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Prof. Prasad Parulekar

ENERGY AUDIT


WHAT IS ENERGY AUDIT?

Various Definitions:

1. Energy audit serves the purpose of identifying where a building or plant facility uses
energy, how it uses energy and identifies energy conservation opportunities (ECOs).
2. Energy audit identifies opportunities for financial savings by elimination of wasteful use of
electricity, coal and fuel oil, without affecting the process or quality of product.
3. The first step in an energy management program is to conduct an energy audit which is
nothing but the systematic gathering and analysis of energy use information within a
facility. Once the data has been analysed or energy audit has been conducted the
information can then be used to promote energy efficient practices in the areas of the
facility where they will prove to be most effective. Progress of any initiative that is put in
place can then be accurately monitored.
4. The energy audit serves to identify all of the energy streams into a facility and to quantify
energy use according to discrete functions.
5. An energy audit may be considered as similar to the monthly closing statement of an
accounting system; one series of entries consists of the amount of energy which were
consumed during the month in the form of electricity, gas, fuel oil, steam and the second
series lists how the energy was used i.e. how much for lighting, how much for air-
conditioning, heating, processes etc. The energy audit process must be carried out
accurately enough to identify and quantify the energy and cost savings that are likely to
be realized through investment in an energy saving measure.

*(Facility: Any building, plant or industry for which energy audit is to be conducted.)

Need for Energy Audit:

It has been established that Energy savings of the order of 5 to 20% are possible by optimizing
use of Energy with better house keeping, low cost retrofitting measures and use of Energy
efficient equipment at the time of replacement, renovation or upgradation. Indian industry
consumes much more energy per unit production as compared to its counterparts in the
developed countries.

An energy audit can be broken down into three basic steps;
Step 1: Audit of historical data
Step 2: Screening survey or walk-through audit
Step 3: Detailed investigation and analysis.
Step 1: Audit of historical data:
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The first step, audit of historical data, requires the auditor to identify and quantify each of the
energy forms as well as establish a general trend or pattern in energy use over a number of years.
Some of the things that should be covered at this point of the audit are; energy costs and
consumption levels, seasonal patterns, a review of purchasing arrangements, comparison of
energy consumption with output where appropriate, and a calculation of specific energy
consumption.
Step 2: Screening survey or walk-through audit:
The screening survey or walk through audit is used to identify any immediate opportunities to
reduce energy costs (e.g. switching off lights or fans which are unnecessarily on in the facility).
This second step will also establish the feasibility for potential cost savings in each area of energy
consumption and the priority for allocating resources. At this stage a monitoring and reporting
procedure can be established.
At this stage it is a good idea to conduct a simple survey. The survey could involve a walk around
the work place identifying areas where there seems to be excessive energy usage, or it could be
conducted using a questionnaire or checklist. Getting other people involved will often identify
areas in the business where energy savings can be made immediately at little to no cost.
When reviewing the energy use recording and reporting system it is important to identify what
are the most readily available sources of information. Many offices that share a large building will
not have the individual floors metered. In these cases it may be necessary to capture the
information through the energy bills. This may require some cooperation from the finance or
administration departments for larger businesses. All energy consumption should be recorded in
consistent units, for example reporting electricity and gas in megajoules, to enable meaningful
comparisons.
The final action in this step of the audit is to report a plan of action to management. It is
important to develop a plan of action for management's approval in order to establish their
commitment to identified energy management activities. It will also help promote the principle of
energy management through the work place, having gained management's endorsement.
The plan of action itself should include things like;
Immediate energy savings achievable
Further investigation required for identifying savings which could be achieved through
larger scale energy efficiency projects
Problems in the controlling of energy costs and in collecting and reporting energy data
An estimate of the costs of the business as usual scenario. That is outline what the future
cost of energy use will be if no action is taken with regards to the identified potential
savings
A "Plan of Action" that covers in detail the most important areas of saving as identified
through the data collection and survey. This should also include an indication as to what is
the most efficient sequence of action in order to reduce energy costs.
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Prof. Prasad Parulekar
Step 3: Detailed investigation and analysis:
The third major step in an energy audit is the detailed investigation and analysis. This step is
based on the areas that were identified in Step 2 as requiring further investigation.
With results from this step and those obtained in the walk through survey a detailed energy
management program for the business can be developed, or an existing program reviewed. Once
a program or policy has been put in place it needs to be reviewed on a regular basis to make sure
that it is achieving its objectives.
So in general we can say that two basic parts of energy audit are data acquisition and data
analysis.
(A) Data acquisition: This phase requires the accumulation of utility bills and establishing a
baseline to provide a historical documentation and a survey of the facility for which audit
is being carried out. The information about energy rate structures based upon various
types of utilities being consumed is also collected in this stage.
(B) Data analysis: The data collected during data acquisition phase is analysed in detail and
ECOs are identified. This is the important phase of auditing program as here energy
management team has to continuously monitor the facility even after the ECOs has been
implemented.
ENERGY AUDIT METHODOLOGY:
The stepwise methodology of energy audit is as given below.
Step 1 - Interview with Key Facility Personnel

