Current Global Energy Scenario

• World’s economy is based on 1015 Kilo Joules

fossil fuels 700
History Projections 612

– 80% of world energy consumption 600

500
493
552

comes from fossil fuels 400 345 365 382

439

– Only 13.5% comes from renewable 300 243

285
311

resources and 6.5% from nuclear 200

207

resources 100

• Global primary energy = 10.54 0

1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020

billion tons of oil equivalent in

2005
– Seen to increase by 1.3% for IC and
9.2% for DC
• Concentration of CO2 in the
atmosphere continuously
increases
– causing the mean global
temperature to rise, resulting to
climate change
 Energy Conservation
Why do we need to conserve
energy?
 High Cost of Electricity/Fuel
 Environmental Impacts (e.g. Air
Pollution, Global warming)

How do we conserve energy?

 Improve efficiency of energy utilization
 Energy Efficiency
 measure of the productivity per unit of energy
consumed
 portion of energy which ends up doing useful work

Efficiency of an energy conversion

A Hot water X Useful

boiler energy(KJ)
Energy Input, KJ
Y Waste
energy (kJ)

Efficiency (%) = X x 100

A
What is improved Energy Efficiency?

Energy Efficiency uses less energy for same

output and reduces CO2 emissions

Incandescent Lamp Compact fluorescent Lamp

100 W 18W

CO2 Emission – 110 g/hr CO2 Emission – 20 g/hr

ENERGY MANAGEMENT
Judicious and effective
use of energy
to maximize profits
(minimize costs)

to enhance competitive
positions
7
 WHY ENERGY MANAGEMENT?
PLANT LEVEL Reduce emissions

Reduce electricity GHG EMISSIONS

consumption

ELECTRICITY

PROCESS

SOLID AND LIQUID

FUEL WASTES

Reduce fuel consumption

Reduce wastes

Increase Productivity 8
 Benefits of Energy Efficiency Programs
(Plant Level)

 Lower production costs and

higher profits
 Better competitive position
 Improved ability to withstand
future energy cost increases or
energy curtailments
 Improvement in the plant’s
productivity
 Environmental benefits
9
 WHY ENERGY MANAGEMENT?
NATIONAL LEVEL
GHG EMISSIONS Reduce emissions
GHG EMISSIONS
Reduce electricity
consumption
POWER
PLANT ELECTRICITY
PROCESS

SOLID AND LIQUID

FUEL WASTES

Reduce fuel consumption

FUEL Reduce wastes

Increase Productivity 10
 Benefits of Energy Efficiency Programs
(National Level)
 Deferred construction of
new power plants
 Reduction in imported fuel
(e.g. oil, coal)
 Conservation of dollar
outflow
 Improve industrial
productivity
 Improved energy security
 Reduced greenhouse gas
emissions
11
 Energy Efficiency
Improvement Strategies

Equipment improvement
Process improvement
Better energy management
Better operational practices
Combination of strategies
 Energy Audit

Systematic procedure
Verification, monitoring and analysis
in the use of energy
Includes technical report
– cost benefit analysis and action plans
to reduce energy consumption”
 Energy Audit Goals
 clearly identify the types and costs of
energy use;
 understand how that energy is being
used- and possibly wasted;
 identify and analyze alternatives that
could substantially reduce energy
costs; and
 perform an economic analysis on
those alternatives and determine
which ones are cost-effective
Why Energy Audit?
Helps Energy Managers to:
Identify areas for
energy reduction
Prioritize energy
conservation projects
Develop action plans
Track progress
 Levels of Energy Audit

Primary audit
or walk-thru

Detailed audit
 LEVELS OF ENERGY AUDIT
Primary Audit (Walk Through)
• 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
• uses existing, or easily obtained data
 LEVELS OF ENERGY AUDIT
Detailed Audit
• Provides a detailed energy project
implementation plan for a facility, since it
evaluates all major energy using systems.
• Offers the most accurate estimate of energy
savings and cost.
• 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.
• Arrives at energy balance 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.
ENERGY AUDIT METHOD
PROJECT PLANNING

