Energy Auditing/Assessment

Energy Audit/Assessment
• First step in identification and implementation of various energy
efficiency opportunities in residential, commercial, institutional and
industrial facilities.
• The objective is to identify economical energy/cost saving measures
that do not adversely affect the quality of work/product and the
environmental consequences of the equipment and processes.
• Energy audit is a needed step in implementation of any detailed and
sizable energy efficiency project. Often there will be the need for
engineering design before implementation/ construction of the
project.
• The major impetus behind an energy audit is that the analysis of
energy consumption and identification of potential conservation
measures in facilities relate to various disciplines of engineering, that
are often beyond the expertise of one person or small engineering
firms.
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 Energy Audit

• For example, on the less complex end of energy consumers, in

the residential facilities, energy consumption depends on the
structure, windows and doors, lighting, HVAC and
refrigeration systems as well as cooking equipment.

• On the other end of the spectrum, in manufacturing facilities,

the energy consumption is very process-dependent and greatly
varies from facility to facility. Industrial facilities do not often
lend themselves to standard prescriptive energy efficiency
measures customarily used in residential, commercial and
institutional facilities.
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 Energy Audits
 Walk-through audit
 Detailed Audit or Investment Grade Audit (also called feasibility)
 An investment grade audit may be a comprehensive audit that is
intended to identify all energy efficiency opportunities in a facility, or
a more targeted audit which focuses on a specific piece of equipment
or process, e.g. lighting, a boiler, a drying process, compressed air
system.

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 Walk-through Audits
 Done by utility representatives or equipment
vendors

 In an ideal case a person or a team knowledgeable

in energy efficiency issues walks through the
facility along with a facility personnel and
identifies simple and standard energy efficiency
measures such as lighting replacement, light and
occupancy sensors, and high efficiency motors

 The measures may be reported to the facility

management with little substantiation and back-
up information

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 Walk Through Audit Common Tools

Clipboard
Flashlight
Camera
Light Meter
Screwdrivers
True RMS meter
Amp Meter.
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 Major Focus of Walk through Audits
 Lighting Systems
 Steam Systems
 Motors, Belts and Drives
 Refrigeration Systems
 Hydraulic Systems
 Fans and Pumps
 Compressed Air Systems
 Injection Molding or Extrusion
 Dryers

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 Lighting Systems
 Use binoculars to identify high bay lights
 Check with stockroom to identify type of light
 Light output is measured in lumens
 Lumens/watts is the ratio of the amount of light
produced per the energy input-Criteria for energy
 The amount of light available at a particular location is
measured in foot-candles by hand held meters

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 Lighting System
 Are lights on in unoccupied area?
 Is the exterior light on during the day?
 Manually turn off lights-simplest
 Although reliability depends on reliability of operator
 Install occupancy sensor or photoelectric sensors
 More reliable
 Applications (Pump houses, meeting rooms, bathrooms, warehouse,
storage area, street lights)
 Replace high Pressure sodium (HPS) lights in low use areas with
fluorescent lights for quick on and off control
 HPS cheaper for long running but warming up time for low use areas is an
issue
 Replace or maintain faulty controls

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 Lighting System
 Are existing lighting levels higher than the recommended levels?
 Use hand held meter to check light level
 Remove excessive lighting
 Reduce overall lighting and install task lighting

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 Motors, Belts and Drives

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 Motor, Belts and Drives

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 Motors, Belts and Drives
 Are standard efficiency motors installed?
 Replace motors with high efficiency motors

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 Motors, Belts and Drives

 Are standard drive belts (V-belts) installed?

 Notched V-belts
 High cost but increased life
 Reduce energy loss and frictional heat generation caused by compressing and
decompressing
 Are motors running during periods when the equipment or
process they are driving is idle?
 Reduce equipment operation time to minimum required
 Interlock equipment with related process
 Operate equipment such as a grinder in batches then shut off for
material collection
 Install timers, level sensors, material sensors, or other controls for
automatic operation and/or shut off equipment as required
 Safety must not be compromised in setting timers etc.

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 Motors, Belts and Drives
 Does the facility utilize DC generator sets to provide variable
speed control of equipment?
 Replace generator sets with solid-state variable speed drives
 25% Increase in overall efficiency
 Does the facility utilize Eddy Current drives variable speed
control?
 Eddy Current drives less efficient replace with solid sate
variable speed drives
 Maintenance costs are high
 Are motors installed that operate continuously at part load?

