BEE Book For Energy Audit in Fertilizer Industry
BEE Book For Energy Audit in Fertilizer Industry
BEE Book For Energy Audit in Fertilizer Industry
Fertilizer Sector
MINISTRY OF POWER
GOVERNMENT OF INDIA
NORMALIZATION DOCUMENT - Fertilizer Sector i
© Bureau of Energy Efficiency, Government of India, March 2015
All rights reserved. No part of this document may be reproduced in any form or by any means
without prior permission of Bureau of Energy Efficiency, Government of India.
Published by
Bureau of Energy Efficiency
Ministry of Power,
Government of India
4th Floor, Sewa Bhawan
R K Puram
New Delhi -110 066
Developed specifically for Designated Consumers notified under Perform Achieve and Trade
(PAT) Program for National Mission for Energy Efficiency (NMEEE)
Disclaimer
This document has been developed after an extensive consultation with a number of experts and
stakeholders of the scheme. BEE disclaim any liability for any kind of loss whatsoever, whether
special, indirect, consequential, or compensatory, directly or indirectly resulting from the
publication, or reliance on this document.
1. Introduction 1
2. National Mission for Enhanced Energy Efficiency 1
3. Perform, Achieve and Trade (PAT) Scheme 2
4. Background 2
5. Status of Designated Consumer (DCs) 4
5.1 General Rules for Establishing Baseline Values 4
5.2 Grouping of DC’s for fixing targets for reduction in SEC 5
6. Normalization factors for the Fertilizer sector 9
6.1. Low capacity utilization 9
6.1.1. Pre-requisites for Normalisation 9
6.1.2. Calculation of normalization factor 9
6.1.3. Supporting data / documentation 10
6.1.4. Calculation of Normalization factor for low capacity utilization 11
6.2. Cold startup of the plant after forced shut down 13
6.2.1. Pre-requisites for Normalization 13
6.2.2. Calculation of normalization factor 13
6.3. Use of naphtha 14
6.3.1. Pre-requisites for Normalization 14
6.3.2. Calculation of normalization factor 14
6.4. Catalyst reduction 15
6.4.1. Pre-requisites for Normalization 15
6.4.2. Calculation of normalization factor 15
6.5. Deterioration in quality of Coal 15
6.5.1. Pre-Requisites for Normalization 15
6.5.2. Calculation of normalization factor 15
6.6. Additional provisions 16
Foreword
Perform Achieve and Trade (PAT), a flagship initiative under National Mission for Enhanced
Energy Efficiency (NMEEE), is a regulatory intervention for reduction of specific energy consumption,
with an associated market based mechanism through which additional energy savings can be
quantified and traded as ESCerts.
Fertilizer sector is one of the 8 notified energy intensive sectors under which a total of 29 plants
are participating in this program. These plants have been mandated to reduce their Specific Energy
Consumption (SEC) from baseline year of 2009-2010. It is expected that these plants may save
0.478 million tons of oil equivalent annually by the end of PAT cycle –I.
The publication of “Normalization Document and M&V Guidelines” for Fertilizer Sector is
an effort to facilitate the DCs to comply with notified PAT rules to participate with the PAT scheme
and contribute towards achieving national target of energy savings. This document will also be
helpful to all empanelled Accredited Energy Auditors (EmAEAs) and State Designated Agencies
(SDAs) in the monitoring and verification process of PAT.
I want to record my appreciation for members of the Sectoral Expert Committee on Fertilizer
Sector, chaired by Dr. S. Nand, Dy. Director General, Fertilizer Association of India, Shri Sameer
Pandita, Asst. Energy Economist, BEE and Shri VK Goyal, Sector Expert, Shri Vikas Ranjan,
Technical Expert, GIZ who worked tirelessly to put together the baseline data, normalization factors
and M&V methodology for the sector.
I also compliment the efforts of all participating industrial units towards their endeavor in
contributing to the national energy saving targets.
(Ajay Mathur)
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pkSFkk ry] lsok Hkou] vkj0 ds0 iqje] ubZ fnYyh&110 066
4th Floor, Sewa Bhawan, R.K. Puram, New Delhi - 110 066
Vsyh/Tel : 26178316 (lh/kk/Direct) 26179699 (5 Lines) QSDl/Fax : 91 (11) 26178328
bZ&esy/E-mail : [email protected] osclkbZV/Web-Site : www.beeindia.in
Sectoral Expert Committee on Fertilizer
NMEEE
Energy Efficiency Financing Framework for Energy Efficient
Platform Economic Development
(EEFP) (FEEED)
2 Chlor-Alkali
7
Textile
7
Pulp & Paper
48 Aluminium
12
Fertilizer
Cement
Threshold limit for becoming a DC = 30000 1. In case of plants more than 5 years old,
metric tons of oil equivalent (MTOE) per annum data for the last 3 financial years will be
Total number of identified DCs = 29. considered, provided the CU is uniform.
Normalisation will be done in case of
Estimated Energy Consumption = (13.35- 5.15) abnormality in CU in any of the three
= 8.20 Million Tonnes of Oil Equivalent. years.
2. In case of plants more than more than 5
5.0 General Rules for Establishing Baseline
years old, but has data for less than 3 years,
Values
the same will be considered, provided the
A. Definitions CU is uniform. If the CU is abnormally low
[1] Baseline Year in any of the years, the same will not be
considered.
Baseline year is declared as 2009-10.
[2] Baseline Production (Pbase) 3. In case of plants less than 5 years old and
has data for less than 3 years, the available
The arithmetic average of Production
year’s (or years’) data will be considered,
figures of 2007-08, 2008-09 and 2009-10
provided the CU is uniform. If the CU is
[3] Baseline Specific Energy Consumption abnormally low in any of the years, the
(SECbase) same will not be considered.
