Detailed Energy Audit Methodology

A comprehensive audit provides a detailed energy project implementation plan for a

facility, since it evaluates all major energy using systems.
This type of audit offers the most accurate estimate of energy savings and cost. It
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.
In a comprehensive audit, one of the key elements is the energy balance. This is 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. 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
Guide for Conducting Energy Audit at a Glance
Industry-to-industry, the methodology of Energy Audits needs to be flexible.
A comprehensive ten-step methodology for conduct of Energy Audit at field level is presented
below. Energy Manager and Energy Auditor may follow these steps to start with and add/change
as per their needs and industry types.
 Energy Audit Instruments
The requirement for an energy audit such as identification and quantification of energy
necessitates measurements; these measurements require the use of instruments. These
instruments must be portable, durable, easy to operate and relatively inexpensive. The parameters
generally monitored during energy audit may include the following:
Basic Electrical Parameters in AC &DC systems - Voltage (V), Current (I), Power factor,
Active power (kW), apparent power (demand) (kVA), Reactive power (kVAr), Energy
consumption (kWh), Frequency (Hz), Harmonics, etc.
Parameters of importance other than electrical such as temperature & heat flow, radiation,
air and gas flow, liquid flow, revolutions per minute (RPM), air velocity, noise and vibration,
dust concentration, Total Dissolved Solids (TDS), pH, moisture content, relative humidity, flue
gas analysis - CO2, O2, CO, SOx, NOx, combustion efficiency etc.
Key instruments for energy audit are listed below.
The operating instructions for all instruments must be understood and staff should
familiarize themselves with the instruments and their operation prior to actual audit use
i. Electrical Measuring Instruments:
These are instruments for measuring major electrical parameters such as kVA, kW, PF,
Hertz, kVAr, Amps and Volts. In addition, some of these instruments also measure harmonics.
These instruments are applied on-line i.e on running motors without any need to stop the
motor. Instant measurements can be taken with hand-held meters, while more advanced ones
facilitate cumulative readings with print outs at specified intervals.
ii. Combustion analyzer:
This instrument has in-built chemical cells which measure various gases such as O2, CO,
NOX and SOX.
iii. Fuel Efficiency Monitor:
This measures oxygen and temperature of the flue gas. Calorific values of common fuels
are fed into the microprocessor which calculates the combustion efficiency.
iv. Fyrite:
A hand bellow pump draws the flue gas sample into the solution inside the fyrite. A
chemical reaction changes the liquid volume revealing the amount of gas. A separate fyrite can
be used for O2 and CO2 measurement.
v. Contact thermometer:
These are thermocouples which measures for example flue gas, hot air, hot water
temperatures by insertion of probe into the stream. For surface temperature, a leaf type probe is
used with the same instrument.
vi. Infrared Thermometer:
This is a non-contact type measurement which when directed at a heat source directly
gives the temperature read out. This instrument is useful for measuring hot spots in furnaces,
surface temperatures etc.
vii. Pitot Tube and manometer:
Air velocity in ducts can be measured using a pitot tube and inclined manometer for
further calculation of flows.

viii. Water flow meter:

This non-contact flow measuring device using Doppler effect / Ultra sonic principle.
There is a transmitter and receiver which are positioned on opposite sides of the pipe. The meter
directly gives the flow. Water and other fluid flows can be easily measured with this meter.
ix. Speed Measurements:
In any audit exercise speed measurements are critical as they may change with frequency,
belt slip and loading.
 A simple tachometer is a contact type instrument which can be used where direct access
is possible.
More sophisticated and safer ones are noncontact instruments such as stroboscopes.
x. Leak Detectors:
Ultrasonic instruments are available which can be used to detect leaks of compressed air
and other gases which are normally not possible to detect with human abilities.