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 Fans and Pumps
 Are pumps or fans installed that are not sized correctly for the task?
 Reduce pump or fan speed using a sheave adjustment or motor
replacement
 Trim or replace pump impellers
 Replace fan or pump with a more energy efficient model
 Does the facility have a cooling tower?
 Install solid state VSD control on the cooling fans
 More fan speed requirement in day compared to night
 Replace the tower fill material with cellular film fill to improve heat
transfer efficiency
 Install non-clogging, non-corroding spray nozzle to improve water
distribution through the tower
 Install energy efficient airfoil fans
 Install energy efficient motors on the cooling tower fans and pumps

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 Fans and Pumps
 Are pumps or fans being throttled in order to control the flow
rate?
 Is bypass control being utilized to vary the flow out of the Pump?

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 Compressed Air Systems
 Are large compressors serving minimal system needs during off-
hours such as maintaining the minimum pressure requirements for
a Dry Fire Suppression System?
 Install smaller air compressor dedicated to serve minimal after hour
needs, and isolate from main plant air system
 Does the facility have Centrifugal Screw Compressors that operate
at less than full load capacity for than 70 percent of the Time?
 Is throttle control used to modulate the compressor output
capacity?
 Replace throttle control with Load-Unload (on-off) controls
 Throttle must be used when operating at more than 80% Capacity
 Throttle creates vacuum at compressor inlet when required in batches hence
operation is lowered in capacity when the pressure is reduced

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 Compressed Air Systems
 Does the facility have more than one compressor feeding into a common
header? Are the compressors operating at less than full output capacity?
 Sequence multiple compressors for proper control
 Are compressors operating at zero capacity for extended periods of
time?
 Shut off compressors during such times
 Is the discharge pressure of the compressor higher than 110 psig?
 80 psig is common operating pressure
 90-110 psig considered higher range,
 power increase by 0.5% for each psi
 Chances of air leakage higher for higher pressures
 Needed for delivery of air even to remote locations in the plant
 Introduce looped piping
 Install large pipes
 Is high pressure air being used for tanks that do not require high pressure
air?
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 Compressed Air Systems
 Does the compressed air system have significant air leaks?
 Leaks are easiest to find when the plant is quite
 To quantify total air leaks in a plant: note down air compressor
loading and/or air delivery during breaks
 Ultrasonic tools provide most reliable method to locate air leaks
 Common leak locations: valve packing, pneumatic cylinders and
hoses,
 Air leaks exceeding 35% of the air used are excessive in any plant
 Is the pressure drop across auxiliary equipment such as dryers, oil
separators or filters excessive?
 Replace filters, overhaul equipment to reduce pressure drop
 Size equipment to accommodate air flow with acceptable pressure
drop
 Is compressed air the best utility for the given application?
 Replace pneumatic motor with an electric motor

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 Steam Systems

 Is the stack temperature too high?

 Optimum stack temperature 50-100 F above saturated steam
temperature

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 Steam System
 Is the boiler operating at incomplete combustion?
 Tune the Boiler
 Is the condensate return system open to atmosphere?
 Install properly designed steam traps to reduce the amount of steam
lost through the open system
 Install pressurized condensate return system to reduce flash steam
losses
 Insulate condensate storage tanks
 Is the efficiency and performance of the steam system being
monitored manually?
 Is the flow rate of the induced draft and forced draft fans being
controlled by throttling methods?
 Are there any opportunities for heat recovery?

