Energy Audit and Management Chapter 02

CHAPTER 02
ENERGY AUDIT
2.1 Definition
Energy Audit is the key to a systematic approach for decision-making in the area of
energy management. It attempts to balance the total energy inputs with its use, and serves to
identify all the energy streams in a facility. It quantifies energy usage according to its discrete
functions. Industrial energy audit is an effective tool in defining and pursuing comprehensive
energy management programme.
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 containing recommendations for improving energy efficiency with cost benefit analysis
and an action plan to reduce energy consumption"
Energy audit means, monitoring the energy of different equipment and process in
plant and looking into way by which the total sum of energy consumed can be cut down
without affecting production.

2.2 Need of Energy Audit

In any industry, the three top operating expenses are often found to be energy (both
electrical and thermal), labour and materials. If one were to relate to the manageability of the
cost or potential cost savings in each of the above components, energy would invariably
emerge as a top ranker, and thus energy management function constitutes a strategic area for
cost reduction. Energy Audit will help to understand more about the ways energy and fuel are
used in any industry, and help in identifying the areas where waste can occur and where
scope for improvement exists.
The Energy Audit would give a positive orientation to the energy cost reduction,
preventive maintenance and quality control programmes which are vital for production and
utility activities. Such an audit programme will help to keep focus on variations which occur
in the energy costs, availability and reliability of supply of energy, decide on appropriate
energy mix, identify energy conservation technologies, retrofit for energy conservation
equipment etc.
In general, Energy Audit is the translation of conservation ideas into realities, by lending
technically feasible solutions with economic and other organizational considerations within a
specified time frame.
The 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

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“bench-mark" (Reference point) for managing energy in the organization and also provides
the basis for planning a more effective use of energy throughout the organization.
2.3 Scope of Energy Audit
Energy audit includes:
1. Monitoring energy consumptions
2. Considering possibility of savings.
3. Recommending appropriate policies for bringing down energy consumption.
4. Possibility of avoiding losses
5. Detailed analysis of present consumption and past trends.
6. Reviewing lighting requirements.
7. Check capacities and efficiencies of equipment.
8. Check working of controls like Fire alarms etc.
9. Compare standard consumption to actual.
10. Need for publicity campaigns.
11. Examine need of automatic controls.
2.4 Type of Energy Audit
The type of Energy Audit to be performed depends on:
- Function and type of industry.
- Depth to which final audit is needed.
- Type of fuel/energy is being used.
- Potential and magnitude of cost reduction desired and
- Investment and time availability
Thus Energy Audit can be classified into the following two types.
i) Preliminary Audit
ii) Detailed Audit
2.5 Preliminary Audit
Preliminary energy audit is a relatively quick exercise to:
Establish energy consumption in the organization
Estimate the scope for saving
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

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2.6 Detailed Audit

A comprehensive audit provides a detailed energy project implementation plan for a
facility, since it evaluates all major energy using systems.
This type of audit offers the most accurate estimate of energy savings and cost. It
considers the interactive effects of all projects, accounts for the energy use of all major
equipment, and includes detailed energy cost saving calculations and project cost.
In a comprehensive audit, one of the key elements is the energy balance. This is based on
an inventory of energy using systems, assumptions of current operating conditions and
calculations of energy use. This estimated use is then compared to utility bill charges.
Detailed energy auditing is carried out in three phases: Phase I, II and III.
Phase I - Pre Audit Phase
Phase II - Audit Phase
Phase III - Post Audit Phase

2.7 Procedure for Carrying Out Energy Audit

Industry-to-industry, the methodology of Energy Audits needs to be flexible.
A comprehensive ten-step methodology for conduct of Energy Audit at field level is
presented below.

