This document outlines the process and significance of energy audits, detailing various types such as preliminary, targeted, and detailed audits. It explains energy management concepts, energy types, benefits of conducting audits, and steps for implementation, alongside case studies demonstrating energy substitution for cost savings. Various methodologies for assessing and optimizing energy use are discussed to improve efficiency and reduce operational costs.

1. MIM THIRD Year (2015 – 18)
SEM VI
NAME ROLL NO
MUFADDAL NULLWALA 15-I-131
ENVIRONMENTAL MANAGEMENT
ENERGY AUDIT
JBIMS-
MUFADDAL

2. List of Topics
1. What is Energy 13. Detailed Energy Audit
2. Type of Energy 14. Steps for Energy Audit (Phase1,2,3)
3. What is Energy Audit 15. Results of Energy Audit (Phase 1,2,3)
4. Definition of Energy Audit 16. Energy Costs in Indian Scenario
5. The Need for Energy Audit 17. Bench Marking Energy Performance
6. Why Energy Audit 18. Measuring Energy Performance
7. Energy Audit Process 19. Matching Energy Usage to Requiremen
8. Audit Programme Advantages 20. Optimizing Energy Input Requirement
9. Approach and Types of Energy
Audit
21. Fuel and Energy Substitution – Steps
towards Conservation
10. Preliminary Energy Audit 22. Case Study – Energy Substitution.
11. Targeted Energy Audit 23. Energy saving calculations:
12. Energy Pyramid 24. References

3. Energy Audit
JBIMS-
MUFADDAL

4. What is Energy?
 Energy is the capacity of a physical system to perform
work. Energy exists in several forms such as heat, kinetic
or mechanical energy, light, potential energy, electrical or
other forms.
 According to the law of conservation of energy, the total
energy of a system remains constant, though energy
may transform into another form.
JBIMS-
MUFADDAL

5. Types of Energy
ENERG
Y
MECHANICA
L ENERGY
THERMAL
ENERGY
THERMAL
ENERGY
NUCLEAR
ENERGY
CHEMICAL
ENERGY
ELECTROMAGNET
IC ENERGY
JBIMS-
MUFADDAL

6.  “Energy audit” means 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.
What is Energy Audit
JBIMS-
MUFADDAL

7.  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,
Definition of Energy Audit
JBIMS-
MUFADDAL

8. In any industry three top operating costs are often found to
be.
1. Material.
2. Labour.
3. Energy (both Electrical & Thermal).
Among the three Energy has highest potential for cost
reduction
Energy Audit will help to understand more about ways
energy is used in industry & help in identifying areas where
waste can occur and where scope for improvement exists.
Energy audit is translation of energy conservation ideas into
reality, by evolving technically feasible solutions with
The need for Energy Audit?
JBIMS-
MUFADDAL

9.  To minimize costs for energy
 To minimize operational costs
 To minimize costs for repairs and reconstruction
 Increase quality of environment that contributes to
increased work productivity
Why Energy Audit?
JBIMS-
MUFADDAL

10. Energy Audit Process
JBIMS-
MUFADDAL

11. Audit Programme Advantages.
 Review variations in Energy costs.
 Availability of energy.
 Reliability of supply.
 Decide on appropriate energy mix.
 Identification of energy conservation
technologies.
 Retrofit for energy conservation
equipment.
 Benchmarking.
 Plant energy performance
JBIMS-
MUFADDAL

12. Approach and Type of Energy
Audit
Approach
• Type of industry.
• Depth to which final audit needed.
• How potential.
• Magnitude of cost reduction desired.
Classification of Energy Audit
1. Preliminary Energy Audit.
2. Targeted Energy Audit.
3. Detailed Energy Audit.
JBIMS-
MUFADDAL

13. • 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
Types of Energy Audits
JBIMS-
MUFADDAL

14. • 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
Preliminary Energy Audit
JBIMS-
MUFADDAL

15.  It is also known as Walk-Through audit & Diagnostic
audit.
 Establish energy consumption, (Bills and Invoices).
 Estimate the scope of energy saving.
 Identify areas more detailed study / measurements.
 Set up baseline or reference point for energy
consumption
 Identify most likely and easiest areas for attention
(unnecessary lighting, higher temp. setting, leakage)/
 Installation / upgrading insulation on equipment.
 Modifying process to reduce energy demand.
 Evaluating waste heat streams for potential waste heat
recovery.
Preliminary Energy Audit
JBIMS-
MUFADDAL

