One India One People Magazine
Energy auditing India for sustainable development
Energy audit is imperative to energy conservation programmes and is a vital link in the entire energy management chain, which in turn can guide and control energy use so as to yield maximum possible output per unit of energy, writes Leena Mehendale.
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Just as an industry needs to know if it is working efficiently, and is fully utilising its resources without wastage, so also a country needs to examine if its resources — raw material, energy, water, finances and man power— are being used efficiently. It also needs to think on the scope for reducing the wastage and conserving the resources for sustainable development.
If we decide to Energy Audit India, how would we proceed? This was a question taken up way back in 2004 at PCRA (Petroleum Conservation Research Institute), while I was in charge of it. We felt that there were two facets of this approach — one was to base the module on same lines as we do in Energy Audits in four major sectors namely: industrial, transport, agriculture and domestic, and of course, in power-generation plants. The second was to look beyond them.
One of the objectives of PCRA is to function as a “Think Tank” to the Government of India for future policies and strategies on energy efficiency, petroleum conservation and environment protection. PCRA through its various brain-storming sessions, assessed that just on the lines of Energy Audit in industries, we carry out Energy Audit of the country on a fixed frequency – preferably once in five years, co-terminus with the plan period. Such a report generated one year before each plan period, shall become a part of the plan document.
Energy conservation is a multifaceted activity involving both promotional and regulatory measures. The level of energy efficiency in developing countries is very low, the reasons for this being lack of technical knowledge, non-availability of energy efficient equipment or machinery and wrong energy subsidies. Energy subsidies, particularly those encouraging energy consumption by keeping the energy prices low, result in low efficiency, environmental degradation and increased energy intensity.
As per world energy outlook, India’s Specific Energy Consumption per unit of GDP is much higher than that in the developed countries, indicating very high energy wastage and thus potential for substantial energy savings.
In an ideal situation, the Specific Energy Consumption measures how much energy is consumed per unit of GDP growth. The Specific Energy Consumption is closely related to economies of scale, process technology, instrumentation and control, structural changes, government policies and end users’ behaviours. It is a universal scale for bench-marking and setting energy efficiency targets, something that has been effectively used by the Japanese.
In India, the industrial sector consumes 50% of the total commercial energy but contributes only 25% to the country’s GDP growth. Currently, this sector consumes more than 100 MTOE (million tones of oil equivalent), with a growth rate of about 6% per annum. There is a need therefore, to bring about substantial improvements in the efficiency of energy use in the industrial sector. This alone can enable the Indian industry to compete effectively in the global market and also ensure higher profits. Based on various analyses, a saving potential of around 20% has been identified in the industrial sector without significant investment.
In an ideal situation, the Specific Energy Consumption measures how much energy is consumed per unit of GDP growth. The Specific Energy Consumption is closely related to economies of scale, process technology, instrumentation and control, structural changes, government policies and end users’ behaviours. It is a universal scale for bench-marking and setting energy efficiency targets, something that has been effectively used by the Japanese.
In India, the industrial sector consumes 50% of the total commercial energy but contributes only 25% to the country’s GDP growth. Currently, this sector consumes more than 100 MTOE (million tones of oil equivalent), with a growth rate of about 6% per annum. There is a need therefore, to bring about substantial improvements in the efficiency of energy use in the industrial sector. This alone can enable the Indian industry to compete effectively in the global market and also ensure higher profits. Based on various analyses, a saving potential of around 20% has been identified in the industrial sector without significant investment.
Taking cue from Energy Audit of an Industry — To do this let us take a look at how Energy Audit is conducted
Energy Audit of Industry
An industrial energy audit helps in optimising energy cost, pollution control, safety aspects and suggest methods to improve the operating and maintenance practices of the system. The energy audit provides necessary information base for overall energy conservation programmes and is a vital link in the entire energy management chain. Energy management in turn can be construed as the process of guiding and controlling energy use so as to yield maximum possible output per unit of energy.