During the initial audit, a meeting is scheduled between the auditor and all key operating
personnel to kick off the project. The meeting agenda focuses on: audit objectives and scope of
work, facility rules and regulations, roles and responsibilities of project team members, and
description of scheduled project activities.

In addition to thee administrative issues, the discussion during this meeting seeks to establish:
operating characteristics of the facility, energy system specifications, operating and maintenance
procedures, preliminary areas of investigation, unusual operating constraints, anticipated future
plant expansions or changes in product mix, and other concerns related to facility operations.

Step 2 - Facility Tour

After the initial meeting, a tour of the facility is arranged to observe the various operations first
hand, focusing on the major energy consuming systems identified during the interview, including
the architectural, lighting and power, mechanical, and process energy systems.



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Prof. Prasad Parulekar

Step 3 - Document Review

During the initial visit and subsequent kick-off meeting, available facility documentation are
reviewed with facility representatives. This documentation should include all available
architectural and engineering plans, facility operation and maintenance procedures and logs, and
utility bills for the previous three years. It should be noted that the available plans should
represent "as-built" rather than "design" conditions. Otherwise, there may be some minor
discrepancies between the systems evaluated as part of the audit and those actually installed at
the facility.

Step 4 - Facility Inspection

After a thorough review of the construction and operating documentation, the major energy
consuming processes in the facility are further investigated. Where appropriate, field
measurements are collected to substantiate operating parameters.

Step 5 - Staff Interviews

Subsequent to the facility inspection, the audit team meets again with the facility staff to review
preliminary findings and the recommendations being considered. Given that the objective of the
audit is to identify projects that have high value to the customer, management input at this
juncture helps establish the priorities that form the foundation of the energy audit. In addition,
interviews were scheduled with key representatives designated by the facility as having
information relevant to the energy audit. These representatives may include major energy
consuming system service and maintenance contractors and utility representatives.

Step 6 - Utility Analysis

The utility analysis is a detailed review of energy bills from the previous 12 to 36 months. This
should include all purchased energy, including electricity, natural gas, fuel oil, liquefied petroleum
gas (LPG) and purchased steam, as well as any energy generated on site. If possible, energy data
is obtained and reviewed prior to visiting the facility to insure that the site visit focuses on the
most critical areas. Billing data reviewed includes energy usage, energy demand and utility rate
structure. The utility data is normalized for changes in climate and facility operation and used as a
baseline to compute projected energy savings for evaluated ECM's.

Utilities generally offer a comprehensive portfolio of rate tariffs and riders that can be tailored to
the energy consumption and demand of the end-user. In addition, with the advent of
deregulation, energy can be purchased on contract from a number of third party marketers.
Using energy consumption/demand characteristics revealed by a detailed analysis of recent utility
bills, the optimum energy supply options is identified.

