This document discusses energy audits and provides information on related topics. It defines an energy audit, describes the objectives and types of energy audits. It also discusses benchmarking, energy conservation opportunities, and instruments used in energy audits. Conversion factors and the Energy Conservation Act are outlined. Methodology, steps, and components of preliminary and detailed energy audits are summarized.

1. Energy Audit

2. Energy Audit
Definition: Energy audit
Types of energy audit,
Understanding energy costs
Bench marking
Energy performance
Fuel and energy substitution
Energy audit instruments

3. Conversion Factors for MTOE
1 Kwh = 860 Kcal
1 kg of coal/coke = GCV in Latest Certificates
1 kg FO/LSHS/Naptha = 10500 Kcal/kg (density = 0.93)
1 kg HSD = 11840 Kcal (density = 0.82)
1 kg Petrol = 11200 Kcal (density = 0.708)
1 kg Kerosene = 11110 Kcal (density = 0.778)
1 kg LPG = 12500 Kcal
1 m3 of Natural gas = 8000-10500Kcal (actual as per
certificate)
1 kg of oil equivalent = 10,000 Kcal

4. Energy Conservation Act
Designated consumers : Central Govt. specify
the following criteria for energy Intensive
Industries and other establishments. (As per EC
Act 2001, Section 14(e)
For Industries
Electrical connected load -5000 KW and above
or
Annual energy consumption - 30,000 MTOE
For Commercial Buildings
Connected Load - 500 KW or 600 KVA

5. ELECTRICITY ACT 2001
MAIN FEATURES
1. Replaced all the previous three Electricity
Laws:
– Indian Electricity Act 1910, Electricity
Supply Act 1948
– Electricity Regulatory Commission Act
1998 as amended from time to time
2. 100% metering is mandatory for 11 KV
feeder
3. 100% Rural Electrification
– Accelerated Rural electrification Program,
AREP)
– PRIs & NGOs can be participated)
– 80,000 villages yet to be electrified

6. ELECTRICITY ACT 2001(Contd..)
4. Private sector Investments is allowed in
Renewable Energy Sources
(Generation, Distribution, Supply area)
– No license is required for generation and
distribution of power in Rural areas.
5. Participation in power transmission
sector
6. More stringent provision for theft of
electricity

7. ELECTRICITY ACT 2001(Contd..)
7. Delicensed for Captive power
generation, Thermal power generation,
Hydro power generation
– can be sold directly to other consumers by
wheeling through the grid under open
access
– Banking facility is provided to captive
power plants
8. State Electricity Regulatory
Commission is mandatory for all States

8. Definition of Energy Audit
As per the Energy Conservation Act, 2001, Energy Audit
is defined as
“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
“

9. Objective of Energy Management
To achieve and maintain optimum energy
procurement and utilisation, throughout the
organization
To minimise energy costs / waste without affecting
production & quality
To minimise environmental effects.
TO KNOW TECHNICAL PERFORMANCE OF MAJOR
EQUIPTMENT / SYSTEMS
TO IDENTIFY LOSS AREAS
TO ASSESS TECHNO ECONOMIC FEASIBILITY OF
ENCON OPTIONS.

10. ENERGY AUDIT…..
It’s a tech.Survey to analyze existing energy
utilisation practice, pinpoint areas of wastage
and to evolve energy saving schemes.
•It is an organised and systematic exercise
with top management support
•Energy audit addresses
•House keeping
•Operational improvement/retrofits
•Capital projects requiring investment
•New technology
•Energy audit helps to achieve “savings through
invisibles”.

11. Types of Energy Audit
1. Preliminary energy audit
2. Detailed energy audit

12. Safety Considerations
The audit person or team should be
thoroughly briefed on safety equipment
and procedures
Adequate safety equipment should be
worn at all appropriate times.
Auditors should be extremely careful
making any measurements on electrical
systems/on high temperature devices.

