This document outlines an energy audit conducted for the customs department buildings, focusing on understanding energy consumption and identifying measures for conservation and efficiency. It discusses various energy-saving measures such as reducing vampire loads, improving lighting systems, and maintaining air conditioners, along with projections regarding energy consumption trends in India's chemical industry. The findings include specific recommendations for improving energy efficiency and reducing costs associated with energy use.

1. VISHWAKARMA GOVERNMENT
ENGINEERING COLLEGE,
CHANDKHEDA, AHMEDABAD
DEPARTMENT
OF
CHEMICAL ENGINEERING
SUBJECT: CLEANER PRODUCTION
SUBJECT CODE: 3723023
EXPERIMENT 4
ENERGY AUDIT
SUBMITTED BY
RAHUL JARARIYA
En. No. 200170730001
SUBMITTED TO
PROF. PARIN SHAH

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ENERGY AUDIT
UNDERSTANDING ENERGY AUDIT
The Energy audit is defined as Conduct a simple walk-through audit of observation of the
energy consumption of electrical applications within the customs department building.
Review and analyse energy usage history to create a baseline for which savings can be
measured in the audited building.
Determine what can be done to reduce energy consumption throughout the buildings and what
options are available for system improvements if funding is available.
Identify and evaluate measures that could improve the environmental performance of the
buildings/wards and provide recommendations.
INTERPRETATION
Energy Conservation means steps taken to reduce and to use as much energy as necessary
through changing energy consumption behaviour, e.g., Switching off lights when not in use.
Energy Efficiency means using less energy to provide the same service/output, e.g., Replacing
inefficient light bulbs with efficient ones.
Faulty means an equipment not working or made correctly; having defects.
Potential savings means the actual reduction in operating expenses from the improved energy
efficiency generated by an energy conservation or efficiency activity.
Retrofitting means upgrading an existing system to improve energy efficiency.
Tariff means the amount of money charge by the supplier (utility) per kWh for the use of
electrical energy.

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Vampire Load means the way power is consumed by electronic and electrical appliances while
they are switched off or in standby mode (consuming electricity at a cost but not doing any
work).
Recommendations:
RECOMMENDATIONS
CATEGORY A CATEGORY B CATEGORY C
Apply energy conservation
measures. Isolate or unplug
vampire loads from power when
not in use (i.e., rechargeable
equipment, computer and any
other electronic devices with
standby modes).
Establish Energy Efficiency and
conservation to take lead with
EE&C initiatives and management
within the Customs Department
buildings.
Where applicable, replace all
double frame light fittings *double
tube) with single frame (Single
tube) throughout the building.
Also remove unnecessary lights or
reduce the number of lights per
location.
Remove faulty light holders and
bulbs or remove wire from socket
inside the light holder.
Renovate or improve the lighting
control, i.e., add more switches to
existing rooms where only one
switch controls more than 10
lights, especially the lights in the
conference room.
Replace all lights with energy
efficient light bulbs, i.e., Replace
T8 and T12 fluorescent with T5
retrofits.
Remove any faulty applications
located in the building.
Use fans in places where possible
(especially in unsealed room,
indoor corridor, conference room,
etc.)
The conservation and efficiency
mechanisms are tools for reducing
the energy consumption.
Isolate or unplug faulty air
conditioners if found within the
building (workings but no cold air
coming out) and OR service the
air conditioner units quarterly.
Remove air conditioner if the
room is very poorly sealed (i.e., if
the room has no seals on the door
and frequently open at times. )
Replace old existing outdoor air
conditioner units with efficient
ones.
Findings:
VAMPIRE LOADS FINDINGS
ISSUES OPTIONS
• Electronics applications (computer, printer,
etc.) are still ON even though they are turned
off.
• Applications on standby mode are draining
power even though they are not doing any
use full task.
• Hot water boilers are also considered as
vampire loads when life to ‘keep the water
hot’.
• Faulty light fittings which are left without
bulb and faulty bulb which is intact are also
vampire loads.
• All Electronic application should always be
‘unplugged’ or turned from the power
sockets, after office hours.
• Try to avoid putting applications on ‘Standby
mode’
• Only use hot water heater to boil water
instead of leaving it to’ Keep water hot’
• Remove faulty lightings.
LIGHTING
ISSUES OPTIONS