Step Plan of Action Purpose / Result

Phase 1- Pre Audit Phase

Step 1:  Plan and organise  Resources planning, Establish/ organize a

 Walk through Audit Energy audit team
 Informal interview with energy  Organize instrument & time frame
manager, production/ plant manager  Macro data collection (suitable to type of
industry.)
 Familiarization of process/ plant activities
 First hand observation & assessment of
current level operation and practices.
Step 2:  Conduct of brief meeting/ awareness  Building up cooperation
programme with all divisional head  Issue questionnaire for each department
and persons concerned (2-3 Hrs.)  Orientation, awareness creation

Phase 2- Audit Phase

Step 3:  Primary data gathering, Process flow  Historic data analysis, Baseline data
diagram & energy utility diagram. collection

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 Prepare process flow chart

 All service utilities system diagram
 Design, operating data and schedule of
operation
 Annual energy bill and energy
consumption pattern.
Step 4:  Conduct survey and monitoring  Measurement:
 Motor survey, Insulation and Lighting
survey with portable instrument for
collection of more and accurate data.
Confirm and compare operating data with
design data.
 Step 5:  Conduct of detailed trials/ experiments  Trials/ experiments:
for selected energy guzzlers - 24 hrs power monitoring (PF, kWh etc.)
- Load variation trends in pumps, fan,
compressor etc.
- Boiler efficiency trials
- Furnace efficiency trials
- Equipment performance experiments etc.
Step 6:  Analysis of energy use.  Energy and material balance & energy
loss/ waste analysis
Step 7:  Identification and development of  Identification and consolidation ENCON
Energy conservation opportunities measure.
(ENCON).  Conceive, develop and 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.
Step 8:  Cost benefit analysis  Assess technical feasibility, economic
viability and prioritization of ENCON
options for implementation

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 Select the most promising projects.

 Priorities by low, medium, long term
measures
Step 9:  Reporting & presentation to the top  Documentation, Report presentation to the
management top management.
Phase 3- Post Audit Phase
Step10:  Implementation and Follow up.  Assist and implement ENCON
recommendation measure and monitor the
performance
 Action plan, schedule for implementation
 Follow-up and periodic review

2.8 Instrument used for Energy Audit

The requirement for an energy audit such as identification and quantification of energy
necessitates measurements; these measurements require the use of instruments. These
instruments must be portable, durable, easy to operate and relatively inexpensive. The
parameters generally monitored during energy audit may include the following:
Basic Electrical Parameters in AC &DC systems - Voltage (V), Current (I), Power factor,
Active power (kW), apparent power (demand) (kVA), Reactive power (kVAr), Energy
consumption (kWh), Frequency (Hz), Harmonics, etc.
Parameters of importance other than electrical such as temperature & heat flow, radiation,
air and gas flow, liquid flow, revolutions per minute (RPM), air velocity, noise and vibration,
dust concentration, Total Dissolved Solids (TDS), pH, moisture content, relative humidity,
flue gas analysis - CO2, O2, CO, SOx, NOx, combustion efficiency etc.

Key instruments for energy audit are listed below.

The operating instructions for all instruments must be understood and staff should familiarize
themselves with the instruments and their operation prior to actual audit use.

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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 specified
intervals.

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 Thermometer:
This is a non-contact type measurement
which when directed at a heat source
directly gives the temperature read out.
This instrument is useful for measuring
hot spots in furnaces, surface temperatures
etc.

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Combustion analyzer:
This instrument has in-built chemical cells
which measure various gases such as O2,
CO, NOX and SOX.

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. A
separate fyrite can be used for O2 and
CO2 measurement.

Pitot Tube and manometer:

Air velocity in ducts can be measured
using
a pitot tube and inclined manometer for
further calculation of flows.

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Water flow meter:

This non-contact flow measuring device
using Doppler effect / Ultra sonic
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.

Speed Measurements:
In any audit exercise speed measurements
are critical as they 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.
Leak Detectors:
Ultrasonic instruments are available
which can be used to detect leaks of
compressed air and other gases which are
normally not possible to detect 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

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2.9 Content in Energy Audit Report

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• The following Worksheets can be used as guidance for energy audit assessment and
reporting.

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2.10 Format of Recommendation in Energy Conservation

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2.11 Data Analysis- Energy-Production Relationship

Analysis is a correlation of energy consumption to a measured output (Production
quantity). The energy used by any business varies with production processes, volume and
input. Electricity bills and other fuel bills should be collected periodically and analysed as
below.

A typical format for monitoring plant level information is given below in the Table.

