Energy Management

& Audit
7/23/2018

1
Energy Auditing Analysis
and Conservation

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 Definition of Energy
Management
“The judicious and effective use of energy to
maximize profits (minimize costs) and enhance
competitive positions”
“The strategy of adjusting and optimizing
energy, using systems and procedures so as
to reduce energy requirements per unit of
output while holding constant or reducing
total costs of producing the output from these
systems”
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Objectives of Energy
Management
 To achieve and maintain optimum
energy procurement and utilization,
through out the organization
 To minimize energy costs / waste
without affecting production & quality
 To minimize environmental
effects.

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 Definition of Energy Audit
 Energy Audit is defined as

the verification, monitoring and analysis of

use of energy including submission of
technical report containing
recommendations for improving energy
efficiency with cost benefit analysis and an
action plan to reduce energy consumption

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 Need for Energy Audit
 Three top operating expenses are energy
(both electrical and thermal), labour and
materials.
 Energy would emerge as a top ranker for cost
reduction
 primary objective of Energy Audit is to
determine ways to reduce energy
consumption per unit of product output or to
lower operating costs
 Energy Audit provides a “ bench-mark”
(Reference point) for managing energy in the
organization
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Types of Energy Audit

Preliminary energy audit

Detailed energy audit

Type of energy audit chosen

depends on
– Function and type of industry
– Depth to which final audit is needed
– Potential and magnitude of cost
reduction desired
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 Preliminary Energy Audit Methodology

Preliminary energy audit uses existing, or easily

obtained data Establish energy consumption in
the organization
Estimate the scope for saving
Identify the most likely areas for attention
Identify immediate ( no-/low-cost)
improvements
Set a ‘reference point’
Identify areas for more detailed
study/measurement

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 Detailed Energy Audit

Evaluates all energy using systems,

equipment and includes detailed
energy savings and costs

Carried out in 3 phases

– Pre-audit Phase
– Audit Phase
– Post-Audit

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 Ten Step Methodology of Detailed Audit
Step
PLAN OF ACTION PURPOSE / RESULTS
No
Phase I –Pre Audit Phase

Step 1  Plan and organise  Resource planning, Establish/organize a

 Walk through Audit Energy audit team
 Informal Interview with  Organize Instruments & time frame
Energy Manager, Production  Macro Data collection (suitable to type of
/ Plant Manager industry.)
 Familiarization of process/plant activities
 First hand observation & Assessment of
current level operation and practices

Step 2  Conduct of brief meeting /  Building up cooperation

awareness programme with  Issue questionnaire for each department
all divisional heads and  Orientation, awareness creation
persons concerned (2-3 hrs.)
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 Phase II –Audit Phase
Step 3  Primary data gathering,  Historic data analysis, Baseline data
Process Flow Diagram, & collection
Energy Utility Diagram  Prepare process flow charts
 All service utilities system diagram
(Example: Single line power distribution
diagram, water, compressed air & steam
distribution.
 Design, operating data and schedule of
operation
 Annual Energy Bill and energy consumption
pattern (Refer manual, log sheet, name plate,
interview)
Step 4  Conduct survey and  Measurements :
monitoring Motor survey, Insulation, and Lighting
survey with portable instruments for
collection of more and accurate data.
Confirm and compare operating data with
design data.

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 Step 5  Conduct of detailed trials  Trials/Experiments:
/experiments for selected - 24 hours power monitoring (MD, PF,
energy guzzlers kWh etc.).
- Load variations trends in pumps, fan
compressors etc.
- Boiler/Efficiency trials for (4 – 8
hours)
- Furnace Efficiency trials
Equipments Performance
experiments etc

Step6  Analysis of energy use  Energy and Material balance & energy
loss/waste analysis

Step 7  Identification and  Identification & Consolidation ENCON

development of Energy measures
Conservation (ENCON)  Conceive, develop, and refine ideas
opportunities  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
Step 8
 Cost 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 Documentation, Report Presentation to the top

the Top Management Management.

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Step10 Phase III –Post Audit phase

 Implementation and Follow- Assist and Implement ENCON recommendation

up measures and Monitor the performance
Action plan, Schedule for
implementation
Follow-up and periodic review

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Energy Audit Reporting Format

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 Energy
Audit
Reporting
Format

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Table 3.3 Types and priority of energy saving measures
Type of Energy Annual Annual
Saving Options Electricity Savings Priority
/Fuel savings
KWh/KL /T (Rs Lakhs)
A No Investment
(Immediate)
- Operational
Improvement
- Housekeeping
B Low Investment
(Short to
Medium Term)
- Controls
- Equipment
Modification
- Process change