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• It has been observed there are a lot
of unnecessary light in one single
room.
• Turn OFF lights when not used.
• Reduce the number of lights per
switch, to better manage lighting.
• Too many lights are assigned to 1
switch.
• Reduce the number of lights per
room.
FACULTY LIGHTSOPTIONS
ISSUES OPTIONS
• Ballets of faulty light will draw power when
the lights are ON even though it is not
working.
• Disconnect the live wire connected to the
faulty light bulb to avoid leakage of energy.
AIR CONDITIONERS
ISSUES OPTIONS
• Brand and model not consistent throughout
the building which is expensive for
maintenance.
• Officers leaving the door open when entering
and exiting the room where the air
conditioner is located.
• Windows and doors of the air-conditioned
rooms not sealed properly i.e., using louvers
is ‘highly Not recommended’.
• Use same brand throughout (cheap for
maintenance cost).
• It is recommended that the air conditioners
be serviced quarterly.
• Use sealed glass windows and sealed glass
doors.
• Always close door when entering exiting an
air – conditioners room (put a notice on the
front and back of the door as a remainder.
• Keep and maintain the temperature at 23℃
during summer and occasionally used in
winder.
• Switch OFF when not in use but avoid
reducing to a lower temperature and leave it
ON.
• Use electric fan whenever possible.
• Use outside breeze, when possible, should
the air conditioner be turned off completely
to minimize the cost of electricity.
• Installation of correct sizing of air
conditioner in the rooms.
• All installed air conditioners should be
service at least twice or three times a year.
OFFICE EQUIPMENT
ISSUES OPTION
• Most of the office equipment are usually
left without turning them off after working
hours and are using electricity as Vampire
loads.
• Electronics applications (Computer, printer,
etc.) are still ON when connected to power
point even though they are turned off.
• All office equipment such as printers,
computers i.e., monitor, etc. must be turned
off on the power point unplug from the
power point.
• Avoid putting equipment on ‘STANDBY
MODE’

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Objective of Energy Audit in chemical Industry:
The primary objective of energy auditing in chemical industry ways to reduce energy
consumption per unit of produce output or to lower its operating costs. The energy audit
evaluates the efficiency of all building and process systems that use energy. ISSUES
Steps of making energy audit in an industry:
1. Audit criteria, selection of audit team.
2. Audit plan.
3. Measurements
4. Preliminary analysis.
5. Patterns.
6. Identifying energy.
7. Writing audit energy.
8. Implementation.
PROJECTIONS:
India is projected to sustain the world’s second highest rate of gross domestic product (GDP)
growth, averaging 5.6 % per year. India’s economic growth over the next 25 year is expected
to drive more from light manufacturing and services than from heavy industry, so that the
industrial share of total energy consumption falls from 72% in 2006 to 64% in 2030.
The changes are accompanied by shifts in India’s industrial fuel mix, with electricity use
growing more rapidly than coal use in the industrial sector. The Indian chemical industry was
the 5th
largest in the world, and 2nd
largest in Asia, after China. The volume of major chemicals
produced in India amounted to 8.3 million metric tons (MMT) in 2011-2012.
The energy conservation and utilization of renewable sources are essential factor to fulfill
energy demand. Renewable energy and nuclear power are the world’s fastest growing energy
sources, each increasing by 2.5 % per year. Among the various sectors contributing to
Greenhouse gas (GHG) emissions, the contributing of the industrial sector was significant.
Thus, mitigating GHG emission from the Industrial sector offers the best means of reducing
overall GHG emissions. Therefore, energy conservation means less reliance on energy imports
and, thus less GHG emissions. It can be achieved either by reducing total energy use or by
increasing the production rate per unit of energy used. On the other hand, improving energy
efficiency is the key to reducing GHG emission.
AUDIT IMPLEMENTATION ANALYSIS IN CHEMICAL INDUSTRY:
Henkel Chemical Corporation is a producer of specialty chemicals located in Cedartown,
Georgia. The plant was originally constructed in 1900 as a textile finishing mill and was
converted to a chemical plant in 1937. Several years ago, the facility underwent a $25 million