The weighted average of SEC figures of 4. In case of new plants, the data would be
2007-08, 2008-09 and 2009-10.
considered for the years where the CU is
[4] Baseline Capacity Utilisation in % (CUbase) greater than 70%. If data exists for only
The arithmetic average of CU figures of one year data, the same will be considered
2007-08, 2008-09 and 2009-10. irrespective of the CU.
16
Revamp in Plants
Targets Group -1 14
3.28 = 2.7% BVFCL Namrup -II
3.4 = 5% BVFCL Namrup -III
3.91 = 7.5% Target : 12 % 12
Based on DFR
Group -2 11.54
FO/LSHS Plants
Target : 25% 10
SEC in GCal / MT
8
Group -3 7.04 7.58
Group -4
Targets : 1% Targets : 1.0%
Total Plants : 5 Plants 7.14
Total Plants : 11 Plants 6
5.32
4.97 5.12 5.45
4.28 4.35
TCL Babrala 3.91 3.99
Average = 4 3.37 4.20
3.23 3.28 3.28 3.40 4
2.99
NG in place of Fuel Oil. Existing Plant originally designed for Naphtha feed.
shall also be utilized at part load Subsequently, these have changed
to augment CO2. Commissioning over to NG and also carried out
is scheduled in 2012-13. Assessed retrofits. Thus, there is no margin left
potential for reduction is 10%. for further improvement. Assessed
(b) NFL Nangal ( 1974), NFL Bhatinda potential for reduction is 1.0 each.
(1977), NFL Panipat ( 1977) having IFFCO Kalol( 1975) is having lower
energy consumption of 7.04, 7.14, SEC of 3.367 G cal/MT Urea. . Plant
7.58 Gcal/MT Urea respectively has carried out major retrofits during
are in the process of conversion for last 3 years. Assessed potential for
switching over feed stock to NG. reduction is 1 %.
Commissioning is scheduled in the RCF Trombay-V ( 1982) having
year 2012-13. Reduction in energy energy consumption of 4.97 Gcal/
consumption has been assessed as 25, MT Urea has been under shut down
24, 22 % respectively. and restarted only in the year 2009-
10. Performance data for last 3 years
(3) Group – 3 ( DC’s : 11) is not available. Assessed potential for
(a) Old vintage Plants SCF Kota ( 1969), reduction is 2.0 %.
GSFC Vadodra ( 1967) & IFFCO (b) Three Plants have undertaken
Phulpur – I ( 1981) are having major retrofits, which are under
energy consumption of 5.1, 4.0, 4.28 implementation. Results will be
G cal/MT Urea. These Plants were
Fertilizer Sector
29 DC’s
Outlier
Out Lierdue
due Fuel Oil Plants Plants have Plants
to local factors under c/o to NG implemented major commissioned in
(2 DC’S) ( 4 DC’s) retrofits during 3-4 eighties and done
yrs ( 7 DC’s) retrofits ( 5 DC’s)
FACT UdhyogMandal
producing Ammonia only
Plants implementing major retrofits (4 DC’s) Old vintage Plants including Naphtha (6 DC’s)
Sr. Description Unit 2007-08 2008-09 2009-10 Baseline Previous 2014-15 Reference
No. data Year
2013-14
A B C D E F G H I
1.1.6 Sp. Energy GCal/MT 7.634 7.520 7.098 7.370 7.253 TOP
consumption ammonia
2.1.6 Sp. Energy Gcal/MT 6.395 6.604 6.542 6.525 6.500 TOP
consumption urea
TOP: Technical Operating Data as submitted to FICC. Data in the above table is representational
and may vary from unit to unit.
Units are advised to refer the Proforma (Production_energy_best monthly ) to Sd Form -1 for better understanding of
the notations above. Data is purely representational and shall vary from DC to DC .
6.2. Cold startup of the plant after forced 6.2.1. Pre-requisites for Normalization
shut down
1. The list of critical equipment failure
In case of sudden failure of a critical equipment, of which leads to complete shutdown
or external factors (as notified), ammonia plant of plant and consequent cold start up,
undergoes a forced shut down. Restarting the allowed under this normalization factor is
plant from cold conditions (Cold start up), given below :-
consumes unproductive energy and shall be
normalized. Cold start up is defined as Fuel and 1. Primary Reformer
Feed cut to reformer for a minimum period of 2. Secondary Reformer
72hrs.
3. Heat Exchange Reformer
(6) The accredited energy auditor shall have (12) The accredited energy auditor shall ensure
documented system for preparing the the confidentiality of all information
plan for verification or check-verification and data obtained or created during the
functions and the said plan shall contain verification or check verification report.
all the tasks required to be carried out in (13) In assessing the compliance with the
each type of activity, in terms of man days energy consumption norms and standards
in respect of designated consumers for and issue of energy savings certificates, the
the purpose of verification and check – accredited energy auditor shall follow the
verification. provisions of the Act, rules and regulations
made thereunder.
(7) The names of the verification or check-
verification team members and their bio- (14) After completion of the verification or
data shall be provided by the accredited check-verification, the accredited energy
energy auditor to the concerned designated auditor shall submit the verification (in
consumer in advance. Form- “B”) or check-verification report,
together with the certificate in Form-‘C’, to
(8) The verification or check-verification the Bureau.
team shall be provided by the accredited
energy auditor with the concerned 1.5. Important Documents required for
working documents indicating their full M&V process
responsibilities with intimation to the
concerned designated consumer. I. Accepted Baseline Audit Report (Available
with BEE and DC)1
(9) The accredited energy auditor shall have
documented procedure-
(i) to integrate all aspects of verification
or check-verification functions;
(ii) for dealing with the situations in
which an activity undertaken for the
purpose of compliance with the energy
consumption norms and standards or
issue of energy savings certificate shall
not be acceptable as an activity for the
said purposes.