16. Targeted Energy Audit
 It results from preliminary Energy
Audit.
 It involves detailed survey of target
subjects and analysis of energy flows,
cost associated with targets.
 Final outcome is recommendations
regarding actions to be taken.
 Example: Lighting system, Boiler,
compressed air system, water supply
system.
JBIMS-
MUFADDAL

17. Energy Pyramid
JBIMS-
MUFADDAL

18. • 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.
• It is comprehensive audit & results in project
implementation plan for facility.
• Analysis Energy balance.
• 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
Detailed Energy Audit
JBIMS-
MUFADDAL

19. PHASE:1
1. a. Plan & organise visit
b. Walk through audit of the set up
c. Informal interview with production or plant manager
or incharge.
2. Conduct brief meeting / awareness program on
energy audit with all divisional heads and persons
concerned.
PHASE:II
3. Primary data collection, process flow diagram, energy
utility diagram and collection of any other relevant data.
4. Conduct survey and monitoring
Steps for Energy Audit
JBIMS-
MUFADDAL

20. 5. Conduct detailed trials / experiments for the selected
energy guzzlers
6. Analysis of energy use
7. Identification and development of energy conservation
opportunities
8. Cost benefit analysis
9. Reporting & presentation to top management on
findings
PHASE:III
10. Implementation, commissioning and follow up
Steps for Detailed Energy Audit
(Contd.)
JBIMS-
MUFADDAL

21. Results of Energy Audit
Phase 1 - Pre Audit phase
The Outcome of Pre Audit phase should
be.
 Finalize Energy Audit team.
To know the expectation of management
from audit.
To identify main energy consuming area/
plant items to be surveyed.
Plan for Audit with time frame.
Collect Macro data on plant energy
resources.
 Build up awareness & support for
JBIMS-
MUFADDAL

22. Results of Energy Audit
Phase 1I - Audit phase
The Outcome of Audit phase should be.
Quantity and Type of Raw material
Technology, Process, and Equipment's
used.
Capacity utilization
Efficiencies / yield
Percentage rejection / reprocessing.
Quantity and Types of Wastes
Potential for fuel substitution, process
modification.
Energy Audit Report.
JBIMS-
MUFADDAL

23. Results of Energy Audit
Phase III - Post Audit phase
The Completion of Energy Audit should
be.
Action plan should be prepared ,
suggesting overall implementation
schedule.
 Feedback / Monitoring implemented
changes.
Measuring Energy Intensity.
Measuring Plant Energy Performance.
Matching Energy Usage to
requirement
JBIMS-
MUFADDAL

24. Common Fuels
Fuel Oil, Low Sulphur Heavy
Stock (LSHS), Light Diesel Oil
(LDO), Liquefied Petroleum Gas
(LPG), Coal, Lignite, Wood
Fuels Cost Inputs & Factors
 Price at source, transport
charge, type of transport,
 Quality of fuel
 Contaminations, Moisture,
Energy content (GCV)
Energy Costs in Indian
Scenario ?
Power Costs
In India, electricity costs vary
substantially not only from
State to State, but also from city
to city and also within consumer
to consumer – though power
does the same work
everywhere.
Reason:
•Tariff Structure
JBIMS-
MUFADDAL

25.  Benchmarking can be a useful tool for understanding
energy consumption patterns in the industrial sector and
also to take requisite measures for improving energy
efficiency.
 FACTORS INVOLVED:
◦ Scale of operation
◦ Vintage of technology
◦ Raw material specifications and quality
◦ Product specifications and quality
Benchmarking
JBIMS-
MUFADDAL

26. Benchmarking for Energy
Performance
• Internal Benchmarking
 Historical and trend analysis
• External Benchmarking
 Across similar industries
Scale of operation, vintage of technology, raw
material specification and quality and product
specification and quality
JBIMS-
MUFADDAL

27.  Quantification of fixed and variable energy consumption
trends vis-à-vis production levels
 Comparison of the industry energy performance w.r.t.
various production levels (capacity utilization)
 Identification of best practices (based on the external
benchmarking data)
 Scope and margin available for energy consumption and
cost reduction
 Basis for monitoring and target setting exercises
Bench Marking Energy
Performance
JBIMS-
MUFADDAL