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 Refrigeration Systems

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 Refrigeration Systems
 Optimize the refrigeration system
 Optimize inter-stage pressure
 A two stage system has three separate pressures maintained by high and low stage
compressors. Choose intermediate pressure so that each compressor has approximately the
same pressure ratio to minimize compressor energy use.
 Economized single stage system
 For applications that require extremely low temperatures such as a blast freezer, a two-stage
compressor is usually preferred. An “economized” single stage system may allow operation at
slightly lower suction temperatures while providing the necessary cooling and avoiding the
cost of a two-stage system.
 Install 2-speed or VSD speed control on condenser and evaporator fans
 By reducing fan speed when full capacity is not needed, the energy consumption of the fan
motors is significantly reduced
 Cycle evaporator and condenser fans
 Evaporate fans move air across refrigerant coils to condition the space. Condenser fans
remove the heat generated during compression of the refrigerant. Evaporator fans can turn
off when not needed for temperature control. Cycling fans saves fan and compressor energy.
Duty cycles can be reduced as much as 50 percent. A timer can be used to cycle primary fans
after a given amount of operation.
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 Refrigeration Systems
 Install computer or “semi-automatic” controls to allow the compressors to
operate at their highest efficiency
 Overlap suction pressure switches on compressors connected to a common
header to allow their operation to be sequenced
 Poor cooler/freezer insulation, undersized or dirty evaporators require
lower suction pressure and wastes energy
 Consolidate and re-pipe loads with similar suction requirements. Dedicate a
compressor to these loads
 Compressor operating at maximum suction pressure are more energy efficient
 Reset suction pressure
 Raise suction pressure to match the actual pressure required to meet the cooling loads.
 When the suction pressure drop increases, compressor work increases.
 Add evaporator capacity to reduce evaporator approach temperature and raise
suction pressure
 The compressor savings resulting from operating at higher suction pressure often offset the
additional evaporator fan energy consumed

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 Walk-Through Audit
 1° Step
 Meeting with the appropriate plant personnel that are familiar with the
physical condition and day-to-day operation of the manufacturing equipment
 Determine which of the systems, technologies, and equipment needs energy
optimization
 2° Step
 Go through the checklist of questions in a guide that pertain to the facility
 All of these questions may not be answered in the meeting and, therefore,
should be “flagged” to be addressed during the walk-through.
 As you go through the checklist of questions, discuss any concerns that the
plant personnel may have with implementing the energy saving measures
 Determine the energy savings measures that have already been implemented
and those that may or may not be applicable

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 Walk Through Audit
 3° Step
 The next step is to tour the facility with the appropriate plant personnel that
are familiar with the various areas that you will be auditing.
 As you tour the facility, refer to the questionnaire to ensure that you answer
any remaining checklist questions.
 Record observations, such as equipment name plate data, gauge readings,
meter readings, and to make notes, such as areas that require further study,
equipment operators names, phone numbers, etc.
 4° Step
 After the tour is completed, a wrap up meeting should be held to review
your findings.
 At this point, a list of potential energy saving opportunities that should be
considered for additional study can be developed.

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 Investment Grade Audits
A detailed or investment grade audit (whether comprehensive or targeted) is a
technical and economic analysis of potential energy saving projects in a facility that:
 Provides information on current energy consuming equipment operations
 Identifies technically and economically feasible energy efficiency improvements for
existing equipment, and process
 Provides the customer with sufficient information to judge the technical and
economic feasibility of the recommended projects.
 Basis for further engineering analysis and design, and investment in energy efficiency
improvements by facility owners or third parties.
 Can be also the basis for performance contract agreements.
 An accurate audit can result in identification of highly cost effective projects, and
result in substantial cost/time savings in realization of the projects, while a low
quality audit will result in unrealistic savings analysis, duplicate work in the
engineering design process, and potential problems in performance contract
agreements.
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Expectations from Investment Grade Audit
 Clear operating hours per department (and equipment in the case of major energy
users)
 Clear inventory of energy consuming equipment including their nominal ratings and
capacities
 Energy rate/cost per unit of energy usage and for different types of energy
 Analysis of at least one year of energy consumption by type of energy/fuel
 Energy balance of the plant per type of fuel and preferably per meter based on rating,
operating hour, utility factor and load factor of equipment. Utility factor is the ratio
of the operating hours of an equipment to the total operating hours of department.
Load factor is the ratio of the actual draw of equipment to the nominal rating of
equipment
 Clear identification of major energy consuming processes and equipment in the whole
facility
 Analysis of major energy efficiency measures including source of energy saving,
amount and type of energy saved, cost savings, implementation cost and a pay-back
analysis
 Clear identification of the retrofit or control scheme/technology, and inclusion of cut
sheets of the proposed equipment
 Clear identification of the measures that may have potential in similar facilities that do
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Dr Nadeem not economical in the audited facility
Investment Grade Audit- Major Concern

It is expected that investment grade energy audits include realistic

assumptions on the conservative side; be complete, self sufficient,
and a clear guide to implementation, and serve as a roadmap to
any future energy efficiency retrofit work in the facility. Assuming
that an identified measure is chosen, and the detailed design is
done, no more detailed energy consumption analysis should be
needed to design and construct the measures.

