session- i - cbs 2016cbs.teriin.org › pdf › s-1-05-bee-milind-deore.pdf · management manuals...

Bureau of Energy Efficiency, Ministry of Power, Government of India 1

ENERGY CONSERVATION GUIDELINES

FOR

INDIAN INDUSTRIES

Milind Deore, Director, BEE

Session- I - Demand Side Perspective – Energy

Management Systems and Solutions for Industries


Background

Under Indo-Japan Energy Dialogue, Bureau of Energy Efficiency was tasked to develop Energy Conservation Guidelines and Energy Management Manuals for Indian Industries by sharing knowledge and experience from Japan.

During the kick off meeting in November 2016, a briefing of EC guidelines and EM Manuals of Japan were presented to Indian stakeholders.

Data collection and analysis for high energy consuming equipment.

Orientation workshop was held by ECCJ in Japan for Indian delegates consisted of representative from DCs and BEE officials in January 2017.


Background …contd. BEE engaged TERI to prepare EC Guidelines for Indian

industries. A working draft was prepared and shared with all stakeholders for comments.

Constitution of steering committee to facilitate the development and finalization of EC Guidelines and preparation of a roadmap for dissemination of these Guidelines.

Two steering committee meetings held to prepare and finalize the draft EC guidelines for Indian industries.


Background …contd.

Various stakeholder consultation were held in India to refine and finalize the EC guidelines for Indian Industries.

The draft guidelines were reviewed by stakeholders and Japanese experts

Draft EC guidelines were published in public domain for comments and the guidelines were revised and finalized.

Workshop was organized by ECCJ in Japan in January 2018 to finalize the Guidelines and to develop the EM manuals.


Launch of EC Guidelines for Industries

The Energy Conservation Guideline were launched by Shri R.K. Singh, Hon’ble Minister of State (IC), Power and New & Renewable Energy, Govt. of India during “Enhancing Energy Efficiency through Industry Partnership” Conclave at New Delhi on 24th September 2018.


Implementation of Energy Management Manual

• 9 Model factories were selected to implement EM manual.

• The draft manuals developed by model factories were reviewed by ECCJ experts and comments were given to model factories for refinement.

• Workshop in Tokyo during 21-25 Jan 2019 to review the EM manuals prepared by Model factories.

Bureau of Energy Efficiency, Ministry of Power, Government of India 7 7

Introduction Development Dissemination

Recognition of

usefulness of

Japanese system on

EE&C Management

Study on Japan’s EC

Guideline

Development of EC

Guideline customized

to India

Study on application of

the Guideline to of

India

Institutionalization of

the EC Guideline of

India

Dissemination of EM

Manual based on EC

Guideline

FY2016 FY2017 FY2018 onward

ECG & EMM introduction

Sep. 2016 Japan proposed India to introduce ECG and EMM

May. 2017 JPN-IND EC Working

Feb. 2018 Round table discussion on draft ECG Sep. 2017

Steering Committee mtg. May. 2018 JPN–IND Energy Dialogue

Nov. 2016 Preliminary meeting called by BEE to reps. of DCs

Nov. 2017 Interactive Session on Draft ECG in Delhi.

Sep. 2018 ECG released by MOP

Jan. 2017 Study workshop in Japan, BEE and reps. From DCs invited

Jan. 2018 Workshop in Japan to review Draft ECG.

Jan. 2019 Workshop in Japan to familiarize creation of EMM based ECG.


AN OVERVIEW OF ENERGY CONSERVATION GUIDELINES

FOR INDIAN INDUSTRIES


A comprehensive document for the industry with utility/ equipment-specific standards to promote energy conservation and improve energy performance in individual industrial units

The EC Guidelines shall guide individual industry to prepare its own “Energy Management Manual” for efficient operation of various energy consuming facilities.

EC Guidelines


Overview of “EC Guideline”

Functions

of Equipment

PDCA Action

Fuel

Combustion

Heating,

Cooling, and

Heat

Transfer

Waste Heat

Recovery

Conversion

of Heat to

Motive

Power

Prevention

of Energy

Loss

Conversion

of Electricity

to Motive

Power

Sta

nd

ard

s

Co

mp

on

en

ts

Management

Measurement

& Recording

Maintenance

& Inspection

Necessary

Measures

when

Installing New

Facilities

Ta

rge

ts

Co

mp

on

en

ts Improvement

of Existing

Facilities

New

Installation

and Updates of

Facilities

In order to promote Energy Efficiency in Factory, it is important to manage facilities so as them kept in as good condition as that can be operated in most energy efficient state.

