TECHNICAL AUDIT
IN
MURUGAPPA GROUP
Management Audit Division
E 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 PROCESS
Awareness 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
TECHNICAL AUDIT PROCESS FLOW DIAGRAM
PROCESS
TECHNICAL
AUDIT MEET
BOILER
WATER
PRODUCT
PROJECT
IDENTIFICATION
STEAM
WALK THROUGH
AUDIT /
DATA COLLECTION
FURNACE
OIL
STORES
UNITS
ENERGY INPUT / OUTPUT
ANALYSIS
kWh
DIESEL
ELECTIRCAL
POWER
ENERGY PERFORMANCE
MODELS
WITHIN LIMITS
NO
AUDIT REPORT
GENSET
SUGGESTED
MODIFICATION OF
PARAMETERS
PLANT HEAD
CONCURRENCE
ACTION PLAN
DATABASE
M.I.S.
IMPLEMENTATION
FACILITATION
DATABASE
REPORT BACK TO
MANAGEMENT
REVIEW / FOLLOW UP
Technical Audit Functional Chart
Technical Audit Areas
Energy &
Fuel Audit
SHE 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.
OBJECTIVES
The 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 & quality
To reduce the effect on environment.
Technical Audit Focus Areas
STEAM
- Generation
- Distribution
- Condensate Recovery
- Steam Traps
- Piping Consideration
- Flow Measuring Instruments
- Insulation
- Flash Steam Recovery
- Waste Heat Recovery
Technical Audit Focus Areas
ELECTRICAL
- Transformer Efficiency
- Power Factor Management
- Energy Saving in Lighting System
- Energy Efficient Tube Lights
- Street Light Control
- Energy Efficient Motors
- Harmonics study
Technical Audit Focus Areas
COMPRESSED AIR SYSTEM
- Compressor Data analysis
- Energy Consumption Pattern
- Compressed Air Pipeline Layout
- Compressor Capacity test
- Compressor Efficiency improvements
Technical Audit Focus Areas
WATER
- Water conservation in Process Area
- Water conservation in Non Process Area
Technical Audit Focus Areas
INSULATION
- Pipe line and Tanks Layout details
- Present Energy Loss : Detailed analysis
- Efficiency improvements Process with
Improved Insulation
Technical 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 Environment
Technical 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 & Control
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 one
need 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 Approach
2. Appoint Energy Auditor
3. Set up an Energy Monitoring and Reporting System
4.Conduct Energy Audit
5. Formalize an Energy Management Policy Statement
6. Prepare and Undertake a Detailed Project
Implementation Plan
7. Implement a Staff Awareness and Training Program
8. Annual Review
ENERGY AUDIT - METHODOLOGY
Energy Audit is the key to a systematic approach for decisionmaking 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 containing
recommendations 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 monitoring
Measurements :
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 8
Cost 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 major
electrical parameters such as kVA, kW, PF,
Hertz, kvar, Amps and Volts. In addition
some of these instruments also measure
harmonics.
These instruments are applied on-line i.e on
running motors without any need to stop the
motor.
ENERGY AUDIT - METHODOLOGY
Combustion analyzer:
This instrument has in-built chemical cells which measure
various gases such as CO2, CO, NOX, SOX etc
Fuel 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 Customers
1. COROMANDEL FERTILISERS
Fertiliser
Pesticides
- Ennore / Vizag
Co-Gen
- Nellikuppam
- Ranipet
Distillery
- Nellikuppam
- Ranipet
Bio Products - Thyagavalli
- Thane
2. E I D PARRY
Parryware
Sugar
- Nellikuppam
- Ranipet
Chemicals
- Alwar
3. PARRY & Co
- Dewas
GSD
- Dare House
- Nellikuppam
Netlon
- Baroda
- Pettavaithalai
- Pugalur
- Pudukottai
- Thyagavalli
Technical Audit Customers
4.PCL
5.TII
- Nellikuppam
- TPI Avadi
- TIMF Bawal
- TIMF Chennai
7.PARRY AGRO
Tea
- Mayura
- Murugalli
- Attikunna
- Caroyln
6.CUMI
Algae - Pudukottai
- Tiruvottiyur
- Pallikaranai
- Hosur
- Maraimalai Nagar
- Edapalli
- Koratty
8. GFCL - Kakinada
35 Locations
No
Internal Workshops / Seminars
Meet Name
Conductedorganised Focus
Month & Year
1.
