DOST Energy Audit and SETUP Program for MSMEs
Presented by: JULIUS CAESAR V. SICAT, Ph.D.
Dept. of Science and Technology (Philippines)
Energy Audit
- critical examination of a facility to improve energy efficiency and
productivity (identify areas of energy loss/ waste; recommend energy saving strategies/opportunities)
- verification, monitoring and analysis of energy use (including technical report with cost benefit analysis and action plan to reduce energy consumption)
Why do we need Energy Audit?
To set energy efficiency & conservation goals.
To identify areas where energy wastes can occur.
Relate energy consumption to production.
Improve process / equipment efficiencies.
Identify and recommend energy saving opportunities.
Flowchart on how Energy Audit Service is availed by SMEs
START Request Letter/Endorsement Approved
YES
NO Inform Client
Terms of Reference Select Experts
Deploy Experts
Conduct of ESO Report
Submission
Implement
Recommendations END
Scope of DOST Energy Audit Services
Boilers and Steam System
Electrical Motors
Lighting Systems
Refrigeration and Air Conditioning Systems
Kilns and Furnaces
Pumps and Fans
Air Compressors
Dryers
Generator Sets and Transformers
DOST Energy Audit Teams
ITDI Energy Audit Team
MIRDC Energy Audit Team
Regional Energy Audit Team with members from:
State Universities and Colleges
Private Higher Education Institutes
Consultants from private companies
DOST Regional Office
Thermal, Electrical & Lighting Energy Audit Equipment
Combustion analyzer
Infrared thermometer
Power meter/analyzer
Thermal scanner
Power data logger
Tachometer
Stroboscope
Light meter
Laser distance meter
Refrigeration & Air-conditioning Energy Audit Equipment
Thermo-hygrometer
Anemometer
Sling psychrometer
Ultrasonic flowmeter
Flashlight & tape
meters
Energy Audits Conducted by DOST-ITDI Energy Audit Team
Some Common Recommendations Made:
Lighting System
Regular cleaning of lamps and lighting fixtures
Replacement/Retrofits of 40W FL with 36W FL or 28W FL with electronic ballast
Replacement of 25W CFL with 8.8W LED lamps
Replacement of 210W Metal Halide lamps with 120W HFED lamps
Maximize daylighting, e.g. solar bulbs
Task lighting
Some Common Recommendations Made:
Refrigeration and Air-conditioning System
Regular cleaning/maintenance of evaporators, condensers and filters
Recharging/replacement with environment friendly refrigerant
Insulation of refrigerant suction line
Replacement of old/dilapidated units with high efficient units with high EER, e.g. inverter type ACU’s
Reduce heat loads, e.g. sun screens & shields, etc.
Regular checking of piping insulation for cracks or damage and repair promptly as needed, to prevent heat lost.
Some Common Recommendations Made:
Refrigeration and Air-conditioning System
Implementation of proper door management by reducing the duration of door openings.
Improvement of the defrosting schedule of the reefer vans as opposed to timed schedules.
Immediate replacement of the damaged door sealants to prevent air leakages.
Provision of cover/shading for the condenser unit exposed to direct sunlight and regular cleaning of the condensers, evaporators and filters of the STACUs and reefer vans.
Regular cleaning of condensers of reefer van and chilling tanks.
Some Common Recommendations Made:
Oven
Check gas leak.
Calibrate oven temperature gauge.
Minimize opening the oven during baking operation.
Regular monitoring of the LPG & diesel consumption of the equipment.
Use of more efficient oven more frequently oven more frequently &
optimization of the load of all ovens.
Regular preventive maintenance of the oven & its burner system, optimization of air to fuel ration of the diesel burner & use of waste heat to heat combustion air.
Energy Audit in MSMEs
A food manufacturing company in Laguna realized:
savings of about $11,230.00 within six months (Dec 2010-May 2011) with
improvements in their boilers and steam system.
savings of around 32 barrels of oil equivalent (boe).
reduction of greenhouse gas emission equivalent to 37 metric tons(MT) of CO2.