In addition, given the high cost of purchased energy it may be cost-effective to produce some of
the facility's energy requirements on-site. Options may include: power generators for emergency
power and peak-shaving, solar panels, wind power and cogeneration.
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Step 7 - Identify/Evaluate Feasible ECMs

Typically, an energy audit will uncover both major facility modifications requiring detailed
economic analysis and minor operation modifications offering simple and/or quick paybacks. A
list of major ECMs is developed for each of the major energy consuming systems (i.e., envelope,
HVAC, lighting, power, and process). Based upon a final review of all information and data
gathered about the facility, and based on the reactions obtained from the facility personnel at
the conclusion of the field survey review, a finalized list of ECMs (energy conservation measures)
is developed and reviewed with the facility manager.

Step 8 - Economic Analysis

Data collected during the audit is processed and analyzed back in our offices. We build models
and simulations with software to reproduce our field observations and develop a baseline against
which to measure the energy savings potential of ECMs identified. We then calculate the
implementation cost, energy savings and simple payback for each of the ECMs being investigated.




Step 9 - Prepare a Report Summarizing Audit Findings

The results of our findings and recommendations are summarized in a final report. The report
includes a description of the facilities and their operation, a discussion of all major energy
consuming systems, a description of all recommended ECMs with their specific energy impact,
implementation costs, benefits and payback. The report incorporates a summary of all the
activities and effort performed throughout the project with specific conclusions and
recommendations.

Step 10 - Review Recommendations with Facility Management

A formal presentation of the final recommendations is presented to facility management to
supply them with sufficient data on benefits and costs to make a decision on which ECMs to be
implemented.

*(ECMs Energy Conservation Measures. It is an alternate name for ECOs)


TYPES OF ENERGY AUDIT:

The term energy audit is commonly used to describe a broad spectrum of energy studies ranging
from a quick walk-through of a facility to identify major problem areas to a comprehensive
analysis of the implications of alternative energy efficiency measures sufficient to satisfy the
financial criteria of sophisticated investors. Three common audit programs are described in more
detail below, although the actual tasks performed and level of effort may vary with the
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Prof. Prasad Parulekar
consultant providing services under these broad headings. The only way to insure that a
proposed audit will meet your specific needs is to spell out those requirements in a detailed
scope of work. Taking the time to prepare a formal solicitation will also assure the building owner
of receiving competitive and comparable proposals.

(1) Preliminary Audit (Walk-through audit):

The preliminary audit alternatively called a simple audit, screening audit or walk-through audit, is
the simplest and quickest type of audit. It involves minimal interviews with site operating
personnel, a brief review of facility utility bills and other operating data, and a walk-through of
the facility to become familiar with the building operation and identify glaring areas of energy
waste or inefficiency.

Typically, only major problem areas will be uncovered during this type of audit. Corrective
measures are briefly described, and quick estimates of implementation cost, potential operating
cost savings, and simple payback periods are provided. This level of detail, while not sufficient for
reaching a final decision on implementing a proposed measures, is adequate to prioritize energy
efficiency projects and determine the need for a more detailed audit.

(2) General Audit (Mini Audit):

The general audit alternatively called a mini-audit, site energy audit or complete site energy audit
expands on the preliminary audit described above by collecting more detailed information about
facility operation and performing a more detailed evaluation of energy conservation measures
identified. The actual tests and measurements in order to quantify the energy uses and losses are
carried out. Utility bills are collected for a 12 to 36 month period to allow the auditor to evaluate
the facility's energy/demand rate structures, and energy usage profiles. Additional metering of
specific energy-consuming systems is often performed to supplement utility data. In-depth
interviews with facility operating personnel are conducted to provide a better understanding of
major energy consuming systems as well as insight into variations in daily and annual energy
consumption and demand.

This type of audit will be able to identify all energy conservation measures appropriate for the
facility given its operating parameters. A detailed financial analysis is performed for each
measure based on detailed implementation cost estimates, site-specific operating cost savings,
and the customer's investment criteria. Sufficient detail is provided to justify project
implementation.