DATA COLLECTION

DATA ANALYSIS

RECOMMENDATIONS
 Project Planning
1. Define Objectives

2. Divide Plant into Facilities

3. Assign the Survey and

Analysis Teams

4. Prepare energy audit

equipment
 Project Planning
1. Define Objectives:
a. Determine forms of energy used
b. Examine historical energy use and
cost data
c. Establish an accounting and
reporting system
d. Relate energy consumption to
production
e. Identify areas where energy
wastes can occur
f. Set energy conservation goals
g. Identify and analyze energy saving
opportunities
 Project Planning
2. Divide Plant into Facilities
Divide Plant into Factors to Consider:
Facilities 1. The cost centers should be the smallest
manageable segments of the plant.
2. There should be only one individual
by process responsible for the performance of a cost
center.
by equipment
3. The number of cost centers should be kept
by divisions within a certain limit so that the paperwork
by departments and coordination problems do not become
insurmountable.

A plant lay out or a

process flow chart
will be very useful.
 Project Planning
3. Assign Survey and Analysis Teams
SURVEY TEAM
 Responsible for identifying
opportunities and collecting data
 Maybe composed of an area
foreman, a plant engineer and a
maintenance supervisor
 Team members should be
experienced in the process or facility
being surveyed; must be familiar
with current operating and
maintenance practices
ANALYSIS TEAM
 Responsible for analyzing
opportunities and calculating
balances
 Depending on the scope of the
audit, may consist of 1 or 2 core
members with an engineering
background supported by persons
with accounting, finance and
computer skills as needed
 Project Planning
4. Prepare Energy Audit Equipment

 Combustion analyzer
 Wattmeter
 Air & water flow
meters
 Light meter
 Thermometers
 Hygrometer
 Tachometer
Required Testing Instruments
Required Testing Instruments
Required Testing Instruments
 Project Planning
4. Prepare Energy Audit Equipment

Energy Audit PPEs

Hard Hat
Protective Goggles
Electrical Gloves
Safety Shoes
Ear Plug
Gas Mask/Dust Mask
ENERGY AUDIT METHOD

PROJECT PLANNING

DATA COLLECTION
 Data Collection
• Introductory Meeting
• Preliminary data gathering
– Past energy bills (usage level
and cost per month)
– Facility layout
– Process flow charts
– Production output
– Operating hours
– Inventory of equipment
• Audit Interview
Data Collection
 Primary Audit Data

 Shows exactly how much

energy is used each month
by each cost center and by
each fuel type
 Should include both
purchased and internally
generated energy
 Electricity Consumption

kWh KW Power Total Electricity Php/

MONTH Consumption Demand Factor Cost kWh
Jan.
Feb.
Mar.
Apr.
May
June
July
Aug.
Sep.
Oct.
Nov.
Dec.
TOTAL
Data Collection
Detailed Audit Data
 Performed to find out where
the energy entering your
system is going
 Provide basis for
calculating energy
balances, energy
efficiencies and energy
savings potential
 Conducted for each energy
source (e.g. take one
source at a time and find
out how this was used)
 Data Collection

E2

Cost
Center 2
Purchased E1 E’1
Cost
E energy for Center 1
the whole
facility
E3
Cost
Center 3

Transfer of Energy Between Cost Centers

 Data Collection – Example

Processing Section
54.46 kW (67.8%)

PURCHASED
ELECTRICITY
80.35 kW

Packaging Section
25.89 kW (32.2%)
 Data Collection
Equipment/Systems Audited by DOST
 Boiler and Steam Systems
 Lighting Systems
 Cooling Towers
 Pumps, Fans and Blowers
 Electrical motors RATED NAMEPLATE
 Refrigeration/Air Conditioning Systems DATA
ACTUAL AUDIT DATA
 Kilns, Furnaces, Dryers and Ovens
PERFORMANCE PARAMETERS &
 Air Compressors and air distribution systems STANDARDS
 Manufacturing Processes
 Data Collection
Manufacturing Systems

• List process steps

• Prepare process
flow chart
• Indicate material
and energy flow
ENERGY AUDIT METHOD

