ENERGY AUDIT

Darshan Vithani ,Pranav Pathak

ME-CSE

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 ENERGY AUDIT (EA)
 pool of activities (systematic procedure) focused on
analysis of current energy need and consumption
going out of valid technical standards,
 analysis of problems (weaknesses and deficiencies),
 EA identifies and in detail quantifies effective
possibilities of energy savings tailored to the object
being analyzed,

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 AIM OF ENERGY AUDIT
to minimize costs for energy
to minimize operational costs
to minimize costs for repairs
and reconstruction
increase quality of environment that
contributes to increased work productivity

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 AIM OF ENERGY AUDIT
to minimize costs for energy
to minimize operational costs
to minimize costs for repairs
and reconstruction
increase quality of environment that
contributes to increased work productivity

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 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, and
- Potential and magnitude of cost reduction desired
 Thus Energy Audit can be classified into the following two
types.
i) Preliminary Audit
ii) Detailed Audit

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 PRELIMINARY ENERGY AUDIT METHODOLOGY
 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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 DETAILED ENERGY AUDIT METHODOLOGY
 It is offers most accurate estimate of energy savings and cost
 This is based on an inventory of energy using systems,
assumptions of current operating conditions and calculations
of energy use.
 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

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Steps For DETAILED ENERGY AUDIT METHODOLOGY

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Steps For DETAILED ENERGY AUDIT METHODOLOGY

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Steps For DETAILED ENERGY AUDIT METHODOLOGY

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Steps For DETAILED ENERGY AUDIT METHODOLOGY

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Steps For DETAILED ENERGY AUDIT METHODOLOGY

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Steps For DETAILED ENERGY AUDIT METHODOLOGY

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 AREAS OF ENERGY AUDIT
Subject of energy consumption analysis are energy resources
consumed in the industrial area, i.e.

 Electricity
 Natural gas
 Steam
 Coal
 Wood, wood chips/pellets
 Fuels (petrol, oil, propane-butane).....

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 AREAS OF ENERGY AUDIT
• thermal-technical protection of buildings,
• heating systems
• hot water preparation,
• ventilation systems and air-conditioning (buildings and technology)
• electric appliances (administrative and technological incl. electrical
connection, transformation, distribution network, el. switchboards, el.
compensation)
• gas or other energy resources consuming appliances (furnaces, cleaning
devices,..)
• Indoor/outdoor lighting,
• measurement and regulation.

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 ENERGY AUDIT METHODOLOGY

 Pre-audit presentation.

 Collection of data / information.

 Measurements and monitoring with instruments.

 Computation and in-depth analysis.

 Post-audit presentation to discuss the Energy Conservation

Opportunities identified by the audit team.

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 INSTRUMENTS USED
 Flue Gas Analyzer

 Power Analyzer, Tachometer

 Ultrasonic Flow Meter

 Trap Man (For Steam Trap Survey)

 Raytech Gun & Digital Thermometer (Non-contact and Contact type

both)

 Anemometer, pH/TDS/Conductivity meter

 LUX Meter, Digital Manometer

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 Case Study

Energy Audit at Mother Dairy

(Milk Plant)

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 BASE LINE DATA
Product
Capacity of the plant
Annual Fuel / Energy Consumption
Annual Energy Bill
Compressed Air generation
Steam Consumption
Bulk Processed Milk (Toned, Double Toned
& Full Cream)
8 Lac liters of Milk per day
PNG: 17,76,000 SCM
Worth: Rs 3.7 Crores
Electricity: 134.6 Lac kVAh
Worth: Rs 6.68 Crores
Rs 10.38 Crores
180 cfm
65,000 kg/month for Milk Plant
15,000 kg/month for Ice Cream Plant

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 Summary of Savings Identified & Realized
(Year 2003 & 2004)
Total Savings projected by Electricity: 21,43,360 kVAh Worth: Rs 78.24 Lac
PCRA LDO: 184.31 KL Worth: 85.8 Lac

Total Savings Realised till Electricity: 5,21,017 kVAh Worth: Rs 19.02 Lac
date LDO: 130.06 KL Worth: Rs 60.55 Lac

% Savings Realised of total Electricity: 3.7%

energy consumption LDO: 20.3%
 Major recommendations implemented:
1. Boiler fuel switched over to PNG from LDO
2. Steam supplied to ICP from this boiler
3. Improvement of Power Factor from 0.9 to 0.996
4. New air compressor installed lowering SEC
5. Installation of Auto Blow Down system for Boiler

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 Summary of Savings Identified
(Year 2005)
Total savings identified Electricity: 7,17,004 kVAh
PNG: 1,36,042 SCM
Worth: Rs 59.18 Lac
No cost savings with immediate Electricity: 95,308 kVAh
payback Worth: Rs 4.1 Lac
Low cost savings with payback < 1 Electricity: 5,41,796 kVAh
year Worth: Rs 23.3 Lac
High cost savings with payback Electricity: 79,900 kVAh
between 1-2 years Worth: Rs 3.44 Lac
Gas: 1,36,042 SCM
Worth: Rs 28.34 Lac
% savings identified of total energy Electricity: 5.32%
consumption Gas: 7.66%

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 BOILERS
Observations:
1. Condensate recovery is not being done.
2. Feed water temperature presently is 50C.

Recommendations:
1. Recover condensate to raise feed water temperature to upto 85C
2. Install de-aerator head on feed water tank and recover condensate.
3. Install steam operated condensate recovery pump

Savings Estimated / year Investment Payback Period

Rs 28.34 Lac Rs 25 Lac 11 Months

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 Air Compressors
Observations:
1. Air leakage are about 26%.

Recommendations:
1. Plugging of air leakages

Savings Estimated / year Investment Payback Period

Rs 4.0 Lac Nominal Immediate

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 Illumination
Observations:
1. HPMV lamps are used for street lighting.
2. 36 Watt Tube lights with copper chokes are used.

Recommendations:
1. Replace HPMV lamps by HPSV lamps
2. Replace 36 Watt Tube lights with T-5 28 Watt with electronic choke in
a phased manner.

Savings Estimated / year Investment Payback Period

Rs 3.34 Lac Rs 4.0 Lac 16 Months

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Conclusion
The gaps may exist in design & actual operations for large complexes due
to integration of :

 Steam thermal systems.

 Electrical systems
 Process systems (Motive/ Thermal loads) due to variation in
efficiencies/ actual requirements
 Continuous monitoring and analysis of integrated systems is essential
for improvements.
 Energy Audits will identify such gaps.
 Implementation of recommendations will result into considerable
energy savings.

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Thank You
Darshan Vithani ,Pranav Pathak
ME-CSE

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