First Technical
July 1998
Audit Meet
Inaugurated /
Presented by
Technical Audit Concepts,
Scope & Coverage, Our
---
Audit Approach, Methodologies
& the Benefits of such Audits
2.
Second Technical
April 1999
Audit Meet
Technical Audit Concepts,
Scope & Coverage, Our
---
Audit Approach, Methodologies
& the Benefits of such Audits
3.
EID Steam Audit
February 2000
Meet
Experience sharing in the
areas of Steam Audit in
Mr.M.M.Murugappan
EIDP - Plants /
Group Companies
4.
EID Power Audit
Meet
October 2000
Experience sharing in the
areas of Power Audit in
EIDP - Plants /
Group Companies
Mr.A.Vellayan
No
Internal Workshops / Seminars
Meet Name
Conducted
organised Focus
Month & Year
5.
SHE Audit
March 2001
Seminar
Inaugurated /
Presented by
Audit Coverage,
Concepts, Audit Experience
Mr.M.M.Venkatachalam
sharing in this area
6.
Seminar on
Mr.H.S.HanumanthaRao
August 2001
Management of
Focus on the
Energy Bill
Electricity in the
(Member - Retired)
TNERC
New Environment
7.
Renewable Energy
November 2001
Meet
Solar Energy Concepts,
Dr.C.Palaniappan
awareness creation,
General Secretary
& possible areas
Planters Energy Network
of applications in our plants.
8.
Guest Audit
Pool Meet
March 2002
Gaining acceptance
Dr.S.S.Pillai
from internal customers
for the Consultancy Activity
VP - Bio Products &
Chemicals
Internal Workshops / Seminars
organised
No
Meet Name
Conducted
Focus
Month & Year
9.
Compressed Air
April 2002
System Meet
10.
Electrical (Motor)
June 2002
Audit Meet
11.
World Energy Day
Meet
November 2002
Inaugurated /
Presented by
Energy Savings in
Mr.U.V.K.M.Rao
Compressed Air System
Energy Consultant
Energy Savings in
Mr.S.Mahadevan
Electrical (Motor) System
Energy Consultant
Climatic Change, Water
Dr.T.G.Sundararaman
Conservation
Energy Consultant
ESCOMP GLOBAL
No
Internal Workshops / Seminars
organised Focus
Meet Name
Conducted
Month & Year
12
13
14
Energy Management
Mr.Anand Rajaraman
Initiative in Lighting
System, Street Lighting
M/S Wipro Lighting
System
Harmonics
Energy Management
April 2003
August 2003
Initiative in Fans & Pumps
15
Boiler Codes & Acts
December 2003
in Indian Industry
16
Presented by
Energy Savings in Lighting
Energy Management
Initiative in Steam
February 2003
Inaugurated /
Second Conference on
Electrical & Heat Energy
Flash Steam
Recovery
Energy Conservations in
Mr.U.V.K.M.Rao
Fans,Pumps & Blowers
Associates
Industrial Boilers - Safety Aspects
& Practice Codes
March 2004
Mr.D.Gnanasambandam
Electrical & Heat Energy
Mr.Thambithurai
Chief Inspectorate of
Boilers
Mr.M.M.Murugappan
Director - 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 Links
www.energymanagertraining.com
www.bee-india.com
www.boiler.com
www.eng-tips.com
www.oit.doe.gov/bestpractices
www.pcra.org
www.energy-efficiency.gov.uk
www.actionenergy.org.uk
www.cia.org.uk
www.altenergy.com
www.energyusernews.com