13. Preliminary Audit Site Survey:
 Take a walk through survey /Observations
 Collection of existing energy and production
records of the entire plant and major energy
consuming facilities and departments.
 Brief data analysis and preparation of
documentation.
 Identification of preliminary energy saving
measures, including an estimation of saving
potentials and economic aspects

14. INDUSTRIAL ACTIVITIES
Final ProductFinal Product
Raw Materials
Fluids
Raw Materials
Fluids
ManpowerManpower
EnergyEnergy
Industrial Wastes
LIQUID
toxic, inorganic
and organic
wastewaters
GASEOUS
Emissions
SO2 , NOx,
CO, etc.
SOLID WASTES
wasted raw material
or product, sludge from
ETP
DISCHARGE
ENERGY
heated fluids,
steam, hot
emissions etc.

15. TYPICAL PLANT UTILITIES
& SCOPE AREAS
 BOILERS/FURNACES
 PUMPS
 FANS
 AIR COMPRESSORS
 A/C PLANTS
 COOLING TOWER
 TRANSFORMERS
 MOTORS
 DG SETS
 LIGHTING
 ELECTRIC
HEATERS

16. Process Flow Diagram Spinning Mils
Raw
Cotton
Blow
room
Carding
Drawing
Combing
Simplex
Ring
frame
spinning
Cheese
Winding
Doubling
Cone winding
Utility
Electricity
Humidifin..
Comp.air
Lighting
Production
Yarn

17. Power Consumption Pattern in
Spinning Mills
15%
45%
10%
18%
7%
5%
Pre Spinning
Spinning
Post Spinning
Humidification
Compressor
Lighting

18. Typical Specific Energy Consumption
Norms in Textile Industry
COMPOSITE MILLS
 Thermal Energy = 19.0 Kg Steam /Kg of cloth
 Electrical Energy = 2.2 Kwh /Kg of cloth
SPINNING MILLS
 Electrical Energy = 3.6 Kwh /Kg of yarn
(UKG adjusted to 40 counts)

19. Preliminary Energy Audit Methodology
It uses existing and easily obtained data
Establish energy consumption pattern
Establishes base line data
Identify the most likely areas for
attention/savings
Identify immediate(no/low-cost) improvements
Identify areas for more detailed
study/measurement
Helps in planning for Detailed
audit(Team/instrument/Duration required)

20. Detailed Energy Audit
Evaluates all energy using system,
equipment and include detailed energy
savings and costs
Different phases of Detailed Audit
– Pre-audit Phase (Preliminary audit)
– Audit Phase (Instrumented/Comprehensive)
– Brief presentation,Report Preparation/Vendor details
collection
– Draft Report presentation and Final Presentation
– Post-Audit

21. PLANT ENERGY AUDIT COVERS
 ENERGY GENERATING EQUIPMENTS
 ENERGY DISTRIBUTION NETWORK
 END USE EQUIPMENTS.
OPERATIONAL FEATURES PLANT.
1. CONTINUOUS PROCESS PLANT
2. ONE/TWO SHIFT OPERATION
3. INTERMITTENT.

22. ?????????????????
What type of energy used
How much energy is used?
How much does it cost?
Where it is used?
How efficiently it is used?
How can it be managed more efficiently
and effectively?
This is identified through carrying out
ENERGY AUDITs

23. STEPS INVOLVED IN ENERGY AUDIT.
1. Data Collection
2. Efficiency Evaluation
3. Loss Quantification
4. Operational Improvement Measures
5. Techno Economic Evaluation of Projects.
6. Designing Energy Data Report System
7. Instrumentation Requirement
8. Action Plan For ENCON Implementation

24. SCOPE OF “DEA” TO INDICATE
 CAPABILITIES & EFFICIENCY OF EQUIPMENT
 NEED FOR AUTOMATIC CONTROLS
 ADEQUACY OF MAINTENANCE
 NEED FOR IMPROVED INSTRUMENTATION
SCOPE AREAS FOR ENERGY SAVING
 COST BENEFITS OF SPECIFIC MEASURES IN SHORT /
MEDIUM / LONG TERM
 MECHANISM OF MONITORING
 VENDOR INFORMATION
 INCENTIVE SCHEMES / PROVISIONS