Energy Audit
Energy Audit is the key to a systematic approach for decision-making in the area of
energy management. It attempts to balance the total energy inputs with its use, and serves to
identify all the energy streams in a facility. It quantifies energy usage according to its discrete
functions. Industrial energy audit is an effective tool in defining and pursuing comprehensive
energy management programme.
Definition:
"The verification, monitoring and analysis of use of energy including submission of technical
report containing recommendations for improving energy efficiency with cost benefit analysis
and an action plan to reduce energy consumption".
Need for Energy Audit
In any industry, the three top operating expenses are often found to be energy (both
electrical and thermal), labour and materials. If one were to relate to the manageability of the
cost or potential cost savings in each of the above components, energy would invariably emerge
as a top ranker, and thus energy management function constitutes a strategic area for cost
reduction. Energy Audit will help to understand more about the ways energy and fuel are used
in any industry, and help in identifying the areas where waste can occur and where scope for
improvement exists.
The Energy Audit would give a positive orientation to the energy cost reduction,
preventive maintenance and quality control programmes which are vital for production and
utility activities. Such an audit programme will help to keep focus on variations which occur in
the energy costs, availability and reliability of supply of energy, decide on appropriate energy
mix, identify energy conservation technologies, retrofit for energy conservation equipment etc.
In general, Energy Audit is the translation of conservation ideas into realities, by lending
technically feasible solutions with economic and other organizational considerations within a
specified time frame.
The primary objective of Energy Audit is to determine ways to reduce energy
consumption per unit of product output or to lower operating costs. Energy Audit provides a "
bench-mark" (Reference point) for managing energy in the organization and also provides the
basis for planning a more effective use of energy throughout the organization.
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
Preliminary Energy Audit Methodology
Preliminary energy audit is a relatively quick exercise to:
• 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
 Energy Conservation Schemes
Development of an energy conservation programme can provide savings by reduced
energy use. However, it is economical to implement an energy conservation program only when
savings can offset implementation cost over a period of time. Potential areas of conserving
energy and a logical analysis of the methods or techniques of conservation would provide a
systematic and disciplined approach to the entire conservation strategy as a sequel to the energy
audit. Some established conservation trends are replacement, retrofit, process innovation, fuel
conservation and co-generation.
It is generally considered that investment for energy conservation should be judged by
exactly the same criteria as for any other form of capital investment. Energy conservation
measures may be classified on an economic basis and fall into the following three categories:
(i) Short term: These measures usually involve changes in operating practices resulting in little
or no capital expenditure.
(ii) Medium term: Low-cost modifications and improvements to existing equipment where the
pay-back period is less than two years and often under one year.
(iii) Long term: Modifications involving high capital costs and which frequently involve the
implementation of new techniques and new technologies.
While the first two categories together can achieve savings of the order of 5-10%, capital
expenditure using existing and new technology may achieve a further 10-15%. It is impossible
to give a comprehensive list of all items in each category but selected examples are given for
each section.
i. Short-term energy conservation schemes
Items in this group can be considered as a tightening of operational control and improved
housekeeping.
(a) Furnace efficiencies: Greater emphasis should be placed on minimum excess combustion
air. Oxygen levels of flue gases should be continually monitored and compared with target
values. Oil burners must be cleaned and maintained regularly.
(b) Heat exchangers: In the case of heat where useful heat is transferred from product streams
to feed streams, careful monitoring of performance should be carried out to determine optimum
cleaning cycles. Frequency of cleaning will generally increase as a result, with consequent
improved heat recovery.
(c) Good housekeeping: Doors and windows should be kept closed as much as possible during
the heating season. Wear natural light is sufficient, do not use artificial light. Avoid excessive
ventilation during the heating season. Encourage staff to wear clothing appropriate to the
temperature of the working areas.
(d) Use of steam: Major steam leaks should be repaired as soon as possible after they occur:
often a firm specializing in ‘on stream’ maintenance can be used.
(e) Electrical power: In industries where all the electrical power is ‘imported’ conservation
measures can reduce the annual electricity costs by 10–15 percent. Steam driven turbines may
prove more economical as prime movers. Natural air cooling may be sufficient and therefore
induced–draught fans may be taken out of commission. Pumping costs can sometimes be saved
by utilizing gravity to move products from one tank to another. Where possible, use off-peak
electricity.
ii. Medium-term energy conservation schemes
Significant savings in energy consumption are often available for quite modest outlays
of Capital based on a pay-back period of less than two years,
(a) Insulation: Improving insulation to prevent cold air leaking into the building and also,
improving insulation of the steam distribution system.
(b) Heating Systems: Improving the time and temperature control of the heating systems in
buildings should result in substantial energy savings.
(c) Replacing air compressors: the damaged air compressors must be replaced by new ones
which gives good compressed air.
(d) Instrumentation: To measure and control the energy conservation parameters, adequate
instrumentation must be provided or operators will soon lose interest in maintaining efficiencies
if they are working with inadequate an unreliable instrument.
(e) Process modifications: Many of these schemes will depend on the nature of the industry
concerned. However, one general scheme will be considered, improved condensate return
systems can increase the amount recovered.
(f) Burners: The control and amount of atomizing stream is important and often in furnaces and
boilers the amount of atomizing steam is far in excess of design.
(g) Electrical Power Savings: Considerable savings may be made by adjusting the electrical
power factor correction.
iii. Long-term energy conservation schemes
To obtain further economics in energy consumption required the spending of significant
amounts of capital, although, in many cases, the return on capital for the long-term investment
may not be as good as that of the medium term. Full financial evaluation is needed, using the
appraisal techniques discussed in Unit-V, to ensure the investment is economically viable.
(a) Heater modifications: The installation of heating tubes and air pre-heaters to extract more
heat from furnace flue gases.
(b) Improved Insulation: Additional lagging of heated storage tanks. This type of project often
comes within the medium-term group.
(c) Heat recovery: improved heat recovery in the processing areas by additional heat exchange
schemes.