BASELINE ENERGY AUDIT

&
METHODOLOGY OF DATA VERIFICATION
Venue : PAT WORKSHOP for
TEXTILE - Sector , at Bhilwara
Date – 22nd February 2011

Presented By: R.B.SINHA

ENERGY AUDIT SERVICES, Faridabad
mail <sinhaeas@vsnl.com>
Mob.: 09811229516
POTENTIAL FOR ENERGY SAVING

Several steps have already been undertaken in Textile Sector for the
improvement in Energy Saving. Still there is substantial potential for
further more Energy Saving.

PAT framework includes the following elements:-

1. Methodology for setting Specific Energy consumption (SEC) for

each DC in the baseline year.

2. Methodology for setting the Target to reduce the Specific

Energy consumption (SEC) in the next 3 years. Target for reduction
in SEC would vary from D.C. to D.C.
3. The process to issue energy savings certificates (E.S. Certificates) to
those DCs, who achieve SEC lower than the specified value.
4. Trading of E.S. Certificates.

Example of SEC level in Spinning Mills

• CASE STUDY # 1
Data from an overseas spinning mill, having 4 units ,each Unit having
25,000 to 28,000 of spindles.
Totally Air conditioned( by Chillers) throughout the year.
‘Specification Power consumption’ worked out in KWH per 100 kg.
Main Observations
1. Wide variation from month to month in each of 4 Plants – all managed by
the same team of Managers & Engineers, under the same compound.

2. Lot of variation in specific Energy Consumption is a Positive indication for

the substantial potential for Energy Saving.
CASE STUDY- 2
Sp. Power consumption in KWH per 100 kg. for several overseas units:-
1st Mill A1, A2, A3, A4
2nd Mill B1, B2
3rd Mill C1 & C2
All these Spinning Mills are very well managed and on the
identical lines as described in Case Study # 1.
Efficient Plants & Equipments
Totally Air Conditioned (Centrifugal Chillers) throughout the year.

• CONCLUSION

Specific Energy Consumption variation in so vast range, gives added

confidence for the success for Energy Saving.
 TABLE # 1
SPECIFIC POWER CONSUMPTION, YEAR 1997
MONTH PRODUCTION (Kg.) POWER CONSUMPTION KWH PER 100 KG.

P1 P2 P3 P4 TOTAL TOTAL P1 P2 P3 P4 AVERAGE

PRODN. POWER (P1-P4)
(P1-P4) CONSUMP. (P1-
P4)
JAN. 1076839 336115 250386 29937 1693277 6279280 345 335 390 - 371
FEB. 1028758 328404 240860 161934 1759956 6864710 349 331 419 - 390

MAR. 1161208 361063 266715 325683 2114669 8856430 374 360 405 656 419

APR. 1006532 311621 247210 339744 1905107 7907510 368 360 394 620 415

MAY. 1089086 355620 267622 430010 2142338 9094698 419 398 416 466 425

JUNE 1030119 355620 274426 463576 2123741 9146572 431 406 409 462 431
JULY 993831 348363 271251 502132 2115577 9000450 423 421 403 444 425
AUG. 996099 335208 274333 505307 2110947 8844620 415 427 394 435 419

SEPT. 1039191 331126 283952 509843 2164112 8858680 400 430 383 430 409

OCT. 1059603 325683 272158 494421 2151865 8876760 395 433 390 447 413

NOV. 1031480 329765 270797 496235 2128277 8662990 401 409 365 441 407

DEC. 982945 294384 269890 500318 2047537 8548083 409 445 385 436 417

1997 - - - - - - 393 385 402 472 407

1996 - - - - - - 410 357 392 - 395
1995 - - - - - - 405 366 388 - 393
 TABLE # 2
SP. POWER CONSUMPTION
Comparison Several Overseas Spinninbg Mills
MONTH UNITS CONSUMED 100 KG.

A1 A2 A3 A4 B1 B2 C1 C2

JAN. 345 335 390 - 297 354 327 431

FEB. 349 331 419 - 297 317 322 433
MAR. 374 360 405 656 294 298 320 431
APR. 368 360 394 620 283 290 317 426
MAY 419 398 416 466 287 281 322 435
JUNE 431 406 409 462 293 282 333 425
JULY 423 421 403 444 287 302 331 433
AUG. 415 427 394 435 284 308 333 436
SEPT. 400 430 383 430 283 385 332 436
OCT. 395 433 390 447 - - 276 386
NOV. 401 409 365 441 - - 280 379
DEC. 409 445 385 436 - - - -
AVG. 393 385 402 472 289 313 318 423

AVG. 29.28 24.10 29.73 26.96 25.47 27.37 23.96 26.71

COUNT
 METHODOLOGY
A. Brief Description about the Plant

1. Present installed capacity and stages of capacity addition (if any).

2. Trend of capacity utilization (last 5 years).

3. Trend of monthly production & capacity utilization of last one year.

B. Review of Process Flow diagrams.

Entire Process should be divided into Sub – Systems for this study.
 SPINNING MILLS