25. Detailed Energy audit tasks:-
1. Elaboration and discussion of audit
methodology.
2. Selection of plants items to be audited.
3. Collection of more detailed energy and
production data.
4. Comprehensive measurements at
selected plants items.
• Process flow and utility diagram
• Measurement survey/performance trials
1. Data analysis and calculations
2. Elaboration of energy and material
balance for the audited plant items.

26. 7. Investigation of energy saving options
(improved maintenance of equipment,
improved energy management,
modification or rationalization of
process configuration, improved
insulation/ control of refrigeration, etc.)
8. Recommendation of feasible energy
efficiency measures.
9.Financial analysis of recommended
measures, including cost benefit
calculation.
10.Ranking of measures and elaboration of
an energy saving action plant
11.Reporting
12.Presentation to plant management

27. DATA COLLECTION
How Much Data ?
What Data ?
Data Availability –Plant Records-metering
How To Proceed In Case Of Data Not Available
To Know Source of Information
Experience To Device Data From Secondary
Information
Planning For Field Trials And Observation

28. Plant data
Present landed cost of all types of energy used in
the plant.
Types of energy used :Electricity, Fuel oil , Coal, Gas
Annual energy consumption and cost for all
purchased and internal fuel .(3 years)
Monthly purchased electricity & self generated.
• Month,kva,kwh,PF,bill amount. (Grid Power)
• Month,kva,kwh,PF,fuel cons.(Captive power plant)
Annual Production for Past 3 Financial Year
To know seasonal variation
to know production and energy trend

29. Electricity Tariff Structure
What are the elements of Electricity Bill ?
Elements TNEB APSEB KEB Gujarat / Maharashtra
MD Charge Rs.300/KVA RS.117/KVA <1000 kw
Minimum 90% of CMD RS.116/KVA 1000-3000
Rs.115/kva > 3000 Kw
MD Penalty Rs 600/Kva Rs. 225/Kva
Energy 3.5.00 P/Unit Rs.1.8 <400 kwh
charges Rs.1.6 >400 kwh
TOD Tariff 6 - 9 AM/PM 10AM-6PM Oct-Feb
20% more 2 PM-10PM Mar- Sep
20paise /unit more
PF minimum 0.9 0.85
PF Penalty <.9 2P unit for each 1% decrease in
PF below .85

30. SPECIFICATION OF MAJOR ENERGY CONVERSION
EQUPT.
• BOILERS
• HEATERS
• FURNACES
• THERMIC FLUID HEATER
• POWER GENERATING UNITS
DETAILS OF MAJOR UTILITIES(PUMPS/FANS/COMPRESSORS)
• MAKE
• TYPE
• CAPACITY
• SINGLE STAGE/MULTISTAGE
• FLOW, HEAD
• DESIGN KW – EFFICIENCY
• CAPACITY CONTROL METHOD
• ACTUAL REQUIREMENTS
• ANNUAL OPERATING HOURS
• Operating Schedule(Design and Operating parameters)

32. Benchmarking
• Internal Benchmarking
• Historical and trend analysis
• External Benchmarking
− Across similar industries
•kWh/MT Cement produced (Cement Industry)
•kWh/MT Paper produced (Paper Industry)
•kWh/ton of refrigeration (AC&R PLANT) /kWh /litre (DG Sets)
Energy cost as a percentage of total
manufacturing cost - 30 to 60 %
Generally a decreasing trend in specific energy consumption
Specific power consumption varies from 66 to 127 kWh per tonne of cement
Specific thermal energy consumption varies from 692 to 879 kCal/kg clinker