28. Production Factor = Current year’s production
Reference year’s production
Reference Year Equivalent Energy Use
 The reference year’s equivalent energy use (or reference year equivalent) is
the energy that would have been used to produce the current year’s
production output.
 The reference year equivalent is obtained by multiplying the reference year energy use
by the production factor (obtained above)
Reference year equivalent = Reference year energy use x Production factor
 Plant Energy Performance is the improvement or deterioration from the
reference year. It is a measure of plant’s energy progress.
Plant Energy = Reference Year Equivalent – Current Year’s Energy X 100
Performance Reference Year Equivalent
Measuring Energy Performance
JBIMS-
MUFADDAL

29.  The mismatch between equipment capacity and user
requirement often leads to inefficiencies due to part load
operations, wastages etc. It is thus essential that proper
energy matching studies are carried out & actions
implemented.
 Examples :
◦ Eliminate throttling
◦ Eliminate damper operations
◦ Fan resizing for better efficiency.
◦ Moderation of chilled water temperature for
process chilling needs
Matching Energy Usage to
Requirement
JBIMS-
MUFADDAL

30.  Replace pumps, fans, air compressors, refrigeration
compressors, boilers, furnaces, heaters and other energy
conservation equipment, wherever significant energy
efficiency margins exist
 Eliminate steam leakages by trap improvements
 Maximize condensate recovery
 Adopt combustion controls for maximizing combustion
efficiency
Maximizing System Efficiencies
- Some Measures
JBIMS-
MUFADDAL

31. • In order to ensure that the energy given to the system is
being put to optimal use, site specific measures and
checks should be carried out regularly.
• EXAMPLES:
◦ Shuffling of compressors to match needs.
◦ Periodic review of insulation thickness
◦ Identify potential for heat exchanger networking and
process integration.
Optimizing Energy Input
Requirement
JBIMS-
MUFADDAL

32. Fuel substitution
 Replacement of coal by coconut shells, rice husks, etc
 Replacement of LDO by LSHS
Energy substitution
 Replacement of electric heaters by steam heaters
 Replacement of steam based hot water by solar systems
Fuel and Energy Substitution –
Key steps towards conservation
JBIMS-
MUFADDAL

33. Case Study:
Example of Fuel Substitution
A textile process industry replaced old fuel oil fired thermic fluid
heater with agro fuel fired heater. The economics of the project
are given below:
Title of Recommendation : Use of Agro Fuel (coconut chips) in place
of Furnace oil in a Boiler
Description of Existing System and its operation : A thermic fluid
heater with furnace oil currently. In the same plant a coconut chip fired
boiler is operating continuously with good performance.
Description of Proposed system and its operation : It was
suggested to replace the oil fired thermic fluid heater with coconut chip
fired boiler as the company has the facilities for handling coconut chip
fired system.
JBIMS-
MUFADDAL

34. Energy saving calculations:
Old System:
Type of fuel Firing: Furnace Oil
fired heater
GCV: 10,200 kCal/kg
Avg. Thermal Efficiency: 82%
Heat Duty: 15 lakh kCal / hour
Fuel Cost: Rs. 1800 / hour
Operating hours: 25 days * 12
months * 24 hours = 7200 hrs
Annual Fuel Cost: 7200 * 1800 =
Rs 130 lacs
Modified System:
Type of fuel Firing: Coconut
chips fired heater
GCV: 4,200 kCal/kg
Avg. Thermal Efficiency: 72%
Heat Duty: 15 lakh kCal / hour
Fuel Cost: Rs. 700 / hour
Operating hours: 25 days * 12
months * 24 hours = 7200 hrs
Annual Operating Cost: 7200 *
700 = Rs 50 lacs
Annual Savings = 130 – 50 = Rs 80 lacs
Additional auxiliary power and manpower cost for modified system =
Rs 10 lacs
Net Annual Savings = Rs 70 lacs
JBIMS-
MUFADDAL

35. Energy, Let’s save it!!!
JBIMS-
MUFADDAL

36. 1. NPC energy audit manual and reports
2. Energy management handbook, John Wiley and Sons -
Wayne C. Turner
3. Guide to Energy Management, Cape Hart, Turner and
Kennedy
4. Cleaner Production – Energy Efficiency Manual for GERIAP,
UNEP, Bangkok prepared by National Productivity Council
5. www.eeca.govt.nz
6. www.energyusernews.com
References
JBIMS-
MUFADDAL

37. THANK YOU
JBIMS-
MUFADDAL