(10) The accredited energy auditor shall
conduct independent review of the opinion
Figure 1: M&V Documents
of verification or check-verification team
1
Baseline Report: Available with BEE and respective DCs. EmAEA to verify the consistency of Report
State Empanelled
Bureau of
Designated Designated Accredited CERC/
MoP Energy
Consumer Agency/ Energy POSOCO
Efficiency
SERC Auditor
2. Broad Roles and Responsibilities Adjudicator and Ministry of Power (MoP) can
be summed up as under
The various roles assessed to be performed in
the verification process include administration, The Designated Consumer shall fill the data in
regulation and services delivery. The key the Sector Specific Pro-formaand Form 1 stating
stakeholders are Ministry of Power, Bureau of source of data in the Form, of its installation as
Energy Efficiency, State Designated Agencies, per GtG boundary concept manually in Excel
Adjudicator, Designated Consumers and Sheet Pro-forma and in PATNET. The filled in
Empanelled Accredited Energy Auditor. Forms with the authentic source of data in terms
of hard copy document shall have to be kept
2.1. General ready by Designated Consumer for verification.
The designated consumer in consultation with
The roles and responsibilities of individuals
the EmAEA, shall put in place transparent,
and designated consumer are set out in Energy
independent and credible monitoring and
Conservation Rules 2012 2
verification arrangement. The verifier shall
ensure transparency, independence and
The roles and responsibilities of the Designated
safeguard against conflict of interest.
Consumer (DC), Empanelled Accredited Energy
Auditor (EmAEA), Bureau of Energy Efficiency
As part of verification process, the EmAEA shall
(BEE), State Designated Agencies (SDA),
2
Energy Conservation Rules 2012: Energy Consumption Norms and Standards for Designated Consumers, Form, Time within which, and Manner
of Preparation and Implementation of Scheme,Procedure for Issue of Energy Savings Certificate and Value of Per Metric Ton of Oil Equivalent of
Energy Consumed) as per Notification G.S.R.269 (E ) dated 30th march 2012
Government have been covered under established to implement the scheme. Bureau
Energy Conservation Act 2001 and notified of Energy Efficiency is leading the process with
PAT Rules 2012 state level capacity supported by AEA and
Sectoral Technical committee constituted for
rationalizing the process.
Figure 3: Institutional Framework
3
Trading Exchanges: IEX & PXIL
(A) (G)
Central Depository/
Government (H) Registry
Designated
(D) (E)
Consumer
(B)
BEE (F)
SDA(s)
(Administrator)
(C)
(A) Targets from Central Government to DCs (E) ESCerts Issuance Instruction from Central
Government to BEE
(B) Performance Assessment Document (Form
A) from DC to SDA (F) Electronic ESCerts Issuance Instruction
from BEE to Depository
(C) PAD (Form-A) with recommendation for
issuance, if overachieved from SDA to (G) DC Interaction with Depository A/c
BEE
(H) ESCerts credit to DC’s A/c
(D) Recommendation of ESCerts Issuance by
BEE to Central Government
No
Under Achiever
Over achiever
Over achiever
DC to purchase the
ESCerts from Exchange
- up to November
DC By June 30 each Year Submission of Energy Return Form I and Sector Specific Supporting Pro-forma for
Form 1
DC Before M&V phase of PAT Cycle Hiring of Empanelled Accredited energy Auditor
DC By June 30 [M&V phase of PAT Cycle] Submission of Verified Form I and Sector Specific Pro-forma, Form A,
Form B and Other Document to SDA & BEE
st nd
DC By June 30 [After end of 1 and 2 Year Submission of Verified Form I and Sector Specific Pro-forma, Form A,
PAT Cycle]For Advance ESCerts Form B and Other Document to SDA & BEE
SDA [15 days of the last date of sub. of Form A] Submission of Comments on Verified Form I and Sector Specific Pro-forma, Form
A, Form B and Other Document to BEE
[10 working days from last date of submission of Recommendation of Energy Saving Certificates to Central Government
BEE Form A by SDA][M&V phase of PAT Cycle]
[10 working days from last date of submission of Form A by SDA]
Central [15 working days from date of receipt of Issue of Energy Saving Certificates[15 working days from date of receipt of
recommendation by BEE][M&V phase of PAT Cycle]
Government recommendation by BEE]
[5 months from date of submission of Form Submission of Form D to SDA and BEE[5 months from date of submission of
DC
A by DC to SDA][M&V phase of PAT Cycle] Form A by DC to SDA]
31. The procedure for selection of EmAEA 36. EmAEA is required to submit the Name
should be followed from guidelines of and detailed Bio-data on Energy Audit or
PAT Rules 2012 Verification experiences of the team head,
team members and experts to the DC prior
32. The Designated Consumer may select to selection
EmAEA based on their experience in
Energy Auditing Field and in the related 37. The Designated Consumer to ensure
sector as per information in Form III and that the EmAEA must have documented
Form IV (REGISTER CONTAINING LIST system on preparing plan for verification
OF ACCREDITED ENERGY AUDITORS) or check-verification along with activities
Submitted by the Accredited Energy chart defining task in man-days for the
Auditor (www.bee-india.nic.in) DC.
33. The EmAEA preferably have attended at 38. The selection process of EmAEA needs to
least one Training Programs organized by be completed before 31st March of the end
Bureau of Energy Efficiency on Monitoring of PAT Cycle
and Verification Guidelines.
