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G.Krishnakumar Chief Operating Officer-SEEM

Energy Management
The strategy of adjusting and optimizing energy, using systems and procedures so as to reduce energy requirements per unit of output while holding constant or reducing total costs of producing the output from these systems"

Energy Management

Objectives of Energy Management

The objective of Energy Management is to achieve and maintain optimum energy procurement and utilisation, throughout the organization and: To minimise energy costs / waste without affecting production & quality To minimise environmental effects.

Principles of Energy management

Lowest possible price Energy use at highest efficiency Reuse Recycle Recover Appropriate technology Reduce losses

Energy management Skills

Managerial Technical Interpersonal

Energy Management Strategy

Corporate approach Energy manager Monitoring and Reporting Energy audit Energy Policy Implementation Plan

Standards for Energy Management

KATS KSA 4000:2007 (South Korea); ANSI/MSE 2000-2008 (USA); DS 2403: 2001 (Danish Standard); UNE-216301:2007 (Spain); EN 16001:2009 SS 62 77 50:2003 (Swedish Standards); IS 393:2005 (National Standards Authority of Ireland); VDI 4602/1 Technical rule on Energy Management (Germany)

Energy Management Standardsctd.

European Standard, management EN 16001 Energy systems Requirements with guidance for use was published on July 2009; EN 16001:2009 is build upon existing national standards within Europe (DS 2403: 2001, SS 62 77 50:2003, IS 393:2005, Energy Management Systems Specifications of Germany and The Netherlands);

The standard is focused on promoting the analysis of energy usage data, and identifying the exact locations, times and underlying reasons behind current and past energy use; EN 16001 is expected to play a role in helping organizations meet the requirements of voluntary energy and GHG emission reduction initiatives.

EN 16001
EN 16001 follows the proven management and performance improvement process based on the Deming cycle: Plan-DoCheck-Act.

Implementation of this standard should lead to reductions in energy cost, greenhouse gas emissions and other environmental impacts, through systematic management of energy; Organizations shall develop and implement an energy policy, establish objectives, targets, and action plans, which take into account legal requirements and information pertaining to significant energy use.

The Effective Energy Management System can results in: - Reduction of energy variation and energy losses; - Improvement of productivity; - Secure energy supply; - Improved business performance.

Continual Improvement
This International Standard is based on the Plan-Do-Check-Act continual improvement framework

PLAN establish the objectives and processes necessary to deliver results in accordance with opportunities to improve energyperformance and the organization's policies DO implement the processes

CHECK monitor and measure processes and product against policies, objectives and the key characteristics of its operations and report the results ACT take actions to continually improve energy performance


Energy Audit
Energy Audit is the key to a systematic approach for decision-making in the area of energy management. EC act 2001 defines Energy audit 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".

Need for Energy Audit

Expenses-material, labour, energy Cost reduction, maintenance, productivity Conservation technology, energy mix Benchmark Technically and economically feasible

Types of Energy Audit

Function Type Depth Expectation

Audits based on Functions

Preliminary Energy Audit Methodology

Consumption Scope of saving Low hanging fruit Reference point Areas for detailed study Data

Detailed Energy Audit Methodology

Pre Audit Phase Audit Phase Post Audit Phase

Pre Audit Phase Activities

Initial Site Visit and Preparation Required for Detailed Auditing Discuss with senior management Tour site a/w technical personnel Obtain drawings Analyse consumption with relevant personnel

Pre Audit Phase Objectives

Identify audit team Identify consuming points to be surveyed Identify instrumentation Plan time frame Macro data Awareness meeting

Detailed Energy Audit Activities

Primary Data Gathering Cyclical data collection Investigate energy material balance

Identification of Energy Conservation Opportunities

Fuel substitution Energy generation Energy distribution Energy usage by processes

Energy analysis

Energy analysis ctd.

Technical and Economic feasibility

Availability, reliability, service etc Impact on safety, quality, production process Maintenance requirements/spares Upfront investment Annual operating cost Annual saving

Classification of Energy Conservation Measures

Low Cost-high return Medium Cost-medium return High Cost-High return

Energy Audit Reporting Format

Energy Audit Reporting Format

Understanding Energy Costs

Fuel Costs Power costs

Benchmarking and Energy Performance

Trend analysis External benchmarking fixed and variable energy consumption trends industry energy performance vs production levels Identification of best practices

Gross production related indices

Examples kWh/MT clinker or cement produced (cement plant) kWh/kg yarn produced (Textile unit Million kilocals/MT Urea or Ammonia (Fertilizer plant

Equipment / utility related


kW/ton of refrigeration (on Air conditioning plant) kWh/NM3 of compressed air generated

Matching Energy Usage to Requirement

throttling of a pump damper operations Moderation of chilled water Recovery of energy lost in control valve pressure drops by back pressure Adoption of task lighting

Maximising System Efficiency

Eliminate steam leakages Maximise condensate recovery Adopt combustion controls Replace pumps, fans, air compressors, refrigeration compressors, boilers, furnaces, heaters and other energy consuming equipment, wherever significant energy efficiency margins exist

Quality of Energy Audit

Quality of Energy Audit

Energy Audit-Quality

Fuel and Energy Substitution

Fuel substitution

Energy Audit Instruments