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renovation which doubled plant capacity and reduced the workforce to the current level of 125
employees. Approximately 200 different products are formulated at this location, and the plant
contains a large number of chemical reactors and raw-material storage tanks.
Steam is an integral part of the production process because all raw material blends are heated
to yield the desired final product. This year alone the Cedartown plant will consume over 100
million pounds of steam for the dual purposes of plant and process heating.
Because a considerable amount of steam is employed for raw material and product heat tracing,
winter steam demand is 4 to 5 times greater than summer. With annual energy expenditures
exceeding $1 million, group managers recognized the negative impact energy waste could have
on company profits. To help site engineers improve the effectiveness of their conservation
efforts, Georgia Tech conducted a facility wide energy audit in the fall of 1993.
ENERGY AUDIT RECOMMENDATIONS
The energy audit was performed through Georgia Tech's Energy Analysis and Diagnostic
Centre in the fall of 1993. Table shows the recommendations contained in the report. The audit
revealed nine cost-effective recommendations worthy of consideration. The recommendations
fell into three broad classes: steam system, lighting, and miscellaneous electrical
improvements. Estimated energy savings for the plant 20.6 percent.
S.No. Recommendation
Energy Savings
(kWh)
Simple Payback
(Years)
1 Downsize boiler 36,634 1.9
2 Increase condensate return 2760 0.7
3 Repair steam leaks 5626 0.1
4 Install Energy Efficient lighting and
Electronic Ballasts
278 2.8
5 Replace incandescent with
fluorescent lighting
46 1.0
6 Replace mercury vapor with Metal
Halide lighting
49 2.9
7 Use High Efficiency Motors 125 2.8
8 Relocate compressed air Intake 83 0.2
Lighting Recommendations
Three recommendations involved improvements to the plant's lighting system. The measures
were use of energy-efficient lamps and electronic ballasts in fluorescent fixtures, replace
existing incandescent lighting with fluorescent, and replace mercury vapor lighting with metal
halide. The use of energy-efficient fluorescent lamps and electronic ballasts can reduce
fluorescent light energy consumption by 14 to 43 percent per fixture. The plant uses a variety
of eight-foot and four-foot fluorescent fixtures in offices and warehouses throughout the
facility. Lamps in four-foot fixtures can be replaced with T8 lamps that are one inch in diameter
and rated at 32 watts each. The eight-foot lamps should be replaced with energy efficient lamps
that are rated at 60 watts each. The stockroom at the plant is fluently lighted with 15 ISO-watt
incandescent lamps. If these fixtures were replaced with fluorescent fixtures on an equivalent
lumen basis, only six two-lamp, eight-foot fixtures would be needed. This leads to a savings of

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13,469 kWh/yr. In addition, fluorescent lamps last up to ten times longer than incandescent
lamps. The drumming area is currently lighted with 250-watt mercury vapor lamps. Metal
halide lamps are available as a direct replacement for the mercury vapor lamps. The lamps,
rated at 215 watts, will provide as much light as the mercury vapor lamps and allow a reduction
of 35 watts per lamp. The mercury vapor lamps should be replaced with metal halide as they
burn out.
Miscellaneous Electrical Recommendations
Two other measures, using high efficiency motors and relocating the compressed air intake,
were included in the energy audit. High efficiency motors, which are 2-3 percent more efficient
than standard motors, were recommended as replacements when the standard efficiency motors
fail.
Relocating the compressed air intake from an indoor to an outdoor location, preferably a shady
location with northern exposure, will result in energy savings. Moving intakes outdoors results
in cooler air intake temperatures throughout the year. Less work is required to compress the
cooler air, thereby saving energy. Although the savings associated with this measure is small,
the associated capital expenditure is also usually low.
CONCLUSION
While energy audits provide a comprehensive plan for energy management, generation of
actual savings depends on proper implementation. This analysis found energy savings had been
achieved at the plant analysed, though not up to the level expected.
Two conclusions can be deduced from this outcome. First, industrial plants are extremely
complex operations and that was calculated energy savings after a one-day audit may not be
highly accurate. Maintenance items like steam and air leaks and leaking steam traps may be
especially difficult to assess accurately. Second, failure to achieve estimated savings could be
due to the misapplication of the specified conservation technology. Continued tracking of
energy efficiency is helpful in determining if implemented measures are effective and still
active. Plant personnel need to be aggressive in tracking savings resulting from audit
implementation. A normalized measure, like production efficiency, can be used to determine
if savings estimates are being achieved.
References:
1. Singh, M., Singh, G. and Singh, H., 2012. Energy audit: A case study to reduce lighting
cost. Asian Journal of Computer Science and Information Technology.
2. Baskar, R.H., Mittal, H., Narkhede, M.S. and Chatterji, S., 2014. Energy audit—A case
study. International Journal of Emerging Technology and Advanced Engineering.
3. Dall'O, G., 2013. Green Energy Audit of Buildings-A Guide for a Sunstainable Energy
Audit of Buildings, Springer-Verlag.
4. Harris, J., Anderson, J. and Shafron, W., 2000. Investment in energy efficiency: a
survey of Australian firms. Energy Policy.

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5. Michael L. Brown, Georgia Tech Economic Development Institute. A Case study -
AUDIT IMPLEMENTATION ANALYSIS FORA CHEMICAL PLANT.