(3) Investment-Grade Audit (Maxi audit):

In most corporate settings, upgrades to a facility's energy infrastructure must compete with non-
energy related investments for capital funding. Both energy and non-energy investments are
rated on a single set of financial criteria that generally stress the expected return on investment
(ROI). The projected operating savings from the implementation of energy projects must be
developed such that they provide a high level of confidence. In fact, investors often demand
guaranteed savings.
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The investment-grader audit alternatively called a comprehensive audit, detailed audit, maxi
audit, or technical analysis audit, expands on the general audit described above by providing a
dynamic model of energy use characteristics of both the existing facility and all energy
conservation measures identified. The building model is calibrated against actual utility data to
provide a realistic baseline against which to compute operating savings for proposed measures.
Extensive attention is given to understanding not only the operating characteristics of all energy
consuming systems, but also situations that cause load profile variations on both an annual and
daily basis. Existing utility data is supplemented with submetering of major energy consuming
systems and monitoring of system operating characteristics.

Here model analysis such as computer simulation is carried out in order to determine energy use
patterns and predictions on a year round basis, taking into account certain variables such as
weather data.

*(Differentiate between walk-through audit and maxi audit)

ENERGY PROFILES:

For a particular industry, the energy audit approach includes process consideration. For preparing
energy audit for any industry, it is necessary to know the energy use patterns there. So for this it
is important to account for total consumption, total cost and use patterns for each utility such as
steam, natural gas, water, air, oil etc. this procedure is necessary to develop the energy
conservation strategy.
General illustration of energy utilization by a typical industrial plant can be shown with the help
of following figures:






Figure 1: Energy Use Profile









Diesel Oil (12%)
1.210
9
BTU/yr Gasoline (8%)
0.810
9
BTU/yr
Electricity (30%)
310
9
BTU/yr
Natural gas (50%)
510
9
BTU/yr
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Figure 2: Energy Cost Profile



Figure 1 and 2 indicates the energy use and energy cost profile. Figure 1 indicates the energy consumption according
to type of fuel i.e. energy consumption in the form of gasoline, natural gas, diesel oil and electricity. However, figure
2 indicates the amount spent for each type of fuel. Such figures are called as pie-chart presentations, which is helpful
in visualizing the pattern in which energy is consumed. Similarly, we can show the energy profile by function, which
shows the energy consumption pattern by different functions like, lighting, process, building heating, ventilation etc.




Figure 3: Energy use Profile by Function






Electricity (50%)
Rs. 210
6
/ yr
Natural gas (29.5%)
Rs. 1.1610
6
/ yr
Gasoline (8.5%)
Rs. 0.3410
6
/ yr
Diesel Oil (12.5%)
Rs. 0.510
6
/ yr







Diesel Fuel (12%)
HVAC Building (25%)
Gasoline (8%)
Process Ventilation
(10%)
Lighting Building (28%)
Process Equipment (32%)
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Figure 4: Energy use Profile by Function

In order to construct energy profile, several sub audits are required to be carried out which will further
proceed to final energy audit. These several types of sub audits are as below:

1. Envelope Audit:

This type of audit basically surveys the building envelope for losses or gains due to leaks, building
constructions, doors, glass, lack of insulation etc.

2. Functional Audit:

This type of audit determines the amount of energy required for particular function and identifies
energy conservation opportunities. Such type of audit includes the functions like:
(a) Heating, ventilation and air conditioning
(b) Building Lighting
(c) Domestic hot water supply for building
(d) Air distribution for building

3. Process Audit:

This type of audit determines the amount of energy required for each process and identifies energy
conservation opportunities. It includes processes like:
(a) Process machinery
(b) HVAC for processes
(c) Heat treatment
Process (40%)
Steam Leaks (4%)
Building heat 30%
Domestic Hot Water (4%)
Boiler Feed water Heat (20%)
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(d) Furnaces

4. Transportation Audit:

It determines the amount of energy required for forklifts, trucks, cars, other vehicles etc.
5. Utility Audit:

It analyses the daily, monthly or yearly usage for each utility.


