Bureau of Energy Efciency

Format for
Baseline
Energy Audit
Format for Baseline Energy Audit
[Adopt the following methodology for conducting baseline energy audit
in Designated Consumers industries. Additional information may be
obtained, if required and found appropriate.
!. "i#e brief description about the plant .
a. History of establishment, ownership (public / private / co-
operative sector)
b. Present nstalle! capacity an! stages of capacity a!!ition (if any)
c. "ren! of capacity utili#ation in last $ years
d. "ren! of monthly pro!uction an! capacity utili#ation of last one
year
e. %eview of process &ow !iagram
$. "i#e the energy scenario of the plant
a. 'i(erent types of energy sources being use! an! their ) share of
contribution
i* Primary Energy (+oli! ,uel, -i.ui! fuel, gaseous fuel etc*)
ii* +econ!ary Energy (Electricity)
/* Purchase! from gri!
0* +elf-generate! (1PP/'2 sets/1o-2eneration)
iii* Energy from internally generate! by-pro!ucts or waste heat
iv* %enewable energy
b. Establish the tren! of following of last 3 years
i* ) share purchage! electricity from gri! to that of total
electricity consume!
ii* ) share of self generate! electricity to that of total
electricity consume!
iii* ) share of internally generate! thermal energy from waste-
heat, co-generation or by-pro!uct of total consume! energy
iv* ) 1ost of energy to that of total pro!uction cost
v* ) share of renewable energy to that of total energy
consume!
c. "ren! of monthly pro!uction an! energy consumption (Electrical
4 thermal) of last one year
d. +hare of Energy in various Purposes ( Process, au5iliaries,
-ighting etc*)
e. 6ny other as may be !eeme! 7t
%. Establish the energy scenario in gate&to&gate '"t"(
concept
0 ) P a g e
a. 'evelop the gate-to-gate schematic of the plant !epicting the
energy input to the plant boun!ary, internally generate! energy
an! the pro!uct output (Please refer to the case situations in
Annexure-A)
b. "ren! the energy consumption in 2t2 concept of last $ years
c. Establish the +peci7c Energy 1onsumption (+E1) in 2t2 concept
*. +e#iew of +eported Data of DCs
a. 1omplete review of reporte! !ata of '1s through noti7e! format
(BEE will provide the data sheet of the DC), the summary sheet of
each '1*
b. ,in! out the source of each !ata which has been reporte! by '1*
"he !ata source may be !ocuments, recor!s, log boo8s, installe!
meters an! ga!gets etc*
,tem -nit .ource of
Data
Frequency of
data recording/
0ethod of Data
+ecording//
Pro!uction
Purchase!
Electricity
6ll Energy
+ources
9 instantaneous/hourly/daily/monthly/yearly
** manual reading or recording /scada/Automatic !"
c. %econcile the !ata with respect to pro!uction, typical parameters
li8e heat rate, speci7c fuel consumption or any other
observations
d. 1learly !e7ne the inclusions / e5clusions of the energy
consumption of colony power, temporary constructions, internal
transportations etc* in the reporte! !ata*
1. +e#iew the 2rocess Flow Diagram and 2resent
0etering .ystem
a. +tu!y an! review the process &ow !iagram (P,')* 'evelop the
schematic of the P,' !epicting the operating parameters li8e
&ow, temperature, pressure etc* at each input-output stage
b. 'ivi!e the entire process into 8ey sub-processes or sub-systems*
"he typical sub-process of the sectors are given below (but not
limite!)*
.ector .ub&2rocesses
3hermal 2ower 2lant 'coal( 1oal han!ling Plant, 6sh
Han!ling +ystem, +team
3 ) P a g e
2eneration +ystem, "urbo-
2enerator system, 1: system,
E+P, 1ompresse! 6ir +ystem
3hermal 2ower 2lant '"as( "urbo-1ompressor +ystem,
:aste Heat %ecovery Boiler, 1:
system, 1ompresse! 6ir +ystem
Aluminium '.melter( %ectiformer, Pot--ines, 1arbon
Plant (2reen 6no!e Plant, Ba8e
;ven, %o!!ing +hop), 1ast-
House, 1ompresse! 6ir +ystem,
,ume "reatment Plant
Aluminium '+e4nery( 'igester system, 1leaning 4
%e7ning +ystem, 1alcinations
+ystem, +team 2eneration
+ystem, 1o-2en +ystem
Cement %aw <aterial Preparation
+ystem, 1ement =iln, 2rin!ing
+ection, 1aptive Power
Plant(1PP)
,ron 5 .teel ',ntegrated( 1o8e oven, +intering Plant, Blast
,urnace, B;,, 1asting +ection,
%olling <ills, 1PP
,ron 5 .teel '.ponge ,ron( +intering Plant, '% section, E6,
section / , +ection, 1asting
section, %olling <ill, 1PP
Fertili6er >itrogen Plant, ?rea Plant,
+team 2eneration +ystem, 1PP
2ulp 5 2aper %aw <aterial Preparation,
Pulping +ection, Paper <achine
+ection, 1PP, 1o-2en Plant
3e7tile +pinning section, 'rying +ection,
+team 2eneration +ystem, 1PP
Chlor&Ala8ali
@#he a$ove su$-processes are indicative only% #he auditor may suita$ly
select the su$-process depending upon the material & energy 'ow and
(uantum of energy consumed)
9. .tudy of .ub&2rocesses
a. 'e7ne the energy 4 material &ow into an! out of each sub-
process, process parameters an! present metering system for all
energy sources in the sub-process un!er stu!y* ("his shoul! be in
the form of Bloc8 'iagrams)*
b. nvestigate the following in each sub-process
2arameters :hat to loo8 for ;alue
Brief Description of
the .ub&2rocess
A ) P a g e
0aterial Flow >ame
,low %ate 'esign operating
Energy ,nput Electricity