C High Investment
(Long Term)
- Energy efficient
Devices
- Product
modification
- Technology
Change
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 Understanding energy costs
Typical summary of energy bill by a company
Table 3.4
Type of energy Original units Unit Cost Monthly Bill Rs.
Electricity 5,00,000 kWh Rs.4.00/kWh 20,00,000
Fuel oil 200,kL Rs.10,000 kL 20,00,000
Coal 1000 tons Rs.2,000/ton 20,00,000
Total 60,00,000

Conversion to common unit of energy

Electricity (1 kWh) = 860 kcal/kWh (0.0036 GJ)

Heavy fuel oil (calorific value, GCV) =10.000 kcal/litre ( 0.0411 GJ/litre)
Coal (calorific value, GCV) =4000 kcal/kg ( 28 GJ/ton)

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Benchmarking for energy
performance
• Internal Benchmarking
 Historical and trend analysis
• External Benchmarking
 Across similar industries
Scale of operation, vintage of technology,
raw material specification and quality
and product specification and quality
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 Bench Marking Energy
Performance
 Quantification of fixed and variable energy
consumption trends vis-à-vis production
levels
 Comparison of the industry energy
performance w.r.t. various production levels
(capacity utilization)
 Identification of best practices (based on the
external benchmarking data)
 Scope and margin available for energy
consumption and cost reduction
 Basis for monitoring and target setting
exercises
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 Benchmarking parameters

•Gross production related

e.g. kWh/MT clinker or cement produced (cement plant)
e.g. kWh/MT, kCal/kg, paper produced (Paper plant)
e.g. kCal/kWh Power produced (Heat rate of a power plant)
e.g. Million kilocals/MT Urea or Ammonia (Fertilizer plant)

•Equipment / utility related

e.g. kWh/ton of refrigeration (on Air conditioning plant)
e.g. % thermal efficiency of a boiler plant
e.g. kWh/NM3 of compressed air generated
e.g. kWh /litre in a diesel power generation plant.

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 Maximizing system efficiency

Eliminate steam leakages by trap

improvements
Maximise condensate recovery
Adopt combustion controls for
maximizing combustion efficiency
Replace pumps, fans, air compressors,
refrigeration compressors, boilers,
furnaces, heaters and other energy
conservation equipment, wherever
significant energy efficiency margins exist
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 Matching Energy Usage to
Requirement
 Mismatch between equipment capacity and
user requirement often leads to inefficiencies
due to part load operations, wastages etc
 Examples :
Eliminate throttling
Eliminate damper operations
Fan resizing for better efficiency.
Moderation of chilled water temperature for process
chilling needs

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 Optimizing Input Energy
Requirements

Shuffling of compressors to match needs.

Periodic review of insulation thickness
Identify potential for heat exchanger
networking and process integration.
Optimisation of transformer operation
with respect to load

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Fuel and Energy Substitution
Fuel substitution
 Natural gas is increasingly the fuel of choice as
fuel and feedstock in the fertilizer, petrochemicals,
power and sponge iron industries.
 Replacement of coal by coconut shells, rice
husk,etc
 Replacement of LDO by LSHS

Energy substitution
 Replacement of electric heaters by steam heaters
 Replacement of steam based hot water by solar
systems

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 Electrical Measuring Instruments:
These are instruments for measuring
major electrical parameters such as kVA,
kW, PF, Hertz, kvar, Amps and Volts. In
addition some of these instruments also
measure harmonics.

These instruments are applied on-line i.e

on running motors without any need to
stop the motor. Instant measurements
can be taken with hand-held meters,
while more advanced ones facilitates
cumulative readings with print outs at

Energy Audit
specified intervals.

Instruments Combustion analyzer:

This instrument has in-built chemical
cells which measure various gases such
as CO2, CO, NOX, SOX etc

Fuel Efficiency Monitor:

This measures Oxygen and temperature
of the flue gas. Calorific values of
common fuels are fed into the
microprocessor which calculates the
combustion efficiency.

Fyrite:

A hand bellow pump draws the flue gas

sample into the solution inside the fyrite.
A chemical reaction changes the liquid
volume revealing the amount of gas.
Percentage Oxygen or CO2 can be read
from the scale.

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 Contact thermometer:

These are thermocouples which measures

for example flue gas, hot air, hot water
temperatures by insertion of probe into
the stream.

For surface temperature a leaf type probe

is used with the same instrument.

Infrared Pyrometer: Energy Audit

This is a non-contact type measurement
which when directed at a heat source Instruments
directly gives the temperature read out.
Can be useful for measuring hot jobs in
furnaces, surface temperatures etc.

Pitot Tube and manometer:

Air velocity in ducts can be measured

using a pitot tube and inclined manometer
for further calculation of flows.

Ultrasonic flow meter:

This a non contact flow measuring device

using Doppler effect principle. There is a
transmitter and receiver which are
positioned on opposite sides of the pipe.
The meter directly gives the flow. Water
and other fluid flows can be easily
measured with this meter.

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 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 Tachometer Stroboscope

Instruments 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.

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