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 Investment Grade Audit Checklist
 Are the energy rates based on historical (or projected) energy consumption and
current (or projected) energy rates?
• Has energy usage (and demand in the case of large electricity users) been balanced
for at least one full year of energy data, separately for different fuels and preferably
per meter? The preferred forms of presentation is graphical (e.g. pie chart) or
tabular.
• Are operating hours for different areas in the facility clearly identified and taken into
consideration?
• Are major energy consumers clearly identified, and taken into consideration in the
energy balance?
• Are the bases for implementation costs clearly identified?
• If a modeling software has been used, are the inputs and outputs clearly identified, so
that another expert can repeat the work?

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 Investment Grade Audit Checklist
• For the proposed measures, is it clear why energy will be saved?
• Is it clear what form of retrofit is proposed and what are the advantages?
• Is it clear where the retrofit should take place?
• Have all potential energy efficiency measures been addressed?
• Lack of consistency in energy cost, demand cost, operating hours of various
area of the facilities; often the basis for the considered demand cost is not
clear
• Lack of energy balance, which often results in overestimation of the cost
savings
• Lack of a clear description of the energy rate schedules, annual energy
analysis, so that the customer is not really provided with a clear picture of
how they are charged.
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 Investment Grade Audits
Be Careful!!!!!

a low quality audit will result in unrealistic savings analysis, duplicate work in the
engineering design process, and potential problems in performance contract
agreements.

And….

More importantly, because some of these energy audits may become a basis for
investment in, and establishment of distributed generation facilities in the
present energy market, energy audit work may have significant economic
repercussions.

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 Energy Audit Report
• Executive Summary • Utility rate structures
• A brief summary of the recommendations and • Tables and graphs of energy consumptions and
cost savings costs
• Table of Contents • Discussion of energy costs and energy bills

• Introduction • Energy Management Opportunities

• Purpose of the energy audit • Listing of potential EMOs
• Need for a continuing energy cost control • Cost and savings analysis
program • Economic evaluation
• Facility Description • Energy Action Plan
• Product or service, and materials flow • Recommended EMOs and an implementation
• Size, construction, facility layout, and hours of schedule
operation • Designation of an energy monitor and ongoing
• Equipment list, with specifications program
• Energy Bill Analysis • Conclusion
• Additional comments not otherwise covered
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 Shortcomings in audit reports
• Audit reports are supposed to provide a clear picture of the energy supply
and consumption, and act as a roadmap for improvement of the energy
utilization and cost reduction, often they lack some key components to serve
the ultimate purpose
• Lack of consistency in energy cost, demand cost, operating hours of various
area of the facilities; often basis for the considered demand cost is not clear
• Lack of energy balance, which often results in overestimation of the cost
savings
• Lack of a clear description of the energy rate schedules, annual energy
analysis, so that the customer is not really provided with a clear picture of
how they are charged.
• Lack of equipment inventory and their ratings
• Lack of clear description and identification of retrofit scheme
• Lack of consideration of the latest retrofit technology
• Lack of pointing out the measures that may exist in similar facilities but do
not exist in the surveyed facility

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Causes of Deficiencies in Audit Reports
 Lack of expertise of people who do the surveys, and more importantly
those who prepare the report
 Lack of basic knowledge of the fundamental engineering principles.
Energy efficiency work is multidisciplinary, which necessitates a strong
knowledge of fundamentals of mechanical and electrical engineering.
 Lack of training in application of sophisticated simulation software.
 Conflict of interest
 An example is when a firm is hired to do a comprehensive energy audit,
but fails to take inventory of all equipment and evaluate them, in the
interest of an attractive lighting retrofit project. Other examples are
consideration of unrealistic operating hours, utility factors, load factors of
the equipment. An oversized 50 hp fan motor may operate at 50% of its
load, but it will not be known in the plant audit if its power draw is not
measured!
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Dr Nadeem Feroze
 COMPLICATED ENERGY AUDIT CASES

Comprehensive energy audit of manufacturing facilities requires significantly

higher expertise than commercial and institutional facilities. While there are
tens of energy saving opportunities in commercial facilities, there are
hundreds of energy efficiency opportunities in industrial facilities.

