System
Technical Audit Customers1. COROMANDEL FERTILISERSFertiliser - Ennore / VizagCo-Gen- Nellikuppam- RanipetDistillery- NellikuppamPesticides- RanipetBio Products- Thyagavalli- Thane- Nellikuppam2. E I D PARRY Parryware- RanipetChemicals- Thyagavalli- Alwar3. PARRY & Co- DewasGSD- Dare HouseSugar- NellikuppamNetlon- Baroda- Pettavaithalai- Pugalur- Pudukottai
4.PCL- Nellikuppam 5.TII 7.PARRY AGRO - TPI Avadi Tea - TIMF Bawal - Mayura - TIMF Chennai - Murugalli - Attikunna - Caroyln6.CUMI Algae - Pudukottai- Tiruvottiyur - Pallikaranai 8. GFCL - Kakinada - Hosur - Maraimalai Nagar - Edapalli - Koratty
35 LocationsTechnical Audit Customers
Internal Workshops / Seminars organisedNoMeet NameConducted FocusInaugurated /Month & YearPresented by1. First TechnicalJuly 1998Technical Audit Concepts,Audit MeetScope & Coverage, Our ---Audit Approach, Methodologies& the Benefits of such Audits2. Second TechnicalApril 1999Technical Audit Concepts,Audit MeetScope & Coverage, Our ---Audit Approach, Methodologies& the Benefits of such Audits3. EID Steam AuditFebruary 2000Experience sharing in the Meetareas of Steam Audit in Mr.M.M.MurugappanEIDP - Plants /Group Companies4. EID Power AuditOctober 2000Experience sharing in the Meetareas of Power Audit in Mr.A.VellayanEIDP - Plants /Group Companies
Internal Workshops / Seminars organisedNoMeet NameConducted FocusInaugurated /Month & YearPresented by5. SHE AuditMarch 2001Audit Coverage,SeminarConcepts, Audit Experience Mr.M.M.Venkatachalamsharing in this area6. Seminar onAugust 2001Focus on the Mr.H.S.HanumanthaRaoManagement ofEnergy Bill (Member - Retired) Electricity in the TNERC New Environment 7. Renewable EnergyNovember 2001Solar Energy Concepts, Dr.C.PalaniappanMeetawareness creation, General Secretary& possible areas Planters Energy Networkof applications in our plants. 8. Guest AuditMarch 2002Gaining acceptance Dr.S.S.Pillai Pool Meetfrom internal customers VP - Bio Products &for the Consultancy Activity Chemicals
Internal Workshops / Seminars organisedNoMeet NameConducted FocusInaugurated /Month & YearPresented by9. Compressed Air April 2002Energy Savings in Mr.U.V.K.M.RaoSystem MeetCompressed Air SystemEnergy Consultant10. Electrical (Motor)June 2002Energy Savings in Mr.S.MahadevanAudit MeetElectrical (Motor) System Energy Consultant
11.World Energy DayNovember 2002Climatic Change, WaterDr.T.G.SundararamanMeet Conservation Energy ConsultantESCOMP GLOBAL
Internal Workshops / Seminars organisedNo Meet NameConducted FocusInaugurated / Month & YearPresented by12 Energy Management February 2003Energy Savings in Lighting Mr.Anand Rajaraman Initiative in Lighting System, Street LightingM/S Wipro Lighting SystemHarmonics
13 Energy Management April 2003 Flash Steam Mr.D.GnanasambandamInitiative in Steam Recovery
14 Energy Management August 2003 Energy Conservations in Mr.U.V.K.M.Rao Initiative in Fans & Pumps Fans,Pumps & Blowers Associates
15 Boiler Codes & ActsDecember 2003Industrial Boilers - Safety Aspects Mr.Thambithurai in Indian Industry& Practice CodesChief Inspectorate of Boilers16 Second Conference on March 2004Electrical & Heat Energy Mr.M.M.Murugappan Electrical & Heat EnergyDirector - Tech.
TECHNICAL AUDIT ACHIEVEMENTS EIDP Management Audit is approved by TNEB to carryout statutory Energy Audit We are also a part of Strategy Planning Committee Member for CII - Energy Management System Workshops We have conducted around 16 Internal workshops for the group companies We are also member of ENFUSE and actively participating in all their activities We are in the process of developing Application software for Energy Management
Useful Linkswww.energymanagertraining.comwww.bee-india.comwww.boiler.com www.eng-tips.comwww.oit.doe.gov/bestpracticeswww.pcra.org www.energy-efficiency.gov.ukwww.actionenergy.org.ukwww.cia.org.uk www.altenergy.comwww.energyusernews.com
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