+oli! ,uel
(1oal/-ignite)
-i.ui! ,uel
(,;/H+'/-HH+***)
2aseous ,uel
(>2/-P2***)
;thers
0a<or Equipment >ame
"echnology
>umbers nstalle
!
;perating
"echnical
+peci7cations
+peci7c Energy
1onsumption
'esign ;perating
Factors A=ecting
Energy E>ciency
"echnical Parameters 'esign ;perating
;perating Parameters 'esign ;perating
0a<or Au7iliaries
Associated '2umps,
Fans, Compressors,
Furnaces, ?;AC
system etc.(
>umbers ;perating
"echnical
+peci7cations
) -oa!ing or 1apacity
?tili#ation
'esign ;perating
Efciency ()) 'esign ;perating
+peci7c Energy
1onsumption
'esign ;perating
3echnology -p
gradation in @ast %
Aears
"echnology 1hange
Process
<o!i7cation
; 4 < Practice
%esulting Energy
+aving
6ppro5* nvestment
!one
@!n order to get the operating values suita$le measurements to $e done $y
energy auditing gadgets or o$servation from installed gadgetsB
B. ,n#estigate the All 2ossible Energy E>ciency
,mpro#ement Cption
a. :aste ?eat +eco#ery Cptions
i* +ource
ii* 1omment on ,easibility
iii* Cuantum of Possible E5tracte! Energy
b. Co&"eneration Cption
i* 1omment on ,easibility
ii* 6ppro5imate "hermal 4 Electrical Energy output
c. Fuel .witch Cptions
d. +etro4t Cptions
$ ) P a g e
e. -se of Energy E>cient Equipment
i* Energy efcient !rives, Pumps, ,ans, 1ompressors, -ighting
system etc*
ii* Dariable ,re.uency 'rives / Dariable +pee! 'rives
iii* 6ny other
f. C 5 0 2ractices
i* :aste minimi#ation (%euse, %ecycle, %esi#ing)
ii* 1ontrol <echanism
iii* 'ata <onitoring 4 6ccounting
g. Cost&Bene4t Cption in all possible options
i* +imple Pay Bac8 Perio!
D. +e#iew the 2ast Energy E>ciency ,mpro#ement
.trategies '@ast % years(
+ub-
Process
6ction
"a8en
1ategory9 Eear of
mplementat
ion
%esulte!
+aving
nvestment
'one
* #echnology *pgradation / Process odi+cation/ ,& Practice / -etro+t/
,thers
E. +e#iew the Future Energy E>ciency ,mpro#ement
.trategy
@'iscuss with Plant <anagement to get the future energy efciency
improvement strategiesB
a. +peci7c ProFects to be un!erta8en
b. nvestment Plan
c. Human %esource Planning in Energy <anagement
d. 6ny target 75e! by management as per their policy
!F. 2repare the Audit +eport with Following
.tructureGFormat
a. Ac8nowledgement
b. .tudy 3eam 0embers
c. E7ecuti#e .ummary
.l +ecommendations Annual
2otential
.a#ing
Appro7.
,n#estment
.imple
2ay&
Bac8
2eriod
+emar8
G ) P a g e
d. ,ntroduction
e. 0ethodology Adopted
f. ,nstruments -sed for Energy audit
g. Brief Description about the plant '2rocess Flow Diagram(
h. Energy .cenario 5 -sage pattern
i. Description about .ub&2rocess 'As per 2oint H 9(
<. ,dentifying EICCI Cptions 'As per 2oint H B(
8. Description about 2ast EICCI acti#ities
l. Description about future EICCI strategy
m.Conclusion 5 Critical Comment
n. Anne7ure
[The report must be equipped with tables, graphs, sample
calculation sheet, assumptions (if any) at suitable places
H ) P a g e
For any clarifcation Please Contact :
!P!"arnai#
Energy Economist
Bureau of Energy E.ciency
inistry of Power/ 0,!
1
th
2loor/ "ewa Bhawan/ -%3%Puram/ 4ew
Delhi-55
Ph6 788-958:;<=9 email6 sgarnai>?$eenet%in
Anne7ure&A
Di=erent Case .ituations in Estimating 3otal Energy
Consumption and .peci4c Energy Consumption in "ate&
to&"ate Concept
"he following are the e5planations on estimating the total energy consumption
an! speci7c energy consumption in various case situations as encountere! in
'esignate! 1onsumer in!ustries*
2re&ConsiderationJ
/* "he plant boun!ary has alrea!y been !e7ne!*
0* "here is a single pro!uct at the output which has been !e7ne!* n case of
multiple pro!ucts, the maFor pro!uct to be consi!ere!*
3* "he energy consumption is to be consi!ere! only for plant process
operations to pro!uce the I!e7ne! pro!uctI* +o, the energy consume! in
internal transportation, resi!ential colony etc* have been e5clu!e!*
A* "he primary energies actually consume! for pro!ucing the pro!uct are
consi!ere!* 6ny primary energy purchase! an! store! insi!e the system
boun!ary is e5clu!e!*
"he cases have been prepare! base! on prevailing scenario of energy usage in
the energy intensive sectors li8e Power Plant, ron 4 +teel, cement, ,ertili#er,
6luminium, pulp 4 paper, "e5tile, 1hlor-6l8ali etc*
J ) P a g e
CA.E &, J All Energy 2urchased and Consumed
$lectricity is purchased from the "rid
K ) P a g e
P%;1E++
Electricity
,; (-iter)
>2 (+1<)
1oal (=2)
;thers (=2 or
Pro!uct (=g)
3otal Energy Consumption 'E
total
( K
@Elect 5 JGL M ,; 5 21D
fo
M 1oal 5 21D
coal
M >2 5 21D
ng
M ;thers 5
21D
each
B =cal
3otal Electrical Energy Consumption 'E@
total
( K
Electricity =:H
3otal 3hermal Energy Consumption '3?
total
( K
@,; 5 21D
fo
M 1oal 5 21D
coal
M >2 5 21D
ng
M ;thers 5 21D
each
B =cal
"ate Lto&"ate .EC K
@E
total
/8g of pro!uctB =cal/8g
CA.E &,, J Electricity 2artially "enerated by D" .ets,
other Energy 2urchased and Consumed
$lectricity is purchased from the "rid % generated by &" set
(a) f N is 8nown an! 6 is 8nown, +,1 O ( N / 6) 8wh/ltr
(b) f 6 is 8nown N O ( 6 5 +,1 ) 8wh where +,1 O 3*L to 3*$ 8wh/ltr
(c) f N is 8nown 6 O ( N / +,1) 8wh where +,1 O 3*L to 3*$ 8wh/ltr
/L ) P a g e