A.1 RINGH FRAMES Design Actual

(a) Count- wise Doff to Doff time
(b) Spindle Speed
(c) % Yarn breakage
(d) Monthly Production
(e) R. F. Main Motor- Efficiency
Level
(f) Pnemofil Blowers
 POST SPINNING

SPEED FRAMES Design Actual

(a) Monthly Production
(b) Speed Control

AUTO CONERS Design Actual

(a) Suction Blower – Speed
Control
(b) Draft - mm
 TFO MACHINES

(a) TFO Motors - % & steps taken Design Actuals

For improving operating

Efficiency

(b) Monthly Production

(c)
 HVAC- H. PLANTS

(a) Fan Efficiency for Design Actual

Supply Air Fans
Return Air Fans
(b) Technology for Rh - % control
(c) Speed Control for these Fans
(d) Spray Water Pumps – control
system
 WEAVING MILLS

(a) Monthly Production Design Actual

(b) Compressed Air requirement
(c) Pressure of Compressed Air
(d) Monthly Power consumption
in Air Compressors Units
Units per Kg
 BOILERS & STEAM

(a) Monthly Steam generation Design Actual

(b) Evaporation ration
(c) Steam Pressure & Temp-
(d) Waste heat Recovery
(e) Steam Condensate Recovery
(f) Specific Steam Consumption
 PROCESSING MACHINES

(a) System for Temperature control Design Actual

(b) System for Fan speed Control
for different Zones of Stenters,
Printing Machines etc
(c) Major Pumps - Speed Control

TECHNOLOGY UPGRADATION
To study steps undertaken for all these areas – 3 years
 BASELINE AUDIT SCOPE OF WORK

Study the process of the entire plant considering a gate-to-

gate concept which would mention type & quantity of energy
sources consumed, self generated energy sources, process
technology, raw material, product output and various variable
factors which affect the energy consumption significantly.
C. ENERGY SCENARIO of the Plant

1. Different types of Energy sources being used and their %

contribution – for 3 years.
Primary Energy (Solid Fuel, Liquid Fuel, Gaseous Fuel etc.)
Secondary Fuel (Electricity)
(a) Purchased from grid
(b) Self generation.

2. Establish the trend of the following for the last 3 years.

(a) % share of grid power to the total power.
(b) % share of self generated power.
(c) % share of internally generated thermal Energy from waste
heat, co-generation or by product of total energy.
 (d) % cost of Energy to that of total cost of production.
(e) % share of renewable Energy.
3. Trend of monthly production & Energy Consumption (Electrical &
Thermal) of the last one year.

The boundary of a DC Gate-to-Gate (GtG) concept.

• The plant boundary would be selected such that the total energy
input and the above defined product output will be fully captured.
• Typically it is the entire plant excluding colony, residential complex
and transportation system.
• Similarly, mining operations in case of Iron & Steel, Aluminium and
Cement sector are not part of plant boundary.
• Once the plant boundary has been fixed, the same boundary should
be considered for entire PAT cycle.
• Ideally, plant boundary should not change during the entire cycle.
The SEC of an industry would be calculated based on Gate-
to-Gate concept with the following formula.

Total energy input to the plant boundary

SEC = --------------------------------------------------------
Quantity of the Product
While calculating the total energy input to the plant, all energy
sources would be converted to a single unit i.e. MTOE (metric ton of
oil equivalent) using standard engineering conversion formulae:

• Electricity purchased from Grid: 1 kWh = 860 kcal.

• Solid fuel: Quantity (kg) * GCV (kcal/kg) kcal.
• Liquid fuel: Quantity (m3) * density (kg/m3) * GCV (kcal/kg) kcal.
• 1 MTOE = 107kcal.
 In this calculation, the following would be considered :

• All forms of energy (Electricity, Solid fuel, Liquid fuel, Gaseous fuel,
by-products used as fuel etc.) which are actually consumed for
production of output should be considered.
• Energy consumed in colony and for outside transportation system
should not be accounted.
• Energy used through renewable energy sources should not be
accounted.
• Any energy consumed for major construction work would not be
accounted as this is not meant for producing the product. Quantity
of such energy should be separated out from total energy
consumption.
OUR PLAN
We would like to divide composite plants into three sub groups:-
(a) Spinning Mills
(b) Weaving Mills
(c) Processing Plant
For Spinning Mills – We would like to collect the details of ‘Count-wise’
monthly production for the last one year.