PROJECT PLANNING

DATA COLLECTION

DATA ANALYSIS
 Data Analysis

 Determine energy balances

 Determine historical energy performance,

benchmark energy use and cost profile

 Determine energy efficiencies of process

equipment and utilities

 Determine specific energy consumption

levels
 Data Analysis

Figuring Energy Balances

The objective of an energy balance is to define in detail

energy input, energy utilized and energy losses
Energy input = Energy output + Energy losses
Data Analysis
Manufacturing Process

PROCESS INPUTS PROCESS OUTPUTS

Record: raw materials, Record: products, by-
water, energy and products, waste and
auxiliaries emissions

DERIVE MATERIAL AND ENERGY

BALANCE
1. Assemble information
2. Derive preliminary balance
3. Evaluate and refine balance
Data Analysis
Establish Baselines

• Establish base year

• Identify metrics (e.g. kWh per
pack of product)
• Publish results

Data Analysis
Benchmarking
• Benchmarking allows you
to compare the energy
performance of similar
facilities or an established
level of performance.
• Can be used to develop
relative measures of
energy performance, track
change over time, and
identify best energy
management practices.
Benchmark - a point of reference from
which measurements can be made.
Facility or organizational
performance may be
benchmarked to:
 Past performance - A
comparison of current versus
historical performance.
 Industry average - Based on an
established performance
metric, such as the recognized
average performance of a peer
group.
 Best in class - Benchmarking
against the best in the industry
and not the average.
 Best Practices - A qualitative
comparison against certain,
established practices
considered to be the best in the
industry.
ENERGY USE
PROFILE
1 kWh = 3600 kJ
or Energy Cost Profile (PhP)
 Data Analysis
LPG
8%
Electricity
LPG
33% Fuel Oil Electricity 34%
27% 43%

Coal Fuel Oil

Coal 17%
6%
32%

ENERGY USE PROFILE ENERGY COST PROFILE

 Data Analysis
Figuring Energy Efficiencies
Energy output
Eff = ---------------------- x 100%
Energy input

Energy input - Energy losses

Eff = -------------------------------------- x
100%
Energy input
 ENERGY AUDIT METHOD
Data Analysis
Specific Energy Consumption, SEC
E -monthly energy consumption, tons
E of fuel equivalent
SEC = ------
P -monthly production, tons
P
e - non-production related energy
E e (e.g. electricity for office
SEC = ----- = m + ----- equipment)
P P
 ENERGY AUDIT METHOD
Data Analysis
ENERGY vs. PRODUCTION
(Typical Factory)

E=mP+e

E= Energy
Used Daily
m P = Energy related to
production

e = Energy not related to

production

P = Daily Production
Data Analysis
Specific Energy Consumption
Monthly Production and Energy Consumption

3.0
2.8
2.6
2.4
2.2
2.0
1.8 Production
1.6 (tonnes)
1.4
Energy Cons.
1.2
(toe)
1.0
0.8
0.6
0.4
0.2
0.0
1 2 3 4 5 6 7 8 9 10 11 12

MONTH
 ENERGY AUDIT METHOD
PROJECT PLANNING

DATA COLLECTION

DATA ANALYSIS

RECOMMENDATIONS
 Recommendations

Prepare list of Energy

Efficiency Opportunities
(EEOs)
Conduct techno-economic
feasibility for each EEO
Prepare Report and
Present to the
Management
Listing of Energy Efficiency and Energy
Conservation Opportunities

Listing of all actions that could

lead to system efficiency
improvements and savings in
energy costs
Actions could be changes in
operating procedure to
maintenance, repair or
replacement of line
components
Some actions can be done
immediately, others require
time and money for
implementation
 Techno-economic evaluation of EEOs

Assess Technical Feasibility

1. Availability and reliability of
equipment
2. Requirements for utilities,
process monitoring and
control
3. Maintenance requirements
4. Required technical skills
(operators, technicians)
 Techno-economic evaluation of EEOs