”EC Guideline” describes action standards to drive EE&C PDCA (Plan, Do, Check & Act) cycle and “EM Manual” according to the “EC Guideline” developed for each particular facility enables steady advance in EE&C.


Industries covered

Category Details

Category –A Designated consumers (DCs) covered under PAT scheme but limited to

the following industries:

(1) Aluminium, (2) Cement, (3) Chlor alkali, (4) Fertilizers, (5) Iron

and steel, (6) Thermal power stations (7) Petroleum refineries (8)

Pulp and paper, (9) Textile, (10) Petrochemicals covering only

cracker units,

Category–B Large industries having energy consumption of less than existing

minimum threshold limits for designated consumers

Category –C SMEs with energy costs accounting for more than 30% of total

production cost

Group–D SMEs enterprises with energy costs accounting for 10% to 30% of total

production costs

Group–E Micro industries having material cost more significant than energy

cost


Activities undertaken to prepare EC Guideline

Detailed review of EC guidelines of Japan

Reviewed equipment specific secondary data and information

Data collection and analysis

Sanitation and grouping

Statistical analysis

Working draft of EC guidelines

Interactions with stakeholders (India and Japan)

Review by experts (Indian and Japanese)

Revised draft EC guidelines

Draft EC guidelines published in public domain for comments

Shared the EC Guidelines with Steering Committee members, DCs and other stakeholders for comments and suggestions


Structure of EC Guidelines

Consists of 7 sections

Each section has 2 components

Standard component

Management & Control

Measurement & Recording

Maintenance & inspection

Measures while installing new facility

Target component


Sections of Energy conservation guidelines

S No Name of section Equipment/ utilities

1 Combustion of fuel Boiler, industrial furnace, thermic fluid heater

2 Heating, cooling and heat transfer

2.1 Heating equipment

2.2 Air-conditioning and hot water supply

utilities

Boiler, steam system, condensate recovery system, industrial furnace, thermic fluid heater

Heat transport utilities, air-conditioning utilities,

hot water utilities, thermic fluid heater

3 Waste heat recovery and usage Boiler, condensate recovery system, industrial

furnace, gas turbine, gas engine, diesel engine, thermic fluid heater

4 Conversion of heat to electricity

4.1 Power generation facilities

4.2 Cogeneration facilities

Boiler, steam turbine, gas turbine, gas engine,

diesel engine


S No Name of section Equipment/ utilities

5 Prevention of energy loss due to heat radiation and

electric resistance

5.1 Prevention of heat loss due to radiation and

conduction

5.2 Prevention of electricity loss due to electric resistance

Boiler, steam system,

condensate recovery system, industrial furnace, thermic

fluid heater, electrical

distribution system

6 Conversion of electricity to motive power, heat and light

6.1 Facilities using motors and heaters

6.2 Industrial pump and pumping system

6.3 Industrial air compressor and compressed air network

system

6.4 Industrial fans and blowers

6.5 Industrial lighting system

Motor, industrial heater,

pumping system, air compressor and compressed

air system, fan and blower,

industrial lighting

7 Industry Energy Management System Overall plant energy

management

Sections ….contd.


Components of standard

Component Focus

Management & control

Guidelines for managing and controlling of key operating parameters o Air fuel ratio, surface temperature, flue gas temperature, motor

efficiency, lighting system o Load sharing during part load operation having multi-facility

operation (boiler, air compressor, air conditioning)

Measurement & Recording

Defines frequency of measurement and recording o Fuel consumption, temperature of steam, temperature of flue

gases, analysis of flue gas, inlet & outlet temperatures of heating and cooling media, supply & return temperature of cooling water

Maintenance & inspection

Adhere to preventive maintenance schedule as suggested by vendors Frequency of Maintenance & inspection Calibration of measuring instruments

Measures while installing new facility

Opting high energy efficiency system Better automation & control systems Correct sizing of system to ensure optimum loading


STANDARD VALUES AND

TARGET VALUES


Definition

EC guidelines

Standard value

Optimum values achieved by an energy consuming utility in daily operation

Target value

Best achievable values of an energy

consuming utility in daily operation

Industry data, OEMs, secondary data, stakeholder inputs


Standards and Target Values


Air ratio for boilers….contd.