 Trend the Energy consumption in GtG concept of last 5 years

(2006-07 to 2010-11).
 Establish the Sp. Energy Consumption in GtG concept.
CASE -I : All Energy Purchased and Consumed
Case-II: Electricity Partially Generated by DG Sets, other
Energy Purchased and consumed
 Case – II : Electricity Generated by CPP, other Energy
Purchased & Consumed Electricity partially sold to grid
 DATA VERIFICATION
Review of reported data of each DC – would be reviewed.
It is a friendly verification of the ‘reported – data’.
Most Important Factors
1. Source of Data - documents, records, log books or Metering
or estimated - to be noted so that ‘same yard – stick’ is followed
while verifying the resultant saving after 3 years.
Item Unit Source Of Data Frequency Of Method Of Data
Data Records Records

Production
Purchased Electricity

Energy – others

To analyse data with respect to production and standard performance

values etc.
F. OUR WORK PLAN
Based upon consideration experience in Textile Sector, our team would
study the entire plant on gate – to – gate concept, based on flow diagrams
such as:-
(i) Spinning Section
(ii) Post spinning – TFO & Auto Coners
(iii) Humidification Plants
(iv) Air Compressors
(v) Captive Power Plants
(vi) Boilers
(vii) Chillers (if available)
(viii) Cooling Towers
(ix) Lighting
 GUIDELINES

(a) We shall cover around 85% of the total Energy Consumption.

(b) Performance Evaluation – Energy performance of the main Plants -
Equipments / Utilities would be assessed w.r.t. to Technical
Specifications / design data, operational data, or site data etc.
(c) Measurements would be carried out wherever needed, specially to
quantify expected saving for any particular proposal.

7. Investigate the All Possible Energy Efficiency Improvement Option.

a. Waste Heat Recovery Options
(i) Source
(ii) Comment on Feasibility
(iii) Quantum of Possible Extracted Energy.
b. Co-Generation Option
i. Comment on Feasibility
ii. Approximate Thermal & Electricity Energy Output.
c. Fuel Switch Options
d. Retrofit Options
e. Use of Energy Efficient Equipment
i. Energy efficient drives, pumps, fans, compressors,
lighting system etc.
ii. Variable Frequency Drives / Variable Speed Drives.
iii. Any other.
f. O & M Practices
i. Waste minimization (Reuse, Recycle, Resizing)
ii. Control Mechanism
iii. Data Monitoring & Accounting
 g. Cost-Benefit option in all possible options.
i. Simple Pay Back Period

8. Review the Past Energy Efficiency improvement Strategies

(Last 3 years)

SUB- ACTION CATEGORY* YEAR OF RESULTED INVESTMENT

PROCESS TAKEN IMPLEMENTATION SAVING DONE

*Technology Upgradation / Process Modification / O&M Practice/ Retrofit

/ Others
9. Review the Future Energy Efficiency Improvement Strategy
(Discuss with Plant Management to get the future energy
efficiency improvement strategies)
a. Specific Projects to be undertaken.
b. Investment Plan
c. Human Resource Planning in Energy Management
d. Any Target fixed by management as per their policy.

10. Prepare the Audit Report with following Structure / Format.

a. Acknowledgement
b. Study Team Members
c. Executive Summary
Sl. Recommendations Annual Approx. Simple Pay- Remarks
No. Potential Investment back Period
Saving

d. Introduction
e. Methodology Adopted
f. Instruments Used for Energy Audit.
g. Brief Description about the plant (process Flow Diagram)
h. Energy Scenario & Usage pattern
i. Description about Sub-Process
j. Identifying ENCON options
k. Description about Past ENCON activities.
l. Description about future ENCON strategy.
m. Conclusion & Critical Comment.
 KEY ENABLERS
• Technical diary of the plant (Design data)

• Performance data & specifications of various equipment

• Three annual reports and MIS reports etc.

• Free access to UCB data, onsite data, Lab data (Coal/ ash
analysis, water quality, % O2 values etc.)

• Access to past ENERGY AUDIT REPORTS of the plant

• Full time association of Energy Manager of the plant and

suitable O&M functionary.
 KEY ENABLERS (CONT.)

• All information will be kept confidential, by us.

• The study will commence only after all the formalities are
completed with EESL.
 TEXTILES UNITS TO BE COVERED BY US
S.NO NAME OF THE INDUSTRY LOCATION REMARKS
1. KANCHAN PROCESSORS PVT. LTD. AJMER ROAD, 09829045888
BHILWARA
2. MAHARAJA SHREE VMAID MILLS LTD. JODHPUR ROAD, PALI,
RAJASTHAN
3. MORDI TEXTILES & PROCESSORS LTD. UDAIPUR ROAD, 0296411297
BANSWARA,
4. NAHAR INDUTRIAL ENTERPRISES LTD. BHIWADI (Raj.)
5. NITIN SPINNES LTD. CHITTAUR ROAD,
BHILWARA
6. ORIENT SYNTEX BHIWADI 09785423667
7. POOJA SPINTEX (P) LTD. INDUSTRIAL AREA,
BHIWADI
8. RAJASTHAN TEXTILES MILLS Bhawani Mandi
9. RELIANCE CHEMOTEX INDUSTRIES CHITTAR ROAD, 41846, 41135
LTD. BHILWARA