Assess Financial Viability (Based on

technical evaluation):
1. Investment costs (Equipment,
construction, training, start-up,
etc.)
2. Financial analysis techniques like
initial cost, interest rate, payback
period, energy savings, net
present value)
3. Operational costs and benefits
(Before and after comparison)
 ENERGY AUDIT REPORT FORMAT

 EXECUTIVE SUMMARY
 A brief summary of the
recommendations and cost savings
 TABLE OF CONTENTS
 INTRODUCTION
 Purpose of the energy audit
 Need for a continuing energy cost
control program
 Scope of the audit
ENERGY AUDIT REPORT FORMAT

 FACILITY DESCRIPTION
 Product or service, materials flow
 Size, construction, facility layout, and
hours of operation
 ENERGY BILL ANALYSIS
 Utility rate structures
 Tables and graphs of energy
consumptions and costs
 ENERGY AUDIT REPORT FORMAT

ENERGY EFFICIENCY OPTIONS (EEO)

 Listing of potential EEO’s
 Cost and savings analysis
 Economic evaluation
ACTION PLAN
 Recommended EEO’s and an
implementation schedule
 Designation of an energy monitor
and on-going program
CONCLUSION
 Presentation to Management
 Present all measurements,
observations, analyses and
recommendations
 Identify possible suppliers and
contractors for suggested measures
 Show current and projected specific
energy values, savings potential,
investments and payback periods
 Point out areas which require further
detailed study
 Energy Management Opportunities
(EMOs)

Category 1 EMOs are EMOs with no cost implication

(Effect: 11%) or Small Investment

Category 2 EMOs are EMOs with little cost implication (Effect: 7%)
or Medium investment

Category 3 EMOs are EMOs with significant investment (Effect:

5%) or Large Investment
 Sample of Category 1 EMOs
Correct air/water flow rate
Switch off fittings in vacant areas
Delamping
Close doors, windows
Check fresh air dampers
Switch off elevators and escalators during off
peak period
Adopt natural or mechanical ventilation
 Sample of Category 1 EMOs
Implement housekeeping measures, e.g. notices,
promotional activities, scheduled operational hours
Check water leakage and air leakage
Clean of luminaires/heat exchanger/filter
Set thermostat
Top up refrigerant, compressor oil
Lower lighting level for bright areas
 Sample of Category 2 EMOs
Install
– Blinds & curtains
– Air curtain for automatic door
– Self luminous exit sign
– Additional switches and controllers
Replace
– Incandescent lamps with compact florescent lamp
– Replace electromagnetic ballasts with
Sealing of building leakages
Plant trees near curtain wall
Sample of Category 2 EMOs
Energy efficient office equipment
Replacing damaged insulation
Occupancy sensor
Time switch
Re-programming of CCMS
Day light sensor
Setback control
CO2 sensor
Harmonic filter
Power factor correction device
 Sample of Category 3 EMOs
Recover waste heat/cool air e.g. thermal wheel,
Heat pump
Automatic condenser cleaning
Modernization of old lifts
Green Initiatives that enhance corporate image,
e.g. renewable energy, replacement of
ozone depleting refrigerant
 Sample of Category 3 EMOs
Installing T5, T8 with electronic ballasts
BMS and software enhancement
New chillers with high COP
Water-cooled system with cooling tower
High efficiency motors
VSD
Water saving tips
Low volume water closet
 Common Findings of Energy Audit
HVAC –EMO Category 1
AC remained “on” outside
office area
AC remained “on” for
unoccupied areas or
redundant areas
Door or window left open
when AC is “on”
Too cold in summer e.g.
room at 210C
Excessive pressure drop
across filters
Chilled water at 60C outside
summer
Automatic control overrides
by manual control
Excessive ventilation
The last man out to turn off
AC or install time switch
The last man out to turn off
AC or install occupancy
sensors
Close door or window
Set thermostat to 240C
Clean filters
Re-set temperature to 80C
Disable manual control
Adjust fresh air dampers
Unnecessary consumption
of energy
Unnecessary consumption
of energy
5 to 20% savings
10 to 30% savings
5 to 20% savings in fan
power
3 to 6% savings of chiller
power
10 to 15% savings
5 to 30% savings
 Common Findings of Energy Audit
HVAC –EMO Category 2
No blinds or blinds not Install or close blinds 5 to 30% savings to offset
closed for windows solar heat gain
Access door of AHU or Rectify leakages 3% of fan power
ductwork has leakage of
say 3%
Excessive water leaving Replace stuffing box with A flow of 1 lit/min flow
pump gland mechanical seal means 1000 kWh per year
Overcooled spots due to Add dampers if required 15 to 25% savings
improper air balancing and balance the system
Overcooled spots due to Add valves if required and 15 to 25% savings
improper water balancing balance the system
Lack of individual control Add controller 10 to 15% savings

