Energy Audit Methodology

&
Thumb Rules for Audit
 Ten Steps Methodology for 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.)
 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.
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.
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
Drawing process flow diagram -Identification of waste
streams and obvious energy wastage
Auto Cane Feeding system
Identification of Energy
Conservation Opportunities

Energy generation
Energy distribution:
Energy usage by processes:
Fuel substitution:
 Technical and Economic feasibility
Technology availability, space, skilled manpower, reliability,
service,Impact of measure on safety, quality, production or
process.Maintenance requirements and spares availability
Sample Worksheet for Economic Feasibility
Name of Energy Efficiency Measure
i. Investment 2. Annual operating costs 3. Annual savings
a. Equipments Cost of capital Thermal Energy
b. Civil works Maintenance Electrical Energy
c. Instrumentati Manpower Raw material
on Energy Waste disposal
d. Auxiliaries Depreciation
Net Savings /Year (Rs./year) Payback period in months
= (Annual savings-annual operating costs) = (Investment/net savings/year) x 12
Energy Audit Reporting Format
Energy
Audit
Reporting
Format
LETS QUICKLY SUMMARIZE

THESE TO BECOME
THE THUMB RULES
FOR YOU IN FUTURE
AUDITS
 THERMAL ENERGY
BOILERS
5% reduction in excess air increases boiler efficiency by 1%
(or: 1% reduction of residual oxygen in stack gas increases
boiler efficiency by 1%).

22 0C reduction in flue gas temperature increases boiler

efficiency by 1%.

60C raise in feed water temperature by economiser / condensate

recovery corresponds to a 1% saving in fuel consumption, in
boiler.

200C raise in pre-heated combustion air temperature by waste

heat recovery results 1% fuel savings.
 THERMAL ENERGY

A 3 mm diameter hole on a pipe line carrying 7

Kg/cm2 steam would waste 32'650 litres of fuel oil per
year.

A 3 mm thick soot deposition on the heat transfer

surface can cause an increase in fuel consumption to
the tune of 2.5%.

A 1 mm thick scale (deposit) on the water side could

increase fuel consumption by 5 to 8%.
 Steam Piping : Features

A 100mm well lagged pipe of 30-meter length

carrying steam at 7 Kg/cm2 pressure can
condense nearly 10 Kg. of water in the pipe in
one hour unless it is removed from the pipe
through traps.
The pipes should run with a fall (slope)of not
less than 12.5 mm in 3 meter in the direction of
flow.
Drain pockets should be provided at every 30 to
50 meters and at any low point in the pipe
network.
 Leaking Steam Pipe / Valve
Audible Leak Visible Leak

Weak whistling Weak hissing

Almost invisible steam jet Visible steam jet
Bac
k
800 litre oil per year 2,000 to 4,000 litre oil per year
 Utilising steam at the lowest possible
pressure

2730.7 KJ/kg 2770.8 KJ/kg Total Heat

Steam should always be generated

2151.3 KJ/kg 2054 KJ/kg
Latent Heat and distributed at the highest
possible pressure but utilised at the
lowest practicable pressure

579.4 KJ/kg 716.8 KJ/kg Sensible Heat

2.4 bar, 121.5oC 6.8 bar, 164.3oC

Minimizing barriers to heat transfer

Resistance to heat transfer of

water is 60 70 times more
than steel and 500 600
times than copper

Resistance to heat transfer of

Air is 1500 times more than
steel and 19,000 times than
copper
 THERMAL INSULATION

The Insulation should be designed such that the skin

temperature is not more than 200C above the ambient
temperature

A bare steam pipe of 150 mm diameter and 100 m length,

carrying saturated steam at 8 kg/cm2 would waste 25'000
litres furnace oil in a year.
 ELECTRICAL ENERGY

PUMPS
Reducing the speed of a centrifugal pump by half would
reduce the power consumption by 8 times
A reduction in 10% impeller diameter would reduce power
consumption by 40 %
 ELECTRICAL ENERGY

COMPRESSED AIR
Every 50C reduction in intake air temperature would result
in 1% reduction in compressor power consumption.

Compressed air leak from 1 mm hole size at 7 kg/cm2

pressure would mean power loss equivalent to 4500 kWh
per year.

Reduction of 1 Kg/cm2 air pressure (8 Kg/cm2 to 7

Kg/cm2) would result in 9% input power savings .
 ELECTRICAL ENERGY

REFRIGERATION
Refrigeration capacity reduces by 6%, for every 3.50C
increase in condensing temperature.

Reducing condensing temperature by 5.50C, results in a

20 - 25% decrease in compressor power consumption.

A reduction of 5.50C in cooling water temperature at

condenser inlet, reduces compressor power consumption
by 3%.

1 mm scale build-up on condenser tubes can increase

energy consumption by 40%.
 ELECTRICAL ENERGY

ELECTRIC MOTORS
For every 100C increase in motor operating
temperature over recommended peak, the motor life
is estimated to be halved.

If rewinding is not done properly, the efficiency can

be reduced by 5 - 8%.

Variable speed drive option can result in input energy

consumption reduction by 5 - 15%. In some
pump/fan applications saved energy could be as high
as 35%.
 ELECTRICAL ENERGY

LIGHTING
Ensure proper illumination & efficacy (lumens / watt)
Install photocells
Use timers
Retrofit occupancy sensor
Use servo stabilizer in lighting circuit
Replace High Pressure Mercury Vapour lamps with
High Pressure Sodium Vapour lamps
Replace conventional chokes with electronic chokes
 But is the Task Really Finished?
Are we Experts in Energy
Conservation and Efficiency ?
When and Why Should we
start to Practice What we
Preach
THANK YOU