33. Energy
Conversion
Boiler efficiency,
Quality of Fuel used,
Maintenance
Energy
Transfer
Insulation of Steam piping,
Jackets for hot fluid pipes to
prevent losses
Energy
Utilization
Equipment efficiency, Maintenance,
Energy
Recovery
Waste heat
exchangers,
Energy Conservation

34. Product
Waste
Raw materials
Separation EquipmentSeparation EquipmentHeat
Recovery
Heat
Recovery
By ProductMaterial
balance
Cause and Effect Analysis
Cost-benefit analysis
Brainstorming
Process 2Process 2Process 1Process 1
Recovery
Recycle, Reuse and Recovery

35. Fuel and Energy Substitution
Fuel substitution
Replacement of coal by Agro fuels
Replacement of LDO by LSHS
Energy substitution
Electric heaters by steam heaters
Steam based hot water by solar systems

36. ENERGY AUDIT REPORT
1. ACKNOWLEDGEMENT
2. CONTENTS
3. EXECUTIVE SUMMARY
4. SUMMARY OF SAVINGS
5. INTRODUCTION
6. PLANT ENERGY SYSTEM
7. ENERGY USAGE PATTERN
8. ENERGY INDICATORS
9. ENERGY SAVING
OPTIONS/RECOMMENDATIONS
10.ANNEXURE/PLANT BASE LINE DATA
Filed observation and savings calculations.
List of suppliers .
Action plan for ENCON implementation

38. Technical and Economic feasibility
Name of Energy Efficiency Measure
1. Investment
• Equipments
• Civil works
• Instrumentatio
n
• Auxiliaries
2. Annual operating
costs
• Cost of capital
• Maintenance
• Manpower
• Energy
• Depreciation
3. Annual savings
• Thermal Energy
• Electrical
Energy
• Raw material
• Waste disposal
Net Savings /Year (Rs./year)
= (Annual savings-annual operating costs)
Payback period in months
= (Investment/net savings/year) x 12

39. Energy Audit Instruments
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
facilitates cumulative readings with print outs at
specified intervals.
POWER ANALYSERS

40. Measurement Technology
-Measures @256 samples/cycle for
better accuracy even on non-linear
waveforms
-Continuous & simultaneous
sampling on all 6 channels for
accurate readings on dynamic loads
Accuracy far
superior when
compared to
conventional
analyzers with low
sampling rate
New Generation Measurement Techniques

41. Application – Textile Mill Study
Readings of KRYKARD
Load Manager ALM 30
Readings of Low & non-
continuous sampling meter
THD in % P.F THD
in %
KWh (%
error)
P.F
8% 0.882
15% 0.837
36% 0.864 36% -1.2% 0.82
52% 0.881 46% -2.77% 0.74
74% 0.880 81% -8.2% 0.68
This picture is taken using the Screen
shot feature of ALM/3032. You can
see that the ALM 30/32 is highly
accurate even on non-linear loads
thanks to the new generation
measuring techniques used by it.

42. FLUE GAS ANALYSERS

43. TEMPERATURE MEASURMENTS

44. FLOW MEASURMENTS – AIR ,WATER

46. Portable Instruments Budget
Price (Rs)
1
Three phase Power Analyzer.
(V, A, KW, KVA, KVAR, PF,
HZ and THD)
2,60,000
2 Single Phase Power Analyzer
with THD
90,000
3 Megger & Resistance Meter 50,000
4 Lux Meter (Digital) 7,000
5 Ultrasonic Flow Meter 4,00,000
6 Pitot Tube & Monometer 60,000
7 Digital Animometer 15,000
8 Hot Wire Animometer 7,000
9 Contact & Non-Contact 5,000

47. 10
Thermal :
Flue Gas Analyzer
(O2
, CO and Template)
1,50,0
00
11 Humidity Meter (Digital)
- For Aircondition Space Survey
12,000
12 Leaf Probe Surface Temp.
Indicator
6,000
13 Stroboscope 5,000
14 Thermocouple for Liquid Gas
and High Temp.(0-100o
C, 0-
500o
C, 2000o
C)
30,000