Energy Audit in MSMEs
A meat processing company in Pampanga realized:
savings of about $40,750.00 within six months (Sept. 2007-March 2008) with improvements in their refrigeration and air conditioning system.
saving of around 155 barrels of oil equivalent (boe).
reduction of greenhouse gas emission equivalent to 132 metric tons (MT) of CO2.
Classification of Energy Audits
43
4 12 6
4 6
3 4 5 5
16
23
Audits According to Type of Industry Food
Chemicals Cement Semiconductor Metals
Water Utility Rubber Automotive Ceramics Hotels & Malls Office & School Bldgs Others
57 65
9
Audits According to Industry Size
SME Large Gov't/Others
Energy Audits Conducted by DOST-ITDI Energy Audit Team
From year 2000 to 2015, a total of 213 detailed energy audits were conducted for 129 SME’s, 70 large companies and 14 other
establishments including government agencies.
Walk-through energy audits also conducted for 72 companies (1999- 2012).
Total potential annual savings amounted to about $4,303,646.82 /year.
Reduction of greenhouse gas emission equivalent to 14,056 metric tons(MT) of CO2.
Savings of around 12,284 barrels of oil equivalents(boe).
S
mallE
nterpriseT
echnologyU
pgradingP
rogramStrategy to
Enhance productivity and competitiveness of MSMEs through Technological innovations and
Upgrading of products and processes towards Progress and growth in the countryside.
Anchored on R.A. 6977 (amended by R.A. 8289) : Magna Carta for Small Enterprises:
“The State shall undertake to spur the growth and development of small and medium enterprises through out the country and thereby attain countryside industrialization”
Strategies to Support MSME’s
Technology Needs Assessment (TNA)
Access to and Acquisition of Appropriate Technology Innovation System Support (ISS) Funding Assistance
Acquiring Appropriate Equipment
Capacity Building and Technical Trainings
Consultancy and Technical Advisory Services
Product Development and Product Standards and Testing Packaging and Labeling
Information System
Priority Areas
Food Processing Furniture Gifts, Decors and Handicraft (GDH)
Health Products and Services Agriculture / Marine
Aquaculture/Forestry/Livestock
Metals & Engineering
ICT Halal Products
and Services Other Regional Priorities
How do technology innovations enhance competitiveness of assisted firms?
FIRMS
Technology Innovations:
Application of new technologies to improve production efficiency and product quality
Compliance to existing standards such as
cGMP/HACCP
Adoption of cost-
effective/environmentally-safe technologies
Continuous R&D on product and process resulting to product
expansion/diversification
Increased in Productivity
Improved product quality and marketability
Increased capability to serve wider market
Access to bigger market (domestic and international market)
Diversification of product lines and expansion
Inspiring stories of Innovative MSMEs in the Gift-Decors- Houseware (GDH) Sector
Arden Classic, Inc.
Mactan, Lapulapu City, Cebu
Technology Innovations:
Introduction of electroplating technology
Application of white metal casting technology
Reduced rejects and reworks from 10% to less than 3% of the production output
Increased production volume by 100%
Improved product quality
through controlled production of electroplated metal
components
Increase in sales by 30% after intervention
High flexibility on the design and quality enabling access to new markets
Inferior quality of outsourced plated
component parts resulting to rejects &
reworks
Inspiring stories of Innovative MSMEs in Furniture Sector
FAG Machine Shop and Services Corporation
Technology Innovations:
Introduction of Precision Engine Lathe Machine with Digital
Readout and Precision Bench Lathe Machine with Digital Readout
Productivity enhancement consultancy (MPEX)
Energy Audit
Introduction of CNC Vertical Machining
Expanded production capability and capacity supporting ship- building industry
Established a Computer
Numerically Controlled (CNCs) Machining Center.
Upgraded capability from
intermediate precision to high precision machining
Reduced cycle time by 50% in high precision machining
requirements.
Increased gross Income by 279%
Generated 60 additional employment (from 20 to 80)
Light Engineering and Metalworking Company
SETUP Accomplishments (2002-2015)
