Processes of Industrial Energy Audit

Transcription

1 Processes of Industrial Energy Audit Page 1 Dr. Khaled Khodary Esmaeil Industrial Energy Assessment Lab Department of Mechanical Engineering, College of Engineering, Qassim University, Saudi Arabia

2 Page 2 OUTLINE INTRODUCTION ENERGY AUDIT LEVELS ENERGY AUDIT PROCESSES INSTRUMENTATION FOR AUDITING

3 Page 3 INTRODUCTION Energy Efficiency Energy efficiency is using less energy to provide the same service. Energy efficiency is not energy conservation Turning off a light is energy conservation, not energy efficiency.

4 INTRODUCTION Energy Audit A process of analyzing and evaluating the energy consumptions and costs of an organization to identify energy efficiency measure (Recommend Energy Management Opportunities EMOs). Page 4

5 INTRODUCTION Energy Audit Practical summery Activities to determine: How and where energy enters the facility, department, system or piece of equipment; Where it goes and how it is used; Any variances between inputs and uses; How it can be used more effectively or efficiently. Page 5

6 ENERGY AUDIT LEVELS Level 1 Walk-Through Audit: A tour through the facility to visually inspect each of the energy using systems Level 2 Detailed Audit (Standard audit): Quantify energy uses and losses through a detailed review and analysis of equipment, systems, and operational characteristics. Level 3 Computer Simulation: A more details of energy use by function and a more comprehensive evaluation of energy use patterns by using simulation software Page 6

7 Page 7 Step 1: ENERGY AUDIT PROCESSES Historical Data Analysis (Pre-site inspection) Step 2: Step 3: Walk-Through Audit (Preliminary Audit) Planning for Detailed Audit Step 4: Detailed Audit Step 5: Evaluation and Report

8 Page 8 Step1: Historical Data Analysis (Pre-site inspection) Historical energy and water consumption and billings data for at least 12 months, preferably multi-year; Basic information of the organization, including at least layout, main processes, products and production lines data; Operations schedule, equipment inventories, and production data; Mechanical, electrical, architectural plans and specifications Available data (if any): energy consumptions measurements, consumption/demand profiles, etc.

9 Step 2: Walk-Through Audit (Preliminary Audit) Page 9 Nature and Purposes High level assessment (Holistic assessment) Assesses merits of doing detailed audit Identifies areas of focus for detailed audit Verify the preliminary data analysis

10 Step 2: Walk-Through Audit (Preliminary Audit) 1) the walk-through (audit tour) Observe: Where/how energy is being consumed/wasted; Determine: Where corrective actions are needed; Conclude: Where capital investment may be needed to improve energy efficiency. Page 10

11 Step 2: Walk-Through Audit (Preliminary Audit) 2) Analyze energy consumption and costs Assess the energy cost and bills Classify energy consumption (fuel, gas or electricity) and relate to process. Assess the trends of consumptions Correlate to independent variables (e.g. production lines, shifts or schedule) Correlate consumption with appropriate index measures like production unit Determine unit energy cost and trends Page 11

12 Step 2: Walk-Through Audit (Preliminary Audit) 3) Comparative analysis Two kinds of comparison: 1. Internal benchmarks multiple facilities Historical consumption Trends and patterns 2. External benchmarks standards of performance established in the industry sector. Page 12

13 Step 2: Walk-Through Audit (Preliminary Audit) Page 13 4) Preliminary audit findings Energy performance indices Energy patterns and trends. Potential EMOs (energy management opportunities)

14 Page 14 Step 3: Planning for Detailed Audit Define the audit mandate: Clarification of the goals and objectives of the audit, and the key constraints that will apply to actions on its recommendations Define the audit scope The physical extent of the audit The energy inputs and outputs The sub-systems to be assessed

15 Page 15 Step 3: Planning for Detailed Audit The audit plan should at least spell out the following: Audit objectives, scope and applicable criteria (if any); Dates and places where the audit is to be conducted; Identification of audit team members; Detailed schedule of audited function and responsibilities; and The energy audit elements with high priority;

16 Step 3: Planning for Detailed Audit Prepare checklists and working documents : The purpose of a checklist is to stimulate thinking, guide the auditor and encourages these energy audit steps: list the existing measuring, metering and monitoring equipment; examine the suitability of the existing equipment; examine the function, management and energy performance of systems and processes; establish what additional information is needed and the steps to be taken; Page 16

17 Page 17 Step 3: Planning for Detailed Audit Other working documents may include: meeting and meeting attendance record forms, audit record forms (auditor s notes), plan of the facility.

