technical audit in murugappa group - toward converting the audit from cost center to profit center...
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Are we adding value - Quantitatively like other departments ! View this presentation of mine !TRANSCRIPT
TECHNICAL AUDIT IN
MURUGAPPA GROUP
Management Audit DivisionE 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
WALK THROUGHAUDIT /
DATA COLLECTION
BOILER
STORES
GENSET
PROCESS
ELECTIRCALPOWER
WATER
STEAM
DIESEL
UNITS
FURNACEOIL
PRODUCT
kWhENERGY INPUT / OUTPUTANALYSIS
ENERGY PERFORMANCEMODELS
WITHIN LIMITS
AUDIT REPORT PLANT HEADCONCURRENCE
ACTION PLAN
SUGGESTEDMODIFICATION OF
PARAMETERSNO
IMPLEMENTATIONFACILITATION
M.I.S.
REPORT BACK TOMANAGEMENT
DATABASE
REVIEW / FOLLOW UP
DATABASE
TECHNICALAUDIT MEET
PROJECTIDENTIFICATION
Technical Audit Functional ChartTechnical 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 AUDITGOAL:
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 AreasSTEAM
- Generation
- Distribution
- Condensate Recovery
- Steam Traps
- Piping Consideration
- Flow Measuring Instruments
- Insulation
- Flash Steam Recovery
- Waste Heat Recovery
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
Technical Audit Focus Areas
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 STRATEGYEnergy 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 Approach2. Appoint Energy Auditor3. Set up an Energy Monitoring and Reporting System4.Conduct Energy Audit5. Formalize an Energy Management Policy Statement6. Prepare and Undertake a Detailed Project Implementation Plan7. Implement a Staff Awareness and Training Program8. Annual Review
ENERGY AUDIT - METHODOLOGY
Energy Audit is the key to a systematic approach for decision-making 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 containingrecommendations for improving energy efficiency with cost benefit analysis and an action plan to reduce energy consumption”.
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 monitoringMeasurements :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 8Cost 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 majorelectrical parameters such as kVA, kW, PF,Hertz, kvar, Amps and Volts. In additionsome of these instruments also measureharmonics.These instruments are applied on-line i.e onrunning motors without any need to stop themotor.
ENERGY AUDIT - METHODOLOGY
Combustion analyzer:This instrument has in-built chemical cells which measure various gases such as CO2, CO, NOX, SOX etcFuel 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.
ENERGY AUDIT - METHODOLOGY
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
AUDIT - TOOLS
Technical Audit Customers1. COROMANDEL FERTILISERS
Fertiliser - Ennore / Vizag Co-Gen - Nellikuppam
- Ranipet Distillery - Nellikuppam
Pesticides - Ranipet Bio Products - Thyagavalli
- Thane - Nellikuppam
2. E I D PARRY Parryware - Ranipet Chemicals - Thyagavalli
- Alwar 3. PARRY & Co
- Dewas GSD - Dare House
Sugar - Nellikuppam Netlon - Baroda
- Pettavaithalai
- Pugalur
- Pudukottai
4.PCL - Nellikuppam
5.TII 7.PARRY AGRO - TPI Avadi Tea
- TIMF Bawal - Mayura
- TIMF Chennai - Murugalli
- Attikunna
- Caroyln
6.CUMI Algae - Pudukottai
- Tiruvottiyur - Pallikaranai 8. GFCL - Kakinada
- Hosur - Maraimalai Nagar - Edapalli - Koratty 35 Locations
Technical Audit Customers
Internal Workshops / Seminars organisedNo Meet Name Conducted Focus Inaugurated /
Month & Year Presented by
1. First Technical July 1998 Technical Audit Concepts,
Audit Meet Scope & Coverage, Our ---
Audit Approach, Methodologies
& the Benefits of such Audits
2. Second Technical April 1999 Technical Audit Concepts,
Audit Meet Scope & Coverage, Our ---
Audit Approach, Methodologies
& the Benefits of such Audits
3. EID Steam Audit February 2000 Experience sharing in the
Meet areas of “Steam Audit” in Mr.M.M.Murugappan
EIDP - Plants /
Group Companies
4. EID Power Audit October 2000 Experience sharing in the
Meet areas of “Power Audit” in Mr.A.Vellayan
EIDP - Plants /
Group Companies
Internal Workshops / Seminars organisedNo Meet Name Conducted Focus Inaugurated /
Month & Year Presented by
5. “SHE” Audit March 2001 Audit Coverage,
Seminar Concepts, Audit Experience Mr.M.M.Venkatachalam
sharing in this area
6. Seminar on August 2001 Focus on the Mr.H.S.HanumanthaRao
“Management of “Energy Bill” (Member - Retired)
Electricity in the TNERC
New Environment”
7. Renewable Energy November 2001 Solar Energy Concepts, Dr.C.Palaniappan
Meet awareness creation, General Secretary
& possible areas Planters Energy Network
of applications in our plants.
8. “Guest Audit March 2002 Gaining acceptance Dr.S.S.Pillai
Pool Meet” from internal customers VP - Bio Products &for the “Consultancy” Activity Chemicals
Internal Workshops / Seminars organised
No Meet Name Conducted Focus Inaugurated /
Month & Year Presented by
9. “Compressed Air April 2002 Energy Savings in Mr.U.V.K.M.Rao
System” Meet Compressed Air System Energy Consultant
10. “Electrical (Motor) June 2002 Energy Savings in Mr.S.Mahadevan
Audit” Meet Electrical (Motor) System Energy Consultant
11. “World Energy Day” November 2002 Climatic Change, Water Dr.T.G.Sundararaman
Meet Conservation Energy Consultant
ESCOMP GLOBAL
Internal Workshops / Seminars organisedNo Meet Name Conducted Focus Inaugurated /
Month & Year Presented by
12 Energy Management February 2003 Energy Savings in Lighting Mr.Anand Rajaraman
Initiative in Lighting System, Street Lighting M/S Wipro Lighting
System Harmonics
13 Energy Management April 2003 Flash Steam Mr.D.GnanasambandamInitiative in Steam Recovery
14 Energy Management August 2003 Energy Conservations in Mr.U.V.K.M.Rao
Initiative in Fans & Pumps Fans,Pumps & Blowers Associates
15 Boiler Codes & Acts December 2003 Industrial Boilers - Safety Aspects Mr.Thambithurai
in Indian Industry & Practice Codes Chief Inspectorate of Boilers
16 Second Conference on March 2004 Electrical & Heat Energy Mr.M.M.Murugappan
Electrical & Heat Energy 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