INSTRUMENTATION PART OF ENERGY AUDIT ACTIVITY:

To carry out energy audit, different measurements are required to carry out which require different
instruments for measuring energy usage, energy leakage etc. Some of these instruments are:

1. Infrared Equipment:

Infrared energy is contained in invisible part of the electromagnetic spectrum. The basic principle behind
this infrared equipment is that, the differences between the infrared emissions from the surface of objects
causes colour variations to appear on the scanner. With the aid of an isotherm circuit, the intensity of
these radiation levels can be accurately measured and quantified. The detector absorbs infrared energy
and converts it into electrical voltage or current. The lightest area of the spectrum on the screen
represents the warmest part of the object and the darkest area represents the coolest portion.

2. Equipments for measuring performance of electrical system:

For this purpose, following various equipments are used:

(i) Ammeter & Voltmeter:

Ammeters are used to measure the electrical currents because for most audits, alternating currents are
measured, however voltmeters are used to measure the voltage.

(ii) Wattmeter & Power factor meter:

Wattmeter indicates the direct reading of electrical energy in watts. Power factor meter is used to
measure the power factor which is a basic parameter to calculate the usage of electrical energy.

(iii) Foot-candle meter:

It measures the illumination in units of foot-candles through a sensitive barrier layer of cells contained
within them.


3. Equipments for measuring Temperature:

To maximize the system performance, knowledge of the fluid temperature, surface temperature etc. is
essential. For this many instruments such as following are used:

(i) Thermometer:
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Used to measure temperature between 50 to 100
0
F.

(ii) Surface pyrometer:

It measure the surface temperature. It is useful in assessing the heat losses through walls and for testing
steam traps. They come in two ranges i.e. low range (up to 250
0
F) and high range (up to 700
0
F).

(iii) Psychrometer:

It measures the relative humidity based on the relation of dry bulb temperature and wet bulb
temperature. Relative humidity is important in HVAC and drying operations.

(iv) Portable electronic thermometer

(v) Thermocouple probe

(vi) Suction pyrometer:

It is used to measure the gas temperature which are of high degrees.


4. Equipments for measuring performance of combustion system:

To maximize the efficiency of the combustion system, it is necessary to know the composition of the flue
gas. By obtaining a good air-fuel ratio, substantial amount energy can be saved. For this following
instruments are used:

(i) Combustion tester:

It determines the concentration of the combustion products in stack gas. Products of combustion are
generally CO
2
and CO. O
2
is tested to assure proper excess levels of air. It uses the orsat apparatus,
which can easily determine the constituents of interest on individual basis.

(ii) Boiler test kit:

It contains CO
2
gas analyzer, O
2
gas analyzer and CO gas analyzer. It evaluates boiler operation on fire
side. Good combustion means high CO
2
, low O
2
and little or no traces of CO.

(iii) Gas analyzer:

It is more simple and easy to use, inexpensive and hence used many times in energy audit.

(iv) Draft guage:

Used to measure pressure.

(v) Smoke tester:

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It is used to measure smoke density during combustion. Smoke is nothing but the unburned carbon
which wastes fuel, causes air pollution and foul heat exchanger surface. During this test, a measured
volume of flue gas is drawn through a filter paper with probe and then smoke pot is compared visually
with standard scale and then smoke density is determined.

(vi) Combustion analyzer:

It is an electronic analyzer to analyze stack gas.
5. Equipments for measuring the performance of HVAC system:

For measuring the performance of HVAC system, following measurements are carried out and respective
instruments are used.

(i) Air velocity measurement:

Air velocity is measured using the instruments like smoke pellets, anemometer, pitot tube, impact
tube etc.

(ii) Temperature measurement:

Temperature is measured using instruments like glass thermometer, resistance thermometers,
thermocouples, optical pyrometers, etc.

(iii) Pressure measurement:

It is measured using absolute pressure manometers, diaphragm, micro manometer, draft gauges,
bourdon tube gauge etc.

(iv) Humidity measurement:

The instruments used here are psychrometer, dew point hygrometer, gravimeter etc.

Identifying steam and utility cost:

The steam and utility costs are significant for most plants. These costs are useful to quantify usage, fuel
cost as a function of production. Steam and utility report is useful to know the effectiveness of energy use.