18 Step 4: Detailed Audit Nature Greater detail in assessment of specific areas identify specific energy efficiency measures to reduce consumption, demand, cost (generally EMOs) Page 18

19 Page 19 Step 4: Detailed Audit Steps Conduct opening meeting Audit facility as per plan Collect information Carry out the diagnostic audit(s), if needed Analyse information Evaluate audit findings Identify main EMOs Review EMOs with auditee s representative Conduct closing meeting

20 Step 4: Detailed Audit opening meeting Review the purposes, scope and plan of the audit change as needed Describe audit methodologies Define communication links Confirm availability of resources and facilities Confirm schedule of meetings with management group Inform about site health, safety and emergency procedures Answer questions - create comfort level with the audit purposes and outcomes. Page 20

21 Step 4: Detailed Audit Audit activities and collecting informtion The audit team disperses with their guides to conduct the audit activities according to the plan. The energy audit may include different techniques to gather audit objective evidence: interviews, Observing activities and reviewing records auditors own measuring and recording activities An audit should be carried out during normal operating conditions, except for tasks like compressed air lines leaks. Page 21 Checklists is your guide.

22 Page 22 Step 4: Detailed Audit Energy use drivers Climate Facility size & Age Schedules Equipment type Building design Processes and operational procedures Organizational culture Behavior

23 Step 4: Detailed Audit Cary out diagnostic audit(s), when needed to verify the data collected from plant records and to gather additional information through detailed observations and discussions with plant personnel. may also include requests for demonstrations and taking additional measurements and recordings. Page 23

24 Step 4: Detailed Audit Analyse the information; Evaluate audit findings; and Identify main EMOs all information gathered during the audit is reviewed, tentative findings and observations are formulated. The team, under the lead auditor s guidance, obtains consensus on the draft of main audit conclusions, recommendations and EMOs. If possible, a rough quantification of anticipated energy savings should accompany this stage Page 24

25 Step 4: Detailed Audit Energy Management Opportunities EMOs STEP 1 - Match usage to requirement STEP 2 - Maximise system efficiencies STEP 3 - Optimise the energy supply Begin the search for opportunities where the energy is the most expensive at the point of end use! Review the EMOs with the auditee s representative before closing meeting Page 25

26 Step 4: Detailed Audit Conduct closing meeting On site closure to the audit process, although other activities still need to follow. Present the audit findings and conclusions to the facility s management team. At the end, there should be a clear understanding and acknowledgement of the result. Page 26

27 Step 5: Evaluation and Reporting the limited time for on-site audit activities does not allow the auditors to carry out a detailed analysis of the energy audit information. more accurate estimates/calculations have to be done after the site visit, including: Page 27 Energy intensity ratios (i.e. energy used per unit of output) savings to be expected from an energy project. Priorities of EMOs projects. A cost-benefit analysis based on future energy costs calculate the project s payback Benchmarks and Best Practices comparisons are very useful tools for evaluations.

28 Step 5: Evaluation and Reporting Page 28 Benchmarking A methodology to improve energy performance Comparison of energy performance to a standard Investigation of the differences between existing and standard practices This facility is different from those benchmarks! Investigate the differences The opportunities lie in the differences

29 Page 29 Step 5: Evaluation and Reporting Best practices Proven solutions for improving performance External sources: Industry / sector case studies Survey / study groups Internal sources: Individuals/groups Best historical performance

30 Page 30 Step 5: Evaluation and Reporting Report Provide a clear account of the facts upon which EMOs recommendations are made Interest those who read the report in acting upon those recommendations

31 Page 31 INSTRUMENTATION FOR AUDITING Electric Power Meter Combustion Analyzer

32 Page 32 INSTRUMENTATION FOR AUDITING Infrared Thermometer Digital Thermometer

33 INSTRUMENTATION FOR AUDITING Psychrometer (Humidity Measurement) Air Flow Measurement Devices Page 33

34 Page 34 INSTRUMENTATION FOR AUDITING Tachometer Ultrasonic Leak Detector

35 Page 35 INSTRUMENTATION FOR AUDITING Other useful items: A camera Binoculars and a small flashlight Duct tape & Tie Wraps Multi- screw driver, adjustable wrench and pliers Tape measure Bucket and stopwatch Safety Glasses, Gloves & Ear Plugs Caution tape

36 Page 36 End of Presentation Thank You and any Question