Electricity
,; (-iter)
>2 (+1<)
1oal (=2)
;thers (=2 or
Pro!uct
3otal Energy Consumption 'E
total
( K
@Elect 5 JGL M 6 5 21D
a
M ,; 5 21D
fo
M 1oal 5 21D
coal
M >2 5 21D
ng
M
;thers 5 21D
each
B =cal
3otal Electrical Energy Consumption 'E@
total
( K
(Purchase! Electricity M N) =:H
3otal 3hermal Energy Consumption '3?
total
( K
@(,;-6) 5 21D
fo
M 1oal 5 21D
coal
M >2 5 21D
ng
M ;thers 5 21D
each
B
=cal
"ate Lto&"ate .EC K
@E
total
/8g of pro!uctB =cal/8g
'2
+et
+,1
6
N
Process
CA.E &,,, J Electricity "enerated by C22, other Energy
2urchased 5 Consumed, Electricity partially sold to grid
$lectricity is generated by Coal 'ased CPP, partially sold to grid
(a) f N is 8nown an! 6 is 8nown, Heat %ate (H%) O @( 6 5 21D
coal
) / NB
=cal/8wh
(b) f 6 is 8nown N O @( 6 5 21D
coal
) / H% B 8wh where H% O 6vg* Plant
Heat %ate
(c) f N is 8nown 6 O@ ( N 9 H%)/ 21D
coal
B =2 where H%O 6vg* Plant
Heat %ate
9 f plant H% is not available, then >ational 6vg* H% i*e* 0H/H =cal/8g may be
consi!ere!
9 "he total electricity consumption also inclu!es the au5iliary power
consumption of 1PP