Calculating the energy content of process:

Knowing the energy content of process is first step in understanding how to reduce its cost. More efficient
use of energy reduces the product cost, increases the profit. To evaluate energy content, all energy
entering and leaving should be known. Based upon the energy content of process, it is decided which
equipments have to be replaced, how should be maintenance program, choice of raw material, etc.
The format of energy content of process report is as shown below:






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Report for Energy Content of Process

Process: (1) Total units produced:..

Energy of raw materials and miscellaneous requirements

Total usage BTUs per unit = Total BTUs
a.. = .
b.. = .
c.. =

(2)Total energy from raw material = (a)+(b)+(c) = .BTUs

Energy from major utilities (electricity, steam, cooling water, natural gas etc.)

Total usage BTUs per unit = Total BTUs
a.. = .
b.. = .
c.. =

(3) Total energy from utilities = (a)+(b)+(c) = ..BTUs

Energy credit as a result of byproducts

Total o/p BTUs per unit = Total BTUs
a.. = .
b.. = .
c.. =

(4) Total energy credit = (a)+(b)+(c) = ..BTUs

(5) Net energy content of process = (2) + (3) (4) = BTUs

(6) Energy content per unit of production = (5) (1) = BTUs



The industries whose energy bills use up a large part of their income or whose energy bills
represent a substantial fraction of their companys operating cost, have a strong motivation to
initiate and continue energy saving or on-going energy cost control program. Most of the
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times some minute operational changes also often save an industry 10-20% on their utility bills.
Such energy control programs many times results in both, the reduced energy consumption and
reduced emissions of environmental pollutants.

Energy auditing services:

The energy audits for industries are performed by the institutes or organizations who have professional
energy engineers or energy auditors on their staff. When such institutes or organizations offer some free
or low cost energy audit, then it means only walk-through audit. Large industries generally hire an
engineering consulting firm to perform a complete energy audit. Some industries hire an energy manager
or set up an energy management team whose job is to conduct periodic audits and keep up with the
available energy efficiency technology.


Basic components of energy audit:

1. Audit process starts by collecting information about a facility (operations and past record on utility
bills of the facility).
2. This collected data is then analyzed to get a picture of energy consumption pattern and ways of
energy wastage of facility. It also helps the energy auditor to learn about areas to be examined in
order to reduce energy cost.
3. Specific changes which are called as energy conservation opportunities (ECOs) are then
identified and evaluated to determine their benefits and their cost effectiveness.
4. These ECOs are assessed in terms of their cost and benefits and an economic comparison is
carried out to rank them.
5. Finally, an action plan is prepared where certain ECOs are selected for implementation and actual
process of saving energy and money begins.

THE ENERGY AUDITORS TOOLBOX:

To obtain the best information for a successful energy cost control program, auditor must carry out some
measurements during audit visit. However the number and range of instruments needed to carry along
with depends upon the characteristics of energy consuming equipments used at facility and on the range
of potential ECOs to be considered.
e.g. If waste heat recovery system is to be analyzed then energy auditor must take substantial
temperature measurements for those heat recovery sources.

General instruments contained in energy auditors toolbox are:

1. Tape measures:
These are used to check dimensions of walls, ceilings, windows and distance between pieces of
equipment. These measurements are especially carried out in order to measure lengths available
for transferring waste heat from one piece of equipment to other.
2. Light-meters:
They are used to measure illumination levels in facility. They allow direct analysis of lighting
systems and comparison with recommended light levels specified by the Illuminating Engineering
Society. They measures excess illumination and allows auditor to recommend a reduction in
lighting levels through programs such as lamp removing, replacing inefficient lamps with high
efficiency lamps etc.
3. Thermometers:
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They measures the temperatures of equipments, processes and allows the auditor to determine
process equipment efficiencies and helps in identifying waste heat sources for potential heat
recovery programs.
4. Voltmeter:
They are used to measure electrical voltage across the equipments.
5. Wattmeter / Power factor meter:
They are used to determine the power consumption and power factor of individual motors and
other inductive devices.
6. Combustion analyzer:
They estimate the combustion efficiency of furnaces, boilers and other fossil fuel consuming
machines.
7. Air flow measurement devices:
They are used to measure the flows of air from heating, ventilating and air-conditioning ducts and
identifies problems with air flows such as to check whether the combustion air flow into a gas
heater is proper or not.
8. Blower door attachment:
These are used to measure the tightness or leak proof nature of building or structure. It
determines the air leakage rate or number of air changes per hour in the facility and thus
determines whether facility has substantial structural or duct leaks that need to be identified and
sealed.
9. Smoke generator:
It identifies the air infiltration and leakage around the doors, windows, ducts and other structural
features. Here analyzer has to take care to wear a breathing mask to protect from any hazardous
or chemical smoke.
10. Safety instruments:
For safety purpose, energy auditor must carry safety instruments with him, like safety glasses,
hearing protectors (in case of visit to noisy areas such as high HP motors driving fans, pumps),
electrically insulated gloves, breathing masks, steel toes, safety shoes, etc.