Air ratio = Ratio of AAS to theoretical air

Parameter Boiler

capacity

(tph)

Load factor

(％）

Air Ratio@

Coal^ Biomass

fuel#

Liquid fuel Gas fuel&

Fixed bed Fluidized

bed*

> 100 50 – 100 1.26-1.33 1.30-1.33 1.25-1.30 - 1.13-1.18

51 - 100 50 – 100 1.33-1.40 1.35-1.42 1.31-1.38 - -

Standardα 11 - 50 50 – 100 1.51-1.59 1.36-1.43 1.47-1.55 1.19-1.25 -

Upto 10 50 – 100 1.54-1.62 1.40-1.48 1.49-1.56 1.26-1.33 1.19-1.25

> 100 50 – 100 1.14-1.22 1.18-1.21 1.20-1.25 - 1.08-1.13

51 - 100 50 – 100 1.17-1.23 1.22-1.28 1.21-1.28 - -

Targetβ 11 - 50 50 – 100 1.31-1.38 1.22-1.28 1.32-1.39 1.13-1.19 -

Upto 10 50 – 100 1.31-1.38 1.25-1.32 1.32-1.39 1.18-1.24 1.14-1.20


Flue gas temperature of boilers

Parameter Boiler capacity (tph)

Flue gas temperature

Coal Biomass fuel

Liquid fuel

Gas fuel Fixed

bed Fluidized

bed*

Standard > 100 140 140 140 - 130

51 - 100 140 140 140 - -

11 - 50 210 140 180 190 -

Upto 10 220 210 220 230 220

Target > 100 130 130 130 - 120

51 - 100 130 130 130 - -

10 - 50 160 130 140 180 -

Upto 10 190 180 180 180 180


Benefits of EC Guidelines for industries

Facilitates updating Energy Management Policy

Provides a set of guidelines to prepare its own EM

Manual focusing on energy efficiency for various energy

intensive equipments

Provides reference values for controlling values for

efficient operation

Monitoring and controlling of operating parameters of

equipment to optimize performance of equipment

Provides direction during retrofitting or while installing

new equipment

Provides add-on help to achieve PAT targets


Relation between EC Guideline and EM Manual

EM Manual

Operation Manuals Operation Standard,

Operation Procedure, Maintenance manual, Replacement criteria,.

Operators shall operate according to

EM Manual and operation manuals.

EC Guideline

Pro

visi

on

by

G

ove

rnm

ent

P

rep

arat

ion

by

Bu

sin

ess

Op

erat

ors

“Guideline” for Energy Managers

EC Guideline is the standards for promoting energy conservation

It shows technical/engineering view points to implement EM and EC.

“Management Manuals” are in-house technical standards concerning facility operation and etc. for realizing the energy

conservation.


Energy Management Manual

• Development of Energy Management (EM) Manuals in reference to the Final EC Guidelines.

• 9 Model factories selected for development of EM manual with reference to the final EC Guidelines.

• BEE and The Energy Conservation Centre of Japan (ECCJ) will guide and facilitate the model factories in the development and implementation of EM manuals


Selected 9 Model Factories

1. Tata Steel Ltd. Jamshedpur

2. Vardhman fabrics, Budhni

3. NTPC Ltd

4. Shree Cement

5. JK Paper Ltd.

6. Vedanta Ltd.

7. IOCL Panipat Refinery

8. ACC Limited

9. DCM Shriram Limited


Introduction of EC Guideline and EM Manual

Energy Management Methodology in Japan

Provision of EC Guideline for Facility Management

Energy Conservation Law

・Designation of Energy Manager

・Appropriate management of Energy Consuming Facility

Energy Consumer

・Develop EM Manual for each facility （Operation, Maintenance, Replace, etc. ）

・Implementation of EM Manual

APPLY EC Guideline to India

EC ACT

・Designation of Energy Manager

・EC promotion thru PAT scheme

・Awareness of efficient use of

energy and promotion of energy

efficient equipment or appliances

・Establish the Guideline for facility management and relating system ・Promotion and dissemination of

the EC Guideline

BEE/SDA

・Develop EM Manual per the EC Guideline. ・Implementation of EM Manual

DCs

If there is a specific GUIDELINE, it will be advantageous for effective implementation of EC activities.

ECCJ supports establishing EC Guidelien & Dissemination

⇒ Each DC is enabled to deal with Energy Management autonomously in the unified and rational manner under the certain standards.


Road Map of EMM


Thank you

session- i - cbs 2016cbs.teriin.org › pdf › s-1-05-bee-milind-deore.pdf · management manuals...

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