// ) P a g e

1oal (=2)
>2 (+1<)
,; (-tr)
;thers (=2 or
Pro!uct
3otal Energy Consumption 'E
total
( K
@,; 5 21D
fo
M 1oal 5 21D
coal
M >2 5 21D
ng
M ;thers 5 21D
each
B =cal
3otal Electrical Energy Consumption 'E@
total
( K
(N - E) =:H
3otal 3hermal Energy Consumption '3?
total
( K
@,; 5 21D
fo
M (1oal-6) 5 21D
coal
M >2 5 21D
ng
M ;thers 5 21D
each
B
=cal
1PP
Heat %ate
6
N
Process
E (=:H) to
2ri!
CA.E &,; J Electricity "enerated by C22, other Energy
2urchased 5 Consumed, Electricity partially sold to grid
from C22.
$lectricity is generated by Coal 'ased CPP, partially sold to grid!
CPP is in separate 'oundary
Here, in case of two separate boun!aries, two !i(erent >orms / "argets to be
establishe!
!. For the M2roduction 2lantN Boundary 'A(J
/0 ) P a g e
B
"ate Lto&"ate .EC K
@E
total
/8g of pro!uctB =cal/8g
A
P%;1E++
N (=:H)
,; (-iter)
>2 (+1<)
1oal (=2)
;thers (=2 or
Pro!uct (=g)
3otal Energy Consumption 'E
total
( K
@N 9JGL M ,; 5 21D
fo
M 1oal 5 21D
coal
M >2 5 21D
ng
M ;thers 5
21D
each
B =cal
3otal Electrical Energy Consumption 'E@
total
( K N 8wh
3otal 3hermal Energy Consumption '3?
total
( K
@,; 5 21D
fo
M 1oal 5 21D
coal
M >2 5 21D
ng
M ;thers 5 21D
each
B =cal
1PP
E (=:H) to
1oal
6u5 P (a ;thers (=2 or
2 (=:H)
$. For the MCapti#e 2ower 2lantN Boundary 'B(J
Here, the target setting criteria of PPower PlantQ shoul! be a!opte! which is base!
on P>et Heat %ateQ*
/3 ) P a g e
"ate Lto&"ate .EC K
@E
total
/8g of pro!uctB =cal/8g
3otal Energy Consumption 'E
total
( K
@,; 5 21D
fo
M 1oal 5 21D
coal
M ;thers 5 21D
each
B =cal
3otal Electrical Energy Consumption 'E@
total
( K
( 2 ) 5 (a//LL) 8wh
"ate Lto&"ate .EC ' i.e Iet ?eat +ate( K
E
total
/ (2 - E-
total
) =cal / 8wh
CA.E &; J Energy 2urchased 5 Consumed, Electricity 5
?eat partially "enerated through Co&"en plant
$lectricity % (eat are generated by Co)"en Plant

/A ) P a g e

1oal (=2)
>2 (+1<)
,; (-tr)
;thers (=2 or
Pro!uct
3otal Energy Consumption 'E
total
( K
@Elect 5 JGL M,; 5 21D
fo
M 1oal 5 21D
coal
M >2 5 21D
ng
M ;thers 5
21D
each
B =cal
3otal Electrical Energy Consumption 'E@
total
( K
(Elect M N) =:H
3otal 3hermal Energy Consumption '3?
total
( K
@,; 5 21D
fo
M 1oal 5 21D
coal
M >2 5 21D
ng
M ;thers 5 21D
each M
EB
=cal
"ate Lto&"ate .EC K
@E
total
/8g of pro!uctB =cal/8g
1o-
2e
n
Plant E(* ())
6 N
Process
Elect
(=:H)
E (=cal)
CA.E &;, J Energy 2urchased 5 Consumed, ?eat energy
partially met by waste G by&product of the 2rocess
Heat 1ontent of By-Pro!uct O E =cal / =g
+o, Energy 6vailable R O N 9 E =cal

/$ ) P a g e

P%;1E++
1oal (=2)
>2 (+1<)
,; (-tr)
;thers (=2 or
Pro!uct
3otal Energy Consumption 'E
total
( K
@Elect 5 JGL M,; 5 21D
fo
M 1oal 5 21D
coal
M >2 5 21D
ng
M ;thers 5
21D
each
B =cal
3otal Electrical Energy Consumption 'E@
total
( K
(Elect) =:H
3otal 3hermal Energy Consumption '3?
total
( K
@,; 5 21D
fo
M 1oal 5 21D
coal
M >2 5 21D
ng
M ;thers 5 21D
each M
RB
=cal
"ate Lto&"ate .EC K
@E
total
/8g of pro!uctB =cal/8g
Elect
(=:H)
By-Pro!uct (N
=2)
R =cal