To meet the stated objective of Energy Audit in a holistic manner, the overall process of an industrial energy audit can be placed under five broad categories:
An industrial energy audit helps in optimising energy cost, pollution control, safety aspects and suggest methods to improve the operating and maintenance practices of the system. The energy audit provides necessary information base for overall energy conservation programmes and is a vital link in the entire energy management chain. Energy management in turn can be construed as the process of guiding and controlling energy use so as to yield maximum possible output per unit of energy.
To meet the stated objective of Energy Audit in a holistic manner, the overall process of an industrial energy audit can be placed under five broad categories:
1. Minimise obvious wastages
Reduce wastage such as too much movement of inventory, making two trips when one is sufficient, non-balancing raw material, using excess water, lighting etc.
2. Current plant performance
A good understanding of the manufacturing process is essential in order to break it up into smaller units for purpose of energy audit. By looking at individual current performance of major operating departments, their key equipments and the parameters of each of their process, we can do technical analysis to check the energy efficiency of each stage and identify areas where technical improvement might be made. The cost involved for achieving enhanced performance is determined and financial analysis performed to identify cost effective measures. Here the total energy saving is the sum of energy saving at each stage or department or equipment.
3. Process integration
Process integration always results in bulk energy savings. It is a design tool to optimise energy use in plants employing conventional technologies. It is common sense that manufacturing plants using batch processes would instantly benefit by shifting to continuous processes but the decision is not always easy as it requires considerations of market availability, inventory management, and manpower management too. Where the plant is already having a continuous process, its intensification is the key. It involves making fundamental changes to processing technologies to yield improved product quality, throughput and energy efficiency. The advent of computers have made such an integration much more accurate than was earlier possible with manual controls.
4. Retraining of manpower
As industries are adopting advanced equipment and process technologies for competitiveness, the available manpower also needs to be imparted new knowledge and skills to operate such technologies, for which retraining is very essential. Retraining of manpower can be done through: Qualification improvement programmes, vocational courses, distance education, workshops, training at OEMs (original equipment manufacturers) etc. One major aspect of training is attitudinal change.
5. Paradigm shift
A major scientific or philosophical breakthrough can bring in a paradigm shift leading to energy efficiency. Often it makes some aspects redundant. A typical example of paradigm shift was the Japanese approach of JIT (Just in Time) which obviated the need to keep any inventory in the factory premises.
Reduce wastage such as too much movement of inventory, making two trips when one is sufficient, non-balancing raw material, using excess water, lighting etc.
2. Current plant performance
A good understanding of the manufacturing process is essential in order to break it up into smaller units for purpose of energy audit. By looking at individual current performance of major operating departments, their key equipments and the parameters of each of their process, we can do technical analysis to check the energy efficiency of each stage and identify areas where technical improvement might be made. The cost involved for achieving enhanced performance is determined and financial analysis performed to identify cost effective measures. Here the total energy saving is the sum of energy saving at each stage or department or equipment.
3. Process integration
Process integration always results in bulk energy savings. It is a design tool to optimise energy use in plants employing conventional technologies. It is common sense that manufacturing plants using batch processes would instantly benefit by shifting to continuous processes but the decision is not always easy as it requires considerations of market availability, inventory management, and manpower management too. Where the plant is already having a continuous process, its intensification is the key. It involves making fundamental changes to processing technologies to yield improved product quality, throughput and energy efficiency. The advent of computers have made such an integration much more accurate than was earlier possible with manual controls.
4. Retraining of manpower
As industries are adopting advanced equipment and process technologies for competitiveness, the available manpower also needs to be imparted new knowledge and skills to operate such technologies, for which retraining is very essential. Retraining of manpower can be done through: Qualification improvement programmes, vocational courses, distance education, workshops, training at OEMs (original equipment manufacturers) etc. One major aspect of training is attitudinal change.
5. Paradigm shift
A major scientific or philosophical breakthrough can bring in a paradigm shift leading to energy efficiency. Often it makes some aspects redundant. A typical example of paradigm shift was the Japanese approach of JIT (Just in Time) which obviated the need to keep any inventory in the factory premises.