HOW TO PREPARE FOR ENERGY AUDIT VISIT:

Before the actual visit to facility for energy audit purpose, an energy auditor must carry out some
preliminary work. Some of these preliminary preparations are:

1. Energy use data:

Energy auditor has to collect the data regarding energy use, power demand, cost for at least
previous 12 months in order to understand energy use patterns, and billing methods. Bills for gas,
electricity, oil, coal, etc. should be compiled and examined in order to determine their amount
used and their cost. This data should be tabulated and converted in graphical form to know the
patterns and related problems. Any problem in energy use pattern, raises the possibility for some
significant energy or cost saving by identifying and controlling that problem or adverse behavior.

2. Rate structure:

To fully understand the cost of energy, auditor must determine the rate structure under which
energy use is billed. Some energy rates may be simple or fixed however some rates may be
complex enough which may be changing monthly based upon electricity consumption, energy
charge, demand, power factor charge etc.

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3. Physical and operation data related to facility:

Energy auditor must gather information regarding the factors likely to affect the energy use in the
facility. Such factors are:

(i) Geographic location and weather data:
This data should be collected from local weather station, local utility or state energy office in
order to decide the need of energy for heating or cooling the facility.
(ii) Facility layout:
This data should be obtained and reviewed in order to know the facility size, floor plan,
construction features, wall and roof material, insulation levels, sizes of doors and windows,
etc.
(iii) Operating hours:
These should be obtained to know number of shifts in facility. After knowing it, allows to
decide whether some load of facility operations could be shifted during off-peak times.
Because adding a second shift can often be cost effective from energy cost point of view.
(iv) Equipment list:
This list should be obtained by energy auditor in advance. All large pieces of energy
consuming equipment such as heaters, air-conditioners should be identified. This is helpful
in knowing major energy consuming operations or equipments at facility. As a general
thumb rule, the largest energy and cost related activities should be examined first to see
what savings could be achieved. The greatest efforts should be devoted to ECOs that show
greatest savings and least efforts to those with smallest saving potential.


SAFETY CONSIDERATIONS:

While carrying out energy audit, energy auditing team should never place themselves in position where
they could injure themselves or other peoples at the facility. While carrying out any measurements on any
electrical system, high temperature and pressure devices such as boilers, cookers, heaters, etc. or parts
like open drive shafts, belts or gears, any rotating machinery, energy auditing team must wear safety
accessories and such measurements should be carried out with the help of operator or supervisor
concerned with that particular device or equipment.

For this following safety check list should be followed:

1. Electrical:

Avoid working on live circuits
Lock off switches and circuits before start working on a piece of equipment

2. Respiratory:

Whenever necessary, wear a full face respiratory mask with adequate filtration particle
size
Use activated carbon cartridge in the mask while working around low concentrations of
noxious gases.

3. Hearing:

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Use ear plugs or other sound proof accessories while working around equipments making
a big noise such as grinders, motors, etc.


THE BASIC THINGS TO LOOK FOR DURING ENERGY AUDIT:

1. Lighting:

It is important to make a detail inventory of all lighting system. Data should be recorded related to
number of each type of light fixtures, wattage of lamps, hours of operations for group of lights.
This data should be recorded in lighting inventory data sheet. Light intensity readings for each
area should be recorder with help of light meter. Based upon this, energy auditor will be able to
select an alternate lighting technology which may be more energy efficient.