39. The scope of workmay cover the time
34. The Designated Consumer needs to verify period till the check verification.
following during selection of AEA
(a) Provided that a person who was in the 4.2. Guidelines for Empanelled Accredited
employment of a designated consumer Energy Auditor
within the previous four years, shall
not be eligible to perform the work of 40. For the Work of verification, EmAEA shall
verification or check-verification for constitute a team in accordance to section
such designated consumer; 10 of Energy Conservation Rules, 2012;
comprising following team members
(b) Provided further that any person or
firm or company or other legal entity, 41. Where ever necessary, EmAEA must state
who was involved in undertaking any discrepancies in their final verification
energy audit in any of the designated reports. Potential improvements to achieve
consumer within the previous four more accurate reporting in line with the
years, shall not be eligible to perform PAT Rules and EC Act.
the work of verification or check
42. The EmAEA may constitute any nos of the DCs Energy Manager and Competent
team for verification or check-verification Authority
purpose to carry out the verification 50. EmAEA to submit an undertaking along
process for nos of Designated Consumer. with Form B indicating that there is no
43. The EmAEA shall ensure that it has formal conflict of interest in the team assigned
contractual conditions of team members and PAT Rules 2012 and its amendments
including technical experts for verification have been complied.
and check-verification so as to act in an
impartial and independent manner and 4.3. Guidelines for Verification process
free of potential conflict of interest.
44. The EmAEA, has the sole responsibility 4.3.1. Sector Specific Pro-forma
and signing authority on Form B, Form C
The Sector Specific Pro-forma is made with the
45. The verification by EmAEA should be purpose of capturing the data for Production,
completed for onward submission to Energy and Normalization factors under
SDA and BEE before 30th June in the year equivalent condition for the baseline and
following the assessment year. assessment year. The filled in Pro-forma is
46. The EmAEA should furnish a time plan used to calculate the Notional Energy for
and activities chart to DC after receiving Normalization. Once complete data is filled
valid order from the respective designated in the Pro-forma, the SEC after Normalization
Consumer automatically comes out in the summary sheet
enabling the DC to see the actual performance
47. The Designated Consumer shall inform of the plant
Bureau of Energy Efficiency about the date
of start of verification by EmAEA. 51. The Energy Conservation (Form and
48. The verification shall not be carried out by Manner for submission of Report on the
two different EmAEA for the particular Status of Energy Consumption by the
DC in a single PAT cycle. Designated Consumers) Rules, 2007 directs
every designated consumers to submit the
49. The audit report shall be certified by the status of energy consumption in electronic
EmAEA and shall be counter signed by form as well as hard copy, within three
4
PAT Sectors: Thermal Power Stations, Steel, Cement, Aluminium, Fertiliser, Pulp & Paper, Textile, Chlor-Alkali
5
GtG: Gate to Gate
7
External Factor: Market Demand, Grid Failure (Where CPP is not Sync with Grid), Raw material unavailability, Natural Disaster, Rioting or
Social unrest, Major change in government policy hampering plant’s process system, Any unforeseen circumstances not controlled by plant
management
8
Location of sampling: As fired Fuel after the Grinding Mill
9
Location of sampling: As fired Fuel after the Grinding Mill
10 Government Accredited Lab: National Accreditation Board for Testing and Calibration Laboratories(NABL Labs)
Quality Parameters
1 Raw Material Quality % Lot, 1) Internal Test Certificate 1) Lab Test Report Register
(Sector Specific Raw Monthly 2) External Test Certificate
Material Quality from related Sector Govt
testing) Accredited Lab
1 the Ash % in coal % Lot, Daily, 1) Daily Internal Report 1) Lab Register on Fuel
used in CPP/Cogen/ Monthly, from Lab on Fuel Proximate Testing for Proximate
WHRB Quarterly Analysis performed on each Analysis 2) Calibration
lot. 2) Test Certificate from Record of instrument used
Government Accredited lab. for testing
(Plant to maintain minimum
1 sample test in a quarter
for Proximate and Ultimate
Analysis i.e. 4 test certificates
in a year for each fuel in case
of CPP/Cogen/WHRB Fuel,
for Process Fuel 1 sample test
in a quarter for Proximate
Analysis) 3) Purchase Order,
where guaranteed GCV
range is mentioned
3 the Hydrogen % in
coal used in CPP/
Cogen/WHRB
Sr No Details
Document related to external factor
(i) Market Demand
1)Product Storage Full record from Product Mill Log book 2)SAP entry in SD and FI
module 3) SAP entry in PP module 4) Document related to sales impact of market
(ii) Grid Failure
1) SLDC Reference No. for planned Stoppages from respective Substation 2) Log book
record of Main Electrical Substation of Plant 3) DPR 4) MPR 5) SAP entry in PM module
of Electrical department
(iii) Raw Material un-availability
1) Material Order copy and denial document from Mines owner 2) SAP entry in MM/FI
module on raw material order 3) DPR 4) MPR
(iv) Natural Disaster
1) Supporting Authentic document from Local district Administration 2) Major Eqp Log
Sheet 3) Major Eqp operators Report book 4) DPR 5) MPR
(v) Major change in government policy hampering plant’s process system
1)Government Notification or Statutory order 2) Authentic document from plant on
effect of Major Eqp production due to policy change 3) DPR 4) MPR 5) SAP Entry on
production change
(vi) Unforeseen circumstances/Labour Strike/Lockouts/Social Unrest/Riots
1) Relevant document on Unforeseen Circumstances beyond the control of plant 2)
Energy Meter Readings and Power Consumption during the said period of unforeseen
circumstances 3) Thermal Energy Consumption record during the said period of
unforeseen circumstances from DPR/Log book/SAP Entry
B Note
(i) The hard copy/Printouts is to be signed by Authorised signatory, if SAP data is used as
documents
115. In case a DC commissions a new line/ as applicable in the baseline, will not qualify
production unit before or during the for this Normalization i.e., If any Plant after
assessment/target year, the production the baseline year has deviated from the
and energy consumption of new unit will Environmental Standards imposed in the
be considered in the total plant energy baseline year and additional equipment
consumption and production volumes have been installed after the baseline year
once the Capacity Utilisation of that to comply with these Standards, the plant
line has touched / increased over 70%. is not eligible for Normalization.