Energy Auditing India
For ‘Energy Auditing India’ we can try to apply the above 5 modules. Reducing obvious wastage has great potential. Careless use leading to wastage is a routine affair for water, grains, electricity, fuel, even human beings. Unit-based approach can be useful for a sector specific study of energy conservation pattern and fixing energy saving potential of major industries like aluminium, steel, textiles, cement, paper, fertilizers, petroleum and chemical etc. Such first step has been taken. BEE (Bureau of Energy Efficiency) and PCRA have together fixed these targets under Energy Conservation Act and now adopting various persuasive measures with those industries to achieve them.
For ‘Energy Auditing India’ we can try to apply the above 5 modules. Reducing obvious wastage has great potential. Careless use leading to wastage is a routine affair for water, grains, electricity, fuel, even human beings. Unit-based approach can be useful for a sector specific study of energy conservation pattern and fixing energy saving potential of major industries like aluminium, steel, textiles, cement, paper, fertilizers, petroleum and chemical etc. Such first step has been taken. BEE (Bureau of Energy Efficiency) and PCRA have together fixed these targets under Energy Conservation Act and now adopting various persuasive measures with those industries to achieve them.
Process Integration
In the context of ‘Energy Auditing India’, process integration means synergistic role and action of various actors, which include: -
In the context of ‘Energy Auditing India’, process integration means synergistic role and action of various actors, which include: -
- Government – National and State level
- Energy Efficiency Agencies
- Equipment manufacturers
- Non Government Organisations (NGOs
- Ministries/Departments like
- Planning Commission,
- HRD Ministry
- State Technical Education Boards
- Department of Science and Technology
- Ministry of Power
- State Electricity Boards etc.
The other issues concerning, process integration which require action oriented approach are:- - Integrated resources planning
- Demand side management
- Policy guidelines and concept
Retraining Manpower
For the success of ‘Energy Auditing India’ programme, involvement of people at the grassroots level is important. This involvement can be ensured by motivation, education and legal liability for compliance. In this regard, the approaches can be as follows:
For the success of ‘Energy Auditing India’ programme, involvement of people at the grassroots level is important. This involvement can be ensured by motivation, education and legal liability for compliance. In this regard, the approaches can be as follows:
- Vocational training for skill building and skill updation
- Mass education/awareness campaigns on behavioural and attitudinal changes towards energy and environment
- Statutory measures to curb inefficient use of energy and illegal practices like fuel adulteration and environmental protection
It is worth listing PCRA’s efforts thus far in respect of the above three.
- i) Vocational training for skill building and skill up-dation Unfortunately, in India we have excess of qualified engineers but scarcity of competent middle-level skilled persons like plumbers, electricians, carpenters, etc. Inspite of Government‘s efforts to open Industrial Technical Institutes (ITIs) in every district HQ and other smaller towns, we have not been able to attract sufficient number of candidates to take advantage of these courses. The simple reason for lack of interest in acquiring ITI qualification is that the poor candidates, belonging to a particular category lack the means and basic qualification to enter these courses. For this category of youth it is much easier to learn the traditional skills from their elders, where no basic qualification is required. Also there is no opportunity for them to update their skill and knowledge due to lack of basic qualification, resources and learning forums.
- PCRA has prepared 60 films on vocational training, where persons with such background can update their knowledge to become more competitive. Some of the vocational films, produced by PCRA cover: carpentry, domestic wiring, masonry, Lathe machine, tractor maintenance, plumbing, welding, AC repair, motor winding, etc.
- ii) Behavioural and attitudinal changes through mass mediaOne of the objectives of PCRA is to create awareness among masses about the importance, benefits and methods of conserving petroleum products and environment protection by enhancing information sharing and mass awareness.