2. HVAC equipments:

All HVAC equipments should be inventoried. For this, all specifications regarding these
equipments such as type, size, model number, age, electrical specifications, fuel use specifications,
estimated hours of operations, condition of evaporators, condenser coils, air filters, insulation on
refrigerant lines, air velocity, air leaks should be checked so that alternative HVAC system to
reduce energy cost can be recommended by auditor.

3. Electrical motors:

The information related to motors such as motor size, use, age, model number, estimated hours
of operation, other related electrical characteristics, power factors, measured efficiency, current,
power factors should be noted. All motors over 1 HP and with more than 2000 hours of operation
per year should be replaced with high efficiency motors when old one fails.

4. Water heaters:

In case of water heaters also, type, size, model number, age, electrical or fuel characteristics,
operating characteristics, use patterns should be noted.

5. Waste heat sources

Most of the facilities generally have many sources of waste heat which may possibly provide
opportunities for waste heat recovery to be used as total or substantial source of hot water need.
Such sources of waste heat may be air conditioners, air compressors, heaters, boilers, process
cooling systems, ovens, furnaces, cookers, etc. It is also important to measure temperature for
such waste heat sources.

6. Peak equipment loads:

Energy auditor has to look for any piece of electrically powered equipment that is used
infrequently or whose use could be controlled and shifted to off peak times. Such equipments may
be fire sprinkler system pumps, certain types of welders, drying ovens, back up machines, etc.
Some of the production machines can also be scheduled for off peak times.

7. Other energy consuming equipments:
Compiled by
Prof. Prasad Parulekar

Inventory of all other equipments, which consume a substantial amount of energy, has to be
taken.


PRELIMINARY IDENTIFICATION OF ECOs:

When energy audit is being conducted, the auditor should be aware about the potential ECOs. Energy
auditor should have good knowledge about available energy efficient technologies that can accomplish
the same job with less energy and less cost. Such examples may be
Over-lighting indicates a potential lamp removal or lamp change ECO and inefficient lamps indicate a
potential lamp technology change. Motors with high usage time are potential for high efficiency
requirements. So all such potential ECOs should be identified during walk-through audit so that later it will
become easier to analyze the data and decide final ECO recommendations.

POST AUDIT ANALYSIS:

After the energy audit visit to facility, the data collected from visit is examined, organized and reviewed
for completeness. If any data is missing, then it is obtained from facility personnel or from revisit to
facility. The preliminary ECOs identified during the audit visit are then reviewed for actual analysis of
equipment and operational changes to be carried out. This analysis process involves determining the costs
and benefits of the potential ECOs and making a judgment on the cost effectiveness of that potential ECO.

Cost effectiveness involves a judgment decision that is viewed differently by different peoples and
different companies. For measuring this cost effectiveness, most of the times, Simple Pay back Period
(SPP) is used which is calculated by considering the initial investment (cost) and dividing it by the annual
savings. This helps to find a period for savings to repay the initial investment without using a time value of
money. Sometimes to measure this cost effectiveness, Discounted Benefit Cost Ratio is used.


Simple pay back period (SPP) = (Initial investment for implementing ECO) / (Annual savings after
implementing that ECO)




FORMAT OF ENERGY AUDIT REPORT:

The general format of energy audit report is as shown below:

Executive Summary:

A brief summary of recommendations and cost savings

Table of contents:

Introduction:

Purpose of energy audit, need for continuing energy cost control program

Compiled by
Prof. Prasad Parulekar
Facility description:

Product or services from facility, materials used, size, construction, layout, hours of operation, equipment
list with specifications, etc.

Energy bill analysis:

Utility rate structure, tables and graphs of energy consumption and costs, discussions on energy costs and
energy bills

Energy conservation opportunities:

Listing of potential ECOs, cost and saving analysis, economic evaluation

Action plan:

Recommended ECOs and their implementation schedule, designation of energy monitoring and on-going
program

Conclusion:

Energy action plan:





























Compiled by
Prof. Prasad Parulekar