Building leakage Rectify leakage 5 to 10% savings

Poorly maintained systems Improve maintenance 10 to 30% savings

procedures
 Common Findings of Energy Audit
HVAC –EMO Category 3
Equipment operating
beyond their economic life
expectancy
Inefficient air cooled
chillers
Outdated control system
Air flow controlled by inlet
guide vanes
Chilled water pump driven
by constant speed motor
Replace with energy 10 to 30% savings
efficient equipment
Replace with cooling 20 to 30% savings
tower with water cooled
chillers
Install BMS/CCMS 10 to 25% savings
Install VSD 10 to 30% savings in fan
power
Install VSD 10 to 30% savings in
pump power
 Common Findings of Energy Audit

Lighting Installation –EMO Category 1

Lighting level too high Disconnect power supply 15 to 30% savings

to some fittings
Lighting along window Turn off perimeter lightings 20 to 30% savings
areas turned “on” at day
time
Lighting remained “on” The last man out to turn off Unnecessary consumption
outside office area lighting or install time of energy
switch
Lighting remained “on” for The last man out to turn off Unnecessary consumption
unoccupied areas lighting or install of energy
occupancy sensors
Lighting remained “on” for Remove the unnecessary Unnecessary consumption
redundant function lighting of energy
 Common Findings of Energy Audit

Lighting Installation – EMO Category 2

T12/T10 fittings used in Replace with T5 fittings 30 to 40% savings

lighting
T8 fittings used in lighting Replace with T5 fittings 20 to 30% savings

Manual control for lighting Install occupancy sensor >20% savings

Incandescent lamp being Replace with compact 80% savings

used fluorescent lamp
Not enough lighting Install more switches 10 to 20% savings
control switches (about one per 10 m2)
 Common Findings of Energy Audit

Electrical Installation – EMO Category 2 & 3

Over sizing of motor by Replace with smaller 5% savings

30% motor of proper size
Add VSD 50% savings
Overall power factor of 0.8 Improve to min. of 0.85 Minimize losses through
network

30% total harmonics Add harmonic filter to Minimize losses through

distortion (THD)
Power supply tariff is not
favourable
reduce THD network
Conduct tariff review and Savings in electricity bills
apply to supply company
for a special charge rate
other than general tariff
 2. Monitoring & Review

Subsequent to the implementation of the EMOs,

the audit team should monitor the energy
consumption for at least one year to verify the
predicted savings
Any discrepancies should be analyzed and
corrective actions taken
Success stories should be recorded and used to
justify future energy audit recommendations
Follow up energy audit should be carried out
about 5 years after the first audit
Post Audit Stage
 EXISTING ENERGY AUDIT EQUIPMENT

-High Temperature Infrared Laser

Thermometer 50:1 DS
- Portable Electronic Combustion Gas Analyzer
- Clamp on Power Meter
- Portable Strobo Tachometer
- Heavy Duty Hygro-Thermo Anemometer
- Precision Digital Psychrometer
- Heavy Duty Hot Wire Thermo Anemometer
 EXISTING ENERGY AUDIT EQUIPMENT

- Pocket Foot Candle/Lux Meter

- Power Quality Analyzer with data logger
- CO/Gas Meter
- Laser Distance Meter
- Ultrasonic Flow Meter
- Heavy Duty Differential Manometer
- Heavy Duty Moisture Meter
- Carbon Monoxide Leak Detector
- Insulation Resistance Meter-