- A number of initiatives have been taken by PCRA to bring in attitudinal changes amongst the masses for efficient utilisation of energy, spreading awareness on issues like energy efficiency and protecting environment, through infotainment radio programmes such as ‘Boond Boond ki Baat’ and edutainment programmes such as “Khel Khel Mein Badlo Duniya” on Doordarshan, which has covered episodes on wind energy, solar energy, biogas, vermiculture, metro rail, vehicle population in metros, transportation of petroleum products etc. Regular Press Advertisements are also being released by to achieve maximum reach to the households of the country.
- iii) Statutory measures to curb inefficient use of energy, fuel adulteration and environment protection
- In addition to persuasive measures it is necessary to introduce statutory measures to curb inefficient utilisation of energy. Energy conservation Act 2001, which makes Energy Audit mandatory for certain types of industries is one step in this direction.
- As has already been stated, energy intensity in our country remains very high in comparison to developed countries. It is true that we have improved our energy efficiency to some extent. To be globally competitive, a demand or need driven programme is more likely to succeed than a supply driven program based on subsidies.
- Fuel adulteration is another area of concern in our country. As it results in environment pollution, the Hon’ble Supreme Court of India has given direction to setup two fuel testing laboratories to check fuel adulteration. The lack of will in the enforcement agencies under Petroleum Sector is coming in the way of checking fuel adulteration.
Sustainable eco and energy conservation
For sustainable Eco and Energy conservation, we need two paradigm shifts. First, adopt some new visions for development such as using our Optic Fiber Network to provide Rural Tele-Communication rather than depend on traditional methods, developing our next-to-nil research capabilities, larger thrust on skill education, energy-efficient urban planning, and so on.
For sustainable Eco and Energy conservation, we need two paradigm shifts. First, adopt some new visions for development such as using our Optic Fiber Network to provide Rural Tele-Communication rather than depend on traditional methods, developing our next-to-nil research capabilities, larger thrust on skill education, energy-efficient urban planning, and so on.
Second, question the sanctity of some of our developmental models. I can cite two examples – Our agriculture sector consumes less energy per unit of GDP – why not develop it? Our service sector promotes too much of non-productive services (security guards, super star hospitals, etc) – why promote them?
Let us examine this scenario – the local municipal corporation supplies water but not potable enough – individuals buy water purifiers – GDP grows, but these machines necessarily throw away 50% water – that had been pumped and brought there. We do not calculate how much water and energy have been wasted in the process – we focus only on GDP growth brought in through increased business of individual water purifiers. Another example, let us look at education of urban children. Instead of promoting neighbourhood school model, which requires revamping of quality education in all schools, our policy allows “specialized seven-star schools” requiring daily transportation of thousands of school children across huge distances in the city leading to tremendous energy consumption in unproductive activity.
Let us examine this scenario – the local municipal corporation supplies water but not potable enough – individuals buy water purifiers – GDP grows, but these machines necessarily throw away 50% water – that had been pumped and brought there. We do not calculate how much water and energy have been wasted in the process – we focus only on GDP growth brought in through increased business of individual water purifiers. Another example, let us look at education of urban children. Instead of promoting neighbourhood school model, which requires revamping of quality education in all schools, our policy allows “specialized seven-star schools” requiring daily transportation of thousands of school children across huge distances in the city leading to tremendous energy consumption in unproductive activity.
The most energy-efficient country, namely Japan sets targets for still higher energy efficiency – and one strategy is by educating children to critically examine various lifestyles and choose what promises to ensure sustained energy efficiency. We too need to prepare ourselves for such courageous paradigm shifts.
The author, presently Member CAT Mumbai in the rank of High Court Judge, is an accomplished administrator, teacher, thinker and writer. She has travelled over 400 out of 650 districts in India and is proficient in many Indian languages. As an administrator she has worked in various departments which include education, women, children, industries, petroleum, agriculture, and health.Some of her service highlights are economic rehabilitation of Devdasis, making TV and radio serials for energy conservation, designing, training and framing policies for Yashada (Yashwantrao Chavan Academy of Development Administration) and promoting Indian languages on computers. Presently, she is actively pursuing revival of Sanskrit language.
She has given over 1000 lectures, authored 25 books on diverse subjects and over 600 articles, in Marathi, Hindi and English.