However, the energy consumption and 117. Unavailability of biomass/Alternate
production volume will not be included fuel in assessment year as compared to
till it attains 70% of Capacity Utilisation. the baseline year due to external factor.
Energy consumed and production made (if The normalization for Unavailability for
any) during any project activity during the Biomass or Alternate Fuel takes place only
assessment year, needs to be exclusively if sufficient evidence in-terms of authentic
monitored and will be subtracted from document is produced. Plant to furnish
the total energy and production in the the data replacement of fossil fuel from
Assessment year. Similarly, the same Biomass/ Alternate Fuel (Solid/Liquid)
methodology will be applied on a new unit in the assessment year w.r.t. baseline
installation for power generation (CPP) year. The energy contained by the fossil
within the plant boundary. fuel replacement will be deducted in the
The Capacity Utilisation will be evaluated assessment year
based on the OEM document on Rated 118. If a captive power plant or cogeneration
Capacity or Name plate rating on capacity plant caters to two or more DCs for the
of New Line/ Production Unit and the electricity and/or steam requirements. In
production of that line/unit as per DPR/ such scenario, each DC shall consider such
Log sheet. captive power plant or cogeneration plant
in its boundary and energy consumed by
5.4. Normalisation General Issue such captive power plant or cogeneration
plant shall be included in the total energy
116. Normalisation Environmental Concern: consumption. However, electricity in
Any additional equipment installed to terms of calorific value (as per actual heat
comply with the Environmental standards
This data shall be produced by the DCs for 2. Coal Handling Plant
verification of section wise APC. If any item has a. Coal Input
been missed out in the table above, it shall be
inserted by the DC. The DC shall submit a copy of Fuel
Supply Agreement (FSA) in which
The DC shall submit all design documents, the coal quality shall appear. Also, the
manufacturers data sheet, etc. in support of the DC shall submit the transportation
equipment ratings if required. agreement/ contract indicating the
amount and quality of coal procured.
The colony does not form a part of the plant b. The station energy balance diagram to
boundary and hence it is kept outside. In the be included in the Verification report. A typical
figure above. The DC shall submit a latest Plot sample of the diagram is shown below for
Plan of the station indicating all the systems/ Coal/Lignite/Oil/Gas based Power Plant and
sub-systems. Combined Cycle Gas Turbine
1. The data submitted for verification 3. The transit and handling losses have
and other figure for SEC calculation of to be within the standard norms
any unit has to be in line with the units allowable under financial audit.
declared production and consumption 4. Crude steel is the product output of an
figures as per the statutory financial Integrated Steel Plant (ISP). The term
audit and declaration in their annual is internationally used to mean the 1st
report. solid steel product upon solidification
2. EmAEA, while verifying the SEC of liquid steel. In other words, it
calculation should also cross verify the includes Ingots (in conventional
4. The status quo to be maintained in the 6. Normalisation on Use of Wet Fly Ash due
assessment year for the basis of measuring to non-availability of dry Fly Ash: DC has
GCV of Fuel (For Ex. As Received Basis, to submit proper authentic documents to
As Fired Basis, As Dried Basis etc.) as establish the increase in energy during AY
followed in the baseline year i.e., if DC due to usage of wet fly ash due to external
has submitted GCV value on “as received reason. EmAEA to establish the facts
basis”, the basis will be same in the whether in the vicinity of the particular
assessment year as well. The DC has to DC, other Plants/DCs are getting dry Fly
write in the remarks/source of data field ash or not
on basis of GCV taken in the assessment
year. However, The EmAEA is requested 7. Some of the information sought under
to report the Fuel GCV “As fired basis” in this annexure could be considered as
the verification report, which may become supporting information/documents,
baseline for subsequent PAT cycles. which may help EmAEA in submitting the
Form B.
5. Plant Stoppages and Start due to
high Clinker stock or Silo Full to be 8. Review of Section wise specific power
considered as external factor: Necessary consumption (Line wise)
Process
Coal (Indian) (MT) 0.000 0.000 Clinkerisation-
Coal (Imported ) (MT) 0.000 0.000 Crushing/Raw Mill/Pyro Clinker Export 0.000 MT
Coal (Imported 2)- SA 0.000 0.000
Coal (Imported 3) 0.000 0.000
Coal (Lignite)(MT) 0.000 0.000 OPC 0.000 MT
Coal Fine 0.000 0.000
Coal Dollar 0.000 0.000 Grinding
Coal Dust 0.000 0.000 PPC 0.000 MT
Pet Coke (MT) 0.000 0.000
Bio Mass 0.000 0.000 Others 0.000 MT
petcoke rejects 0.000 0.000
Others 0.000 0.000
10. Mass and Energy balance verification account the Clinker stock difference and Clinker
The clinker balance verification is required Import export. Similarly Energy balance up
from Cement produced and Clinker factor to clinkerisation could be verified as per the
with actual clinker produced by taking into tabulated formulae
Table 18: Mass and Energy balance
11. Section wise Screen shot of SCADA 14. Calibration records of all weighing and
from CCR/DCS is to be included in the measurement system with frequency of
verification report calibration to be included in the verification
12. Raw material input in the Plant boundary report
to be recorded for inclusion in the 15. Clinker Factor Verification
verification report The Clinker factor calculation is to
13. Heat balance of Kilns (Kiln wise)for the be documented and produced in the
assessment year is required to be included verification report, the verification could
in the verification report with boundary be done by taking following factor into
and understanding on CV basis i.e., NCV account from the pro-forma A1-A20
or GCV of fuel
Table 19: Clinker Factor calculation
Item Unit Year1 Year2 Year3 Year 4 Remarks
Gypsum % in Cement %
Clinker used for PPC tonne
Clinker used for OPC tonne
Clinker used for PSC tonne
Clinker Used for Cement tonne
Gypsum used in OPC tonne
Gypsum used in PPC tonne
Gypsum used in PSC tonne
Clinker factor for PPC factor
Clinker Factor for OPC factor
Clinker Factor for PSC factor
16. Establishment of clear inclusion and 17. Some of the factors, which are not covered
exclusion from the plant boundary is in the cement sector pro-forma, the
maintained as in the baseline year. EmAEA is required to report it separately
2. Material balance of all inputs at battery (i) One month having best operation
limit of entire complex as per TOP.
