ENERGY AUDIT

Darshan Vithani ,Pranav Pathak

ME-CSE

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ENERGY AUDIT (EA)

pool of activities (systematic procedure)
focused on analysis of current energy
need and consumption going out of valid
technical standards,
analysis of problems (weaknesses and
deficiencies),
EA identifies and in detail quantifies
effective possibilities of energy savings
tailored to the object being analyzed,
Energy Audit

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AIM OF ENERGY AUDIT

to minimize costs for energy
to minimize operational costs
to minimize costs for repairs
andreconstruction
increase quality of environment that
contributes to increased work
productivity
Energy Audit

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AIM OF ENERGY AUDIT

to minimize costs for energy
to minimize operational costs
to minimize costs for repairs
andreconstruction
increase quality of environment that
contributes to increased work
productivity
Energy Audit

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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

Energy Audit

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PRELIMINARY ENERGY AUDIT

METHODOLOGY

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 Audit

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DETAILED ENERGY AUDIT

METHODOLOGY

It is offers most accurate estimate of energy

savings and cost
This is based on an inventory of energy using
systems, assumptions of current operating
conditions and calculations of energy use.
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

Energy Audit

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Steps For DETAILED ENERGY AUDIT

METHODOLOGY

Energy Audit

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Steps For DETAILED ENERGY AUDIT

METHODOLOGY

Energy Audit

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Steps For DETAILED ENERGY AUDIT

METHODOLOGY

Energy Audit

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Steps For DETAILED ENERGY AUDIT

METHODOLOGY

Energy Audit

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Steps For DETAILED ENERGY AUDIT

METHODOLOGY

Energy Audit

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Steps For DETAILED ENERGY AUDIT

METHODOLOGY

Energy Audit

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AREAS OF ENERGY AUDIT

Subject of energy consumption analysis are energy
resources consumed in the industrial area, i.e.

Electricity
Natural gas
Steam
Coal
Wood, wood chips/pellets
Fuels (petrol, oil, propane-butane).....

Energy Audit

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AREAS OF ENERGY AUDIT

thermal-technical protection of buildings,

heating systems
hot water preparation,
ventilation systems and air-conditioning (buildings and
technology)

electric appliances (administrative and technological incl.

electrical connection, transformation, distribution network,
el. switchboards, el. compensation)
gas or other energy resources consuming appliances
(furnaces, cleaning devices,..)
Indoor/outdoor lighting,
measurement and regulation.

Energy Audit

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ENERGY AUDIT METHODOLOGY

Pre-audit presentation.

Collection of data / information.

Measurements and monitoring with

instruments.

Computation and in-depth analysis.

Post-audit presentation to discuss the Energy

Conservation Opportunities identified by the
audit team.

Energy Audit

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INSTRUMENTS USED

Flue Gas Analyzer

Power Analyzer, Tachometer

Ultrasonic Flow Meter

Trap Man (For Steam Trap Survey)

Raytech Gun & Digital Thermometer (Non-contact

and Contact type both)

Anemometer, pH/TDS/Conductivity meter

LUX Meter, Digital Manometer

Energy Audit

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Case Study
Energy Audit at Mother Dairy
(Milk Plant)
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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 Consumption

PNG: 17,76,000 SCM

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

15,000 kg/month for Ice Cream Plant

Energy Audit

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Summary of Savings Identified &

Realized (Year 2003 & 2004)
Total Savings projected by
PCRA

Electricity: 21,43,360 kVAh Worth: Rs 78.24 Lac

LDO: 184.31 KL Worth: 85.8 Lac

Total Savings Realised till

date

Electricity: 5,21,017 kVAh Worth: Rs 19.02 Lac

LDO: 130.06 KL Worth: Rs 60.55 Lac

% Savings Realised of total

energy consumption

Electricity: 3.7%
LDO: 20.3%

Major recommendations implemented:

1.
2.
3.
4.
5.

Boiler fuel switched over to PNG from LDO

Steam supplied to ICP from this boiler
Improvement of Power Factor from 0.9 to 0.996
New air compressor installed lowering SEC
Installation of Auto Blow Down system for Boiler

Energy Audit

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Summary of Savings Identified

(Year 2005)
Total savings identified

Electricity: 7,17,004 kVAh

PNG: 1,36,042 SCM
Worth: Rs 59.18 Lac

No cost savings with immediate

payback

Electricity: 95,308 kVAh

Worth: Rs 4.1 Lac

Low cost savings with payback < 1

year

Electricity: 5,41,796 kVAh

Worth: Rs 23.3 Lac

High cost savings with payback

between 1-2 years

Electricity: 79,900 kVAh

Worth: Rs 3.44 Lac
Gas: 1,36,042 SCM
Worth: Rs 28.34 Lac

% savings identified of total energy

consumption

Electricity: 5.32%
Gas: 7.66%

Energy Audit

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BOILERS
Observations:
1.
2.

Condensate recovery is not being done.

Feed water temperature presently is 50C.

Recommendations:
3.
4.
5.

Recover condensate to raise feed water temperature to upto

85C
Install de-aerator head on feed water tank and recover
condensate.
Install steam operated condensate recovery pump

Savings Estimated / year

Investment

Payback Period

Rs 28.34 Lac

Rs 25 Lac

11 Months

Energy Audit

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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

Energy Audit

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Illumination
Observations:
1. HPMV lamps are used for street lighting.
2. 36 Watt Tube lights with copper chokes are used.
Recommendations:
3. Replace HPMV lamps by HPSV lamps
4. Replace 36 Watt Tube lights with T-5 28 Watt with
electronic choke in a phased manner.

Savings Estimated / year

Rs 3.34 Lac

Investment
Rs 4.0 Lac

Energy Audit

Payback Period
16 Months

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Conclusion
The gaps may exist in design & actual operations for
large complexes due to integration of :
Steam thermal systems.
Electrical systems
Process systems (Motive/ Thermal loads) due to
variation in efficiencies/ actual requirements
Continuous monitoring and analysis of integrated
systems is essential for improvements.
Energy Audits will identify such gaps.
Implementation of recommendations will result into
considerable energy savings.

Energy Audit

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Thank You

Darshan Vithani ,Pranav Pathak

ME-CSE

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