All the fuels purchased by the plant should be converted into common units such as kCal.

After conversion to a common unit, a pie chart can be drawn showing the percentage
distribution of energy consumption

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Figure: %Share of Fuels Based on Consumption in kCals

After collection of energy consumption, energy cost and production data, the next stage
of the monitoring process is to study and analyse the data to understand what is happening in
the plant.
The energy data is then entered into a spreadsheet. It is hard to envisage what is
happening from plain data, so we need to present the data using bar chart.

Figure: Energy Consumption: Current Year (2000) Vs. Previous Year (1999)

Figure: Moving Annual Total - Energy and Production

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2.12 Specific Energy Consumption

It is defined as, Energy consumption per unit of production. Let‟s see the plot of chart
of SEC

Figure: Monthly Specific Energy Consumption

Figure: SEC with Production

• Level of production may have an effect on the specific consumption.
• If we add the production data to the SEC chart, it helps to explain some of the feature.
• For example, the very low SEC occurred when there was a record level of production.
• This indicated that there might be fixed energy consumption- i.e. consumptions that occur
regardless of production levels.
• Energy consumed for the period = C + M x Production for same period
• Where, M – Energy consumption directly related to production (variable)
• C – Fixed energy consumption (i.e. energy consumed for lighting, heating/ cooling and
general ancillary services that are not affected by production levels).

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2.13 Sankey Diagram

The Sankey diagram is very useful tool to represent an entire input and output energy
flow in any energy equipment or system such as boiler, fired heaters, furnaces after carrying
out energy balance calculation.
This diagram represents visually various outputs and losses so that energy managers can
focus on finding improvements in a prioritized manner.

• A specific type of flow diagram, in which the width of the arrows is shown
proportionally to the flow quantity.
• Used to visualize energy or material or cost transfers between processes.
Examples of Sankey diagrams

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2.14 CUSUM Technique

Cumulative Sum (CUSUM) represents the difference between the base line (expected or
standard consumption) and the actual consumption points over the base line period of time.
This useful technique not only provides a trend line, it also calculates savings/losses to date
and shows when the performance changes.
A typical CUSUM graph follows a trend and shows the random fluctuation of energy
consumption and should oscillate around zero (standard or expected consumption). This
trend will continue until something happens to alter the pattern of consumption such as the
effect of an energy saving measure or, conversely, a worsening in energy efficiency (poor
control, housekeeping or maintenance).

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Figure: CUSUM Chart

From the chart, it can be seen that starting from year 2000, performance is better than
standard. Performance then declined (line going up) until April, and then it started to improve
until July. However, from July onwards, there is a marked, ongoing decline in performance –
line going up.

Case Study:
Energy consumption and production data were collected for a plant over a period of 18
months. During month 9, a heat recovery system was installed. Using the plant monthly data,
estimate the savings made with the heat recovery system. The plant data is given in Table

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Steps for CUSUM analysis

1. Plot the Energy - Production graph for the first 9 months

Figure: Energy Production Graph

2. Draw the best fit straight line
3. Derive the equation of the line
The above steps are completed in Figure, the equation derived is
E = 0.4 P + 180
4. Calculate the expected energy consumption based on the equation
5. Calculate the difference between actual and calculated energy use
6. Compute CUSUM

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7. Plot the CUSUM graph

8. Estimate the savings accumulated from use of the heat recovery system.

Figure: Example of CUSUM Graph

• From the above Figure, it can be seen that the CUSUM graph oscillates around the zero
line for several months and then drops sharply after month 11.

• This suggests that the heat recovery system took almost two months to commission and
reach proper operating conditions, after which steady savings have been achieved.

• Based on the above graph (see Table), savings of 44 toe (50-6) have been accumulated in
the last 7 months. This represents savings of almost 2% of energy consumption.

x 100 = 1.8%

…………………………………………………………………………………………………

Question from University Question Paper.

1. What are the stages in energy audit? Explain
2.Explain different instruments used for energy audit with its use.
3.Write short notes on “CUSUM Technique”
4.Explain importance of Sankey diagram with certain example.
5. Explain the difference between „energy consumption‟ & „specific energy consumption‟

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