Following information is to be filled-in as (ii) For financial year, as per TOP.
follows:-
Sr. No. Description Unit Illustrative figures Actual for 2014-15 Remarks
1.0 Overall plant battery limit
1.1 Inputs
1.1.1 Natural gas ( NG)
a Quantity MMSCM
b NCV of NG Kcal/SCM
1.1.2 Naphtha
a Quantity kl
Total Energy /
feed Input Plant Fuel: 69 MM SCM Power Export
CPP & HRU (Colony+ GAIL)
6.4MkWh
Steam0.0 MT
1211950 MT
82346 MT
102 MkWh
62.15MkWh
1129604 MT
Feed: 485 KL
NG
7.0 MkWh
Urea
752 MM SCM,
1230715 MT
NCV: 8412 Urea Plant
Ammonia
Kcal/SCM
Feed: 490 MM SCMPlant
Ammonia
Naphtha 702170 MT
Ammonia Ammonia Import
701574 MT
4352 KL
596 MT
NCV:
7466Kcal/L
Fuel: 3867 KL
Fuel:193 MM SCM
Service Boiler Other Utilities
Figure 16: Overall Material and Energy balance. Figures mentioned above are indicative and used for representational purpose only . The
actual data will Figure
vary from unit toMaterial
16: Overall unit . and Energy balaance
b. Specific energy consumption (SEC) for three baseline years i.e. 2007-08, 08-09,
Baseline specific energy consumption (SEC) 09-10. Specific energy consumption (SEC)
of urea is obtained by weighted average during target year (2014-15) is reported in
the following table.
10. Normalization factors (i) Forced shut down of the plant and
subsequent Cold start up
PAT procedure provides for “Normalization” (ii) List of critical equipment, which on failure,
of reported data based on capacity utilization cause forced shut down.
factor, when plant load factor (PLF) has a
deviation of more than 30%. The PAT procedure (iii) Plant operation at low load
also provides for normalization by statistical (iv) Reduction of ammonia synthesis and CO
analysis methods. In fertilizer sector, apart shift catalyst
from capacity utilization, there are some other
(vi) Use of naphtha due to non-availability of
important factors viz. number of forced shut
gas
down of the plant, use of naphtha due to
unavailability of natural gas, quality of coal (vi) Deterioration in quality of coal
and commissioning period after major revamp For calculating the unproductive energy
of the plant, which also affect specific energy consumption against individual factor,
consumption of product. Identified causes of formats were developed showing
un-productive energy consumption on account illustrative calculations.
of factors, which are beyond the control of the
plant are as follows:
Sr. No. Best operating Ammonia CU Urea CU SEC SEC Urea Reference
month production production Ammonia
MT % MT % Gcal/ MT Gcal/ MT
(i) Take the month in which , plants have 11. Utility boiler furnace
run for all the calendar days. 12. Gas turbine/HRSG
(ii) Capacity utilization during the month 13. Cooling Tower
should be equal to or above 100%.
14. Major Fire leading to complete
b. Cold startup of the plant after forced shut shutdown of plant and cold
down startup
In case of sudden failure of a critical 15. Turbo generator along with GTG
equipment as per the list below, or external
16. Purifier
factors (as notified), ammonia plant
undergoes a forced shut down. Restarting 17. CO Shift Converter
the plant from cold conditions (Cold start B. The Designated Consumer (DC) shall
up) , consumes unproductive energy and furnished a detailed report on failure of
shall be normalized. such equipment and its impact on energy
i. Pre-requisites for Normalization consumption.
A. The list of critical equipment failure C. The Designated Consumer shall declare
of which leads to complete shutdown with back up documentation, what portion
of plant and consequent cold start of such unproductive consumption during
up, allowed under this normalization the month is due to cold shutdown and
factor is given below :- startup activity.
1. Primary Reformer D. This actual energy loss due to shut down
and cold startup in Gcal/MT of Urea shall
2. Secondary Reformer
be compensated, subject to maximum of
3. Heat Exchange Reformer 0.03 Gcal/MT of Urea.
4. Reformed Gas Boiler ii. Calculation of normalization factor
5. Carbon dioxide absorber and A. Energy loss during the month(s) for
stripper which additional cold startup is being
6. Air, Refrigeration and synthesis claimed shall be calculated as follows:-
compressors (i) (Monthly Energy per MT of
7. Synthesis converters Ammonia during the month–
Weighted Average Monthly
8. Synthesis Gas Waste Heat Boilers Energy Consumption for the
9. High pressure urea reactor, months with 100% on-stream
stripper and carbamate condenser days) X Monthly Ammonia
production for the month of
10. Carbon dioxide compressor
Startup.
