Energy audit

Presented by
Wahid khan
Roll no 21
Energy audit: Definition and Types
 
Energy audit is a systematic study or survey to
identify how energy is being used in a building
or plant, and identifies energy savings
opportunities. Using proper audit methods and
equipment, an energy audit provides the
energy manager with essential information on
how much, where and how energy is used
within an organization (factory or building).
Stages of Energy Audit
Types of energy audit

Energy audit can be categorized into two types,

namely walk-through or preliminary and detail audit.

Walk-through or preliminary audit

 
Walk-through or preliminary audit comprises one day
or half-day visit to a plant and the output is a simple
report based on observation and historical data
provided during the visit. The findings will be a
general comment based on rule-of-thumbs, energy
best practices or the manufacturer's data.
Preliminary Energy Survey
Quick overview of energy use patterns
• Provides guidance for energy accounting
system
• Provides personnel with perspectives of
processes and equipment
• Identify energy inefficiency ,if any
• Set the stage for detailed energy survey
Detail audit
 
Detail audit is carried out for the energy
savings proposal recommended in walk-
through or preliminary audit. It will provide
technical solution options and economic
analysis for the factory management to
decide project implementation or priority. A
feasibility study will be required to
determine the viability of each option.
Detailed Energy Survey

Detailed evaluation of energy use pattern

• By processes and equipment
• Measurement of energy use parameters
• Review of equipment operating
characteristics
• Evaluation of efficiencies
• Recommendation for implementation
Benefits of energy audit
 
There is a lot of potential for energy savings from
energy audits.. Technical solutions proposed in
the energy audits show massive potential for
energy savings in every sub-sector with an
average of almost ten percent of the energy
usage. However, this can only materialize through
replication at other factories within the respective
sub-sector.
Benefits of an industrial energy
audit include:
 
•Energy savings
•Avoiding power factor penalties and environmental
compliance costs
•Quality improvements
•Productivity improvements
•Reduced maintenance
•Fewer breakdowns
•Better safety and protection
•A process for repeatable improvements
 Process VS. Equipment
Equipment efficiency improvement : Max. 5%
Process efficiency improvement : 15% to 30%

Conclusion
Focus on Processes
 Energy intensive processes and equipment
Examples of processes
• Electrical furnace
• Rolling mills
• Gas furnace
• Steam generation
• Feed water system
• Condensate return system
• Steam distribution system
Examples of equipment
• Electrical motor
• Pump
• Fan
• Heater (gas,..,electric)
• Dryer (steam/electric)
• Motor / generator
• Compressor
• Light bulb
 Energy audit of your building
• A thorough energy audit of a building should
include:
• investigation of pipes and heating, ventilation
and air conditioning systems. 
• structural investigation
• investigation of electrical or automated
systems
 Understand Where You Use Energy

Choose Your Facility Type: Hotel

Typical Electricity Cost Breakdown

Refrigeration Annual Electricity Cost Breakdown
Office Equip.
Miscellaneous Service Water 32% $32,000
Heat & Cool Ventilation Lighting 22% $22,000
Heat & Cool 19% $19,000
Ventilation 9% $9,000
Office Equip. 9% $9,000
Miscellaneous 6% $6,000
Refrigeration 3% $3,000

Lighting Service Water

INDIA’S ENERGY DILEMMA
Case Study of Energy Audit
at
Mother Dairy
(Milk Plant)
 Base Line Data
Product Bulk Processed Milk (Toned,
Double Toned & Full Cream)
Capacity of the plant 8 Lac liters of Milk per day
Annual Fuel / Energy PNG: 17,76,000 SCM
Consumption Worth: Rs 3.7 Crores
Electricity: 134.6 Lac kVAh
Worth: Rs 6.68 Crores
Annual Energy Bill Rs 10.38 Crores
Compressed Air generation 180 cfm
Steam Consumption 65,000 kg/month for Milk Plant
 Summary of Savings Identified & Realised
(Year 2003 & 2004)
Total Savings projected Electricity: 21,43,360 kVAh Worth: Rs 78.24
by PCRA Lac
LDO: 184.31 KL Worth: 85.8 Lac

Total Savings Realised Electricity: 5,21,017 kVAh Worth: Rs 19.02

till date Lac
LDO: 130.06 KL Worth: Rs 60.55 Lac

r
% Savings Realised of Electricity: 3.7%
total energy LDO: 20.3%
consumption
 Boilers
Observations:
1. Condensate recovery is not being done.
2. Feed water temperature presently is 50C.

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

Savings Estimated / year Investment Payback Period

Rs 28.34 Lac Rs 25 Lac 11 Months
 Refrigeration System
Observations:
1. Pumps connected to silos are of higher capacity of 15 kW.
2. Cooling water pumps of 45 kW are under loaded.
3. Glycol pumps of 15 kW are under loaded.
4. Water cooled condensers have poor performance

Recommendations:
5. Replace 15 kW pumps connected to Silos with 11 kW pumps.
6. Optimise cooling water flow by minimising pressure drop from
PHE to CT inlet or install VFD for cooling water pumps to save
40 kW.
7. Install VFD for Glycol pumps to save 8 kW.
8. Install air cooled condensers to save 6 kW.
Savings Estimated / year Investment Payback Period
Rs 5.72 Lac Rs 4.8 Lac 9 Months
 Air Compressors
Observations:
1. Air leakage are about 26%.

Recommendations:
2. Plugging of air leakages

Savings Estimated / year Investment Payback Period

Rs 4.0 Lac Nominal Immediate
 Illumination
Observations:
1. HPMV lamps are used for street lighting.
2. 36 Watt Tubelights with copper chokes are used.

Recommendations:
3. Replace HPMV lamps by HPSV lamps
4. Replace 36 Watt Tubelights 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
 Energy substitution
• Replace halogen lamps with cfl
• Replace crt monitor with lcd monitor
• Replace electric heater with steam heater
• Replace petrol, diesel vehicles with
compressed natural gas(cng)
 Sources of energy
• FOSSILS FUEL COVERS:
Coal, petroleum and natural gas.

• RENEWABLE ENERGY COVERS:

solar, wind, hydroelectric, biomass, and
geothermal power.

• NECLEAR ENERGY COVERS:

fission and fusion.
Thank you