It is not uncommon to identify 10-30% energy efficiency

opportunities with simple paybacks of zero to a few years in
industrial facilities.

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Issues in Audit of Manufacturing Facilities
 A much wider scope of measures and advanced technologies (inclusive of
those for commercial facilities) can be identified in industrial facilities.
 While there are significant commonalties between industrial facilities
with different processes, most facilities may have their unique energy
efficiency measures that can be identified and analyzed based on
fundamental engineering principles.
 Load measurements are required for major energy consuming devices.
Some equipment may go through significant load variations.
 Energy usage in most industrial facilities are highly product and
production dependent, and much less dependent on ambient conditions.
 Taking a detailed inventory (which includes the rating, usage pattern,
loading) of energy consuming equipment is an essential component of a
comprehensive energy audit of industrial facilities.

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 Energy Audit Case Studies
Audit Measures Recommended Issues Raised

Office Building Retrofit part of the lighting system Type of lamps and fixtures not identified, energy
Firm A HVAC system upgrade savings overestimated by about 40%
HVAC system energy savings overestimated by about
50% (methodology problem)
Various measures not identified:
•VFD* for chilled water and condenser pumps
•VFD for cooling tower fans
•VFD for return fans
•Proper control of supply fan VFD
•Various control issues
Office Building Installation of a New 400 Ton Variable Speed Chiller No energy or demand balance presented
Upgrade Existing Partial Thermal Energy Storage Utility rate schedules were not identified
Firm B System DOE-2 simulation had been used but no input/output
Install VSD* on Pumps and Fans data were presented
Energy Management Hardware and Software It is not clear how cooling tower fans are controlled
Retrofit Lighting

Office Building Installation of VFDs on the Supply and return Fans. Measured power of the motors is based on current
Firm A Installation of CO2 Controls on the Return Air Fans. measurement, lacks power factor measurement
Installation of Damper Control. Fan curves have been used for VFD justification, not
clear if flow and pressure were measured or assumed,
fan curves are sensitive to both
Numerical errors in power savings calculations
resulted in overestimation of savings by 50%
It is not clear why installation of CO2 sensors are
recommended and how it will result in any energy
savings, maintenance cost savings, etc.
Automating the on/off of the HVAC system not
41 Dr Nadeem Feroze identified, while it is done manually now
 Energy Audit Case Studies
Audit Measures Recommended
Prison Lighting Retrofit
Firm D Energy Management System
Variable Air Volume HVAC
Boiler Economizers and Fan VSDs
Transformer Substation
Cogeneration Replacement
Vocational Institution Lighting Retrofit
Firm D Thermal Energy Storage
Programmable Timeclocks and Thermostats
Boiler Economizer and Fan VSDs
Dairy Chiller Heat Recovery
New Water Booster Pump
Cogeneration
Office Building Lighting Retrofit
Firm D EMS Controls Modifications
VSD’s for Pumps and Chillers
Window Film
Thermal Energy Storage
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Issues Raised
Assumed plug load without justification
No details of the HVAC system to be controlled
by the EMS has been presented
Measurement data for boiler not presented, but
various measures recommended
The basis for choosing the kW rating of the cogen
is not clear
FERC’s criterion for cogen not clarified
Rate schedules not identified
Boiler measurements not included
Boilers optimization not taken into consideration
Cogen calculations do not include actual plant
data
The schedule of operation of HVAC system and
building temperature control (chillers included)
are not clear.
The specs for the HVAC system are not provided.
The DOE-2 simulation has not been properly
calibrated. There is a discrepancy of upto 50% in
demand estimation
 Implementing the Audit Recommendations

 Create support within the company for energy management.

 Generate new ideas.
 Evaluate suggestions
 Set goals.
 Implement the most promising ideas.

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This is NOT a sunset! This is a sunrise!
You have to get up early, there’s a lot to do!

Thank You for Your Attention

44 Dr Nadeem Feroze