iii. Documentation
iii. Documentation
Figure 17: Ex- GtG boundary for Aluminium (Refinery sub sector)
B. Smelter forma
13. Carbon Anode to Molten Aluminium 15. The additional cast house product shall be
ratio: The DC has to provide necessary converted into one product and inserted in
document to EmAEA during M & V. the Product “other” details in pro-forma
Approximately 0.45 kilograms of carbon 16. The energy used in smelter for imported
anode were needed to produce one scrap/ cold metal for production of finished
kilogram of aluminum products shall be considered for product
14. The smelter Energy consumption shall be equivalent hot metal SEC calculation
taken up to Molten Alumina in the pro-
Table 23: Section wise Energy Consumption details
S.No Section Thermal Energy Electrical Energy kWh/tone of kWh/tone of Remarks
Consumption Consumption Anode Aluminium
1 Pitch
2 Coke
3 Baking
Figure 18: Ex- GtG boundary for Aluminium (Smelter sub sector)
Figure 19: Ex- GtG boundary for Aluminium (Cold Sheet sub sector)
7.6. Annexure VI: Pulp & Paper plant caters to two or more DCs for the
electricity and/or steam requirements. In
1. The boundary can be drawn virtually by such scenario, each DC shall consider such
including CPP or Cogen in the boundary captive power plant or cogeneration plant
limit of DCs, if nos DCs exist in a same in its boundary and energy consumed by
boundary limit. such captive power plant or cogeneration
2. The captive power plant (CPP) or cogen plant shall be included in the total energy
will be taken into the virtual boundary consumption. However, electricity in
of each DCs and accordingly import and terms of calorific value (as per actual heat
export of power and steam will be treated rate) and steam in terms of calorific value
as per Pro-forma data entry system. (as per steam enthalpy) exported to other
plants shall be subtracted from the total
3. If a captive power plant or cogeneration energy consumption.
Table 25: General details required in wood based Pulp and Paper Mills
A.2 Wood Pulp Mill (Including Raw material, Chipper , Digester , WSC, ODL , Bleach Plant,
Recovery , WTP, and ETP)
A.3 The Information required is shown in the Flow Chart for Wood Based Pulp and Paper Mill
Saleable
Pulp (6)
MP Steam Header(4)
MP LP
Steam Steam
Generator
Fuel (2)/(5) Power Boiler
Turbine
~ Own Power
(3)
Figure 20: Ex- GtG boundary and metering details for Wood based Pulp and Paper Mill
S.No. Details of input Source / Type of Details of the Source / document and frequency
and output document required
1 Raw Materials Lab Report Report on moisture(%), Ash (%) and other analysis of the
raw materials used by the mill
Frequency: Daily/ weekly/ monthly/ annual lab reports
may be produced for different types of raw materials
used by the mills.
Purchase Document From Purchase documents providing details of raw material
Purchase Department purchased by the mill
Frequency: Daily/ weekly/ monthly/ annual purchase
documents may be produced for purchase of different
types of raw materials used by the mills
Raw Material Consumption Consumption reports giving details of raw material
Reports consumed by the mill. The report may be for raw
material chip production, digester loading etc. from the
concerned department.
Frequency: Daily/ weekly/ monthly/ annual
consumption documents may be produced for different
types of raw materials used by the mill in chipper /
digesters house..
Annual Report Annual report showing details of raw materials
consumed on annual basis by the mill.
Frequency: Annual consumption of raw materials by the
mill.
2 Purchased Fuels Fuel Purchase report/ Purchase documents providing details of fuel purchased
documents by the mill.
Frequency: Daily/ weekly/ monthly/ annual purchase
documents may be produced for purchase of different
types of fuels used by the mills.
Lab report for GCV Lab report on GCV, moisture(%), Ash (%) and other
moisture and Ash analysis (proximate and ultimate) density etc, of the fuel
used by mill.
Frequency: Daily/ weekly/ monthly/ annual lab reports
may be produced for different types of fuels used by the
mills.
Fuel Consumption Report Consumption reports giving details of fuel consumed by
the mill in boilers, DG sets etc. The consumption report
may be from the concerned department showing details
of fuel consumption.
Frequency: Daily/ weekly/ monthly/ annual fuel
consumption documents may be produced for different
types of fuels used by the mill in boiler/DG sets etc.
Annual Report Annual report showing details of fuels consumed on
annual basis by the mill.
Frequency: Annual consumption of fuels by the mill.
B.3 AgroPulp Mill (Including Raw material, Pulper, Digester , WSC, ODL , Recovery, Bleach
Plant, WTP, and ETP)
Type of pulping Capacity t/a Production t/a Total Yield (Including Source /
screening losses) Document
Chemical
Semi Chemical
Chemi Thermo Mechanical
Other
v) Bleaching
v) Pulp Dryer
B.5 The Information required is shown in the Flow Chart for Agro Based Pulp and Paper Mill
Figure 21: Ex- GtG boundary and metering details for Agro based Pulp and Paper Mill
Saleable
Pulp (6)
MP Steam Header(4)
MP LP
Steam Steam
Generator
Fuel (2)/(5) Power Boiler
Turbine
~ Own Power
(3)
S.No. Details of input Source / Type of Details of the Source / document and frequency
and output document required
1 Raw Materials Lab Report Report on moisture(%), Ash (%) and other analysis of the
raw materials used by the mill
Frequency: Daily/ weekly/ monthly/ annual lab reports
may be produced for different types of raw materials
used by the mills.
Purchase Document From Purchase documents providing details of raw material
Purchase Department purchased by the mill
Frequency: Daily/ weekly/ monthly/ annual purchase
documents may be produced for purchase of different
types of raw materials used by the mills
Raw Material Consumption Consumption reports giving details of raw material
Reports consumed by the mill. The report may be for raw
material chip production, digester loading etc. from the
concerned department.
Frequency: Daily/ weekly/ monthly/ annual
consumption documents may be produced for different
types of raw materials used by the mill in chipper /
digesters house..
Annual Report Annual report showing details of raw materials
consumed on annual basis by the mill.
Frequency: Annual consumption of raw materials by the
mill.
2 Purchased Fuels Fuel Purchase report / Purchase documents providing details of fuel purchased
documents by the mill.
Frequency: Daily/ weekly/ monthly/ annual purchase
documents may be produced for purchase of different
types of fuels used by the mills.
Lab report for GCV Lab report on GCV, moisture(%), Ash (%) and other
moisture and Ash analysis (proximate and ultimate) density etc, of the fuel
used by mill.
Frequency: Daily/ weekly/ monthly/ annual lab reports
may be produced for different types of fuels used by the
mills.
Fuel Consumption Report Consumption reports giving details of fuel consumed by
the mill in boilers, DG sets etc. The consumption report
may be from the concerned department showing details
of fuel consumption.
Frequency: Daily/ weekly/ monthly/ annual fuel
consumption documents may be produced for different
types of fuels used by the mill in boiler/DG sets etc.
Annual Report Annual report showing details of fuels consumed on
annual basis by the mill.
Frequency: Annual consumption of fuels by the mill.
Lab reports for GCV, solids, Lab report on GCV, solids (%) moisture(%), Ash (%) and
moisture, ash etc. other analysis (proximate) of the Black liquor, pith, dust
etc. used by the mill.
Frequency: Daily/ weekly/ monthly/ annual lab reports
may be produced for different types of Black liquor, pith,
dust etc. used by the mill.
6 Saleable Pulp Opening and closing stock Documents providing details of opening and closing of
of saleable pulp saleable pulp records by the mill.
Frequency: Daily/ weekly/ monthly/ annual opening
and closing records of the saleable pulp stock may be
produced for different types of pulps produced by the
mill.
7 Uncoated paper / Opening and closing stock Documents/ records providing details of opening and
board, Newsprint , reports closing of Uncoated paper / board, Newsprint , Specialty
Specialty grade grade paper products by the mill.
Frequency: Daily/ weekly/ monthly/ annual opening
and closing records of Uncoated paper / board,
Newsprint , Specialty grade paper products, produced
by the mill.
8 Coated Paper / Opening and closing stock Documents/ records providing details of opening and
board reports closing of Coated Paper / board by the mill.
Frequency: Daily/ weekly/ monthly/ annual opening
and closing records of Coated Paper / board, produced
by the mill.
a. The auditor may collect details required in M&V format) by mentioning the source and
document from where data is collected. Subsequently the data may be verified from the, data
provided by the DC in pro-froma for normalization.
b. The information required is shown in the flow chart for RCF based pulp and paper mill.
c. List of documents required for various monitoring and verification
A.2 RCF Pulp Mill (Including Pulper, Pulp Cleaning and Screening, Deinking, Bleaching, WTP,
and ETP)
i) Pulper / Pulp Cleaning and Screening Process Used
iii) Refining
A.4 The Information required is shown in the Flow Chart for RCF Based Pulp and Paper Mill
S.No. Details of input Source / Type of Details of the Source / document and frequency
and output document required
1 Raw Materials Lab Report Report on moisture(%), Ash (%) and other analysis of the
raw materials used by the mill
Frequency: Daily/ weekly/ monthly/ annual lab reports
may be produced for different types of raw materials
used by the mills.
Purchase Document From Purchase documents providing details of raw material
Purchase Department purchased by the mill
Frequency: Daily/ weekly/ monthly/ annual purchase
documents may be produced for purchase of different
types of raw materials used by the mills
Raw Material Consumption Consumption reports giving details of raw material
Reports consumed by the mill. The report may be for raw
material chip production, digester loading etc. from the
concerned department.
Frequency: Daily/ weekly/ monthly/ annual
consumption documents may be produced for different
types of raw materials used by the mill in chipper /
digesters house..
Annual Report Annual report showing details of raw materials
consumed on annual basis by the mill.
Frequency: Annual consumption of raw materials by the
mill.
2 Purchased Fuels Fuel Purchase report / Purchase documents providing details of fuel purchased
documents by the mill.
Frequency: Daily/ weekly/ monthly/ annual purchase
documents may be produced for purchase of different
types of fuels used by the mills.
Lab report for GCV Lab report on GCV, moisture(%), Ash (%) and other
moisture and Ash analysis (proximate and ultimate) density etc, of the fuel
used by mill.
Frequency: Daily/ weekly/ monthly/ annual lab reports
may be produced for different types of fuels used by the
mills.
Fuel Consumption Report Consumption reports giving details of fuel consumed by
the mill in boilers, DG sets etc. The consumption report
may be from the concerned department showing details
of fuel consumption.
Frequency: Daily/ weekly/ monthly/ annual fuel
consumption documents may be produced for different
types of fuels used by the mill in boiler/DG sets etc.
Annual Report Annual report showing details of fuels consumed on
annual basis by the mill.
Frequency: Annual consumption of fuels by the mill.
Figure 23: Ex- GtG boundary for Textile ( Composite/ Processing sub sector)
b. The Products and sections are e. Fuel used as raw material should not
different in Fiber sub-sector, hence be considered from the input energy
the Pro-forma of the subsector specify and reported in the verification report
the major product and other Products by EmAEA
from 1-5. f. DC has to submit weighted average
c. EmAEA to specify the product details denier value for their products. Plant
with sectional Process Flow Diagram has to submit production value in
in the verification report. single denier by converting all the
denier value
i. Steam Balance Diagram of the Plant j. Product wise, sectional (Sub Process)
from Steam generation to Steam yearlyThermal and Electrical Energy
consumption is required to be included details is required as per following
in the verification report sample table for Product 1
For all practical and legal purposes in connection with M&V guidelines, the English version of the notified PAT
rules 2012 and EC Act 2001 will be considered as final.