A MINI PROJECT/INTERNSHIP REPORT

submitted in partial fulfilment of the requirements for the Award of Degree of

BACHELOR OF TECHNOLOGY
in
ELECTRICAL & ELECTRONICS ENGINEERING
on

“Energy Management & Auditing”

In
(PESI PVT. LTD.)

SUBMITTED BY: PRASHANT UPADHYAY

(ROLL NO. 1809121029)

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

JSS ACADEMY OF TECHNICAL EDUCATION
C-20/1 SECTOR-62, NOIDA
2021- 2022
 ACKNOWLEDGEMENT

First, I would like to thank Mr. Srijan Jaiswal & Sarim Irshad, Head, of PESI
PVT. LTD, for giving me the opportunity to do an internship within the
organization. I also would like all the people that worked along with me PESI
PVT. LTD., with their patience and openness they created an enjoyable learning
environment. It is indeed with a great sense of pleasure and immense sense of
gratitude that I acknowledge the help of these individuals. I am highly indebted
to college for the facilities provided to accomplish this internship. I would like to
thank my Head of the Department Dr. K.S. Sujatha for his constructive criticism
throughout my internship. I am extremely great full to my department staff
members and friends who helped me in successful completion of this internship.

Prashant Upadhyay
(1809121029)

ii
CERTIFICATE

Signature of Supervisor
Swati Mishra Ma’am

iii
 TABLE OF CONTENTS

ACKNOWLEDGEMENT
INTERNSHIP CERTIFICATE
DECLARATION
ABSTRACT
LIST OF FIGURES

CHAPTER 1 Introduction 7-8

CHAPTER 2 Definition 9

CHAPTER 3 Need for Energy Audit 10 - 12

CHAPTER 4 Types of Energy Audit 13 - 21

CHAPTER 5 10 Steps for detailed Energy Audit 22

CHAPTER 6 Question that an energy auditor needs to ask 23 - 26

CHAPTER 7 Industrial format of energy audit report 27 - 28

CHAPTER 8 Energy Auditing Instruments 29 - 41

CHAPTER 9 Identification of energy conservation factors 42

CHAPTER 10 Technical & Economic Feasibility factors 43 - 44

CHAPTER 11 Benchmarking 45 - 48

CHAPTER 12 Conclusion & Reference 49

iv
 DECLARATION

I hereby declare that the internship report entitled “Energy Management &
Auditing” Submitted to the Electrical & Electronics department of JSS Academy
of Technical Education Noida, is a record of an original work done by me under
the guidance of Mr Srijan Jaiswal & Sarim Irshad, Head of PESI PVT. LTD. and
this internship report work is submitted in the partial fulfilment of the
requirements for the award of the Degree of BACHELOR OF TECHNOLOGY
in Electrical & Electronics Engineering. The results embodied in this thesis have
not been submitted to any other University or Institute for the award of any degree
or diploma.

Prashant Upadhyay
(1809121029)

v
 ABSTRACT

Energy Audit is the key to a methodical approach for decision-making in the area
of energy management. The energy management is necessary for procurement
and utilization of energy through optimum management, throughout the area.
Energy Management and Energy Audit is conducted to save money by saving the
energy for different sort of industries, institution, hospitals, domestic areas, etc.,
under the recommendations given by the energy audit team. These management
and audit teams find out the areas, where there is wastage of electricity and
implements the effective and proper use of energy. Through efficient energy
management and auditing methods, environment can be protected; energy and
money can be saved without affecting the natural and quality ongoing work in
any sectors. This paper briefly describes about importance of energy audit and
energy management in and around our place of living.

vi
 LIST OF FIGURES

[Link]. Figure Description Page no.

5.1 Plan of Action (a) 22
5.2 Plan of Action (b) 22
7.1 Detailed Report Format 27
8.1 Instruments 29
8.2 Voltmeter 30
8.3 Ammeter 31
8.4 Power Factor Meter 31
8.5 Power Analyzer 32
8.6 Multimeter 32
8.7 Synergy Meter 33
8.8 Lux Meter 33
8.9 Dragger 34
8.10 Fyrite Kit 34
8.11 Anemometer 35
8.12 Pitot tube 35
8.13 Impact & Smoke Tube 35
8.14 Diaphragm Gauge 36
8.15 Tachometer 36
8.16 Steam Trap Testing 37
8.17 Ultrasonic Leak meter 37
8.18 Dew Point Hygrometer 38
8.19 Psychrometer 38
8.20 Electrolytic Hygrometer 39
8.21 Glass Stem Thermometer 39
8.22 Thermocouple Transducers 39
8.23 Resistance Thermometer 40
8.24 Bimetallic Transducer 40
8.25 Radiation Pyrometer 41
10.1 Worksheet 43
10.2 Energy Bill 43

vii
 Chapter 1
INTRODUCTION

Energy is one of the key inputs for the economic growth of any country [1].
Energy is the strength and vitality essential for continuous physical or mental
activity. Energy is the power derived from the consumption of physical or
chemical resources, especially to provide light and heat or to work machines. The
property of matter and radiation which is manifest as a capacity to perform work
(such as causing motion or the interaction of molecules). Energy is the ability to
do work. Energy comes in different forms such as Heat (thermal), Light (radiant),
Motion (kinetic), Electrical, Chemical, Nuclear energy, Gravitational. Electrical
utilities are becoming more and more stressed since existing transmission and
distribution system are facing their operation constrains with growing load. Now
a days human life cannot be imagined without electricity, saving energy means
decreasing the amount of energy used while achieving a similar outcomes of end
use, because we know we are having limited amount of energy resources in earth
to generate electrical power. Energy demands and costs are increased over time.
Increasing usage of energy-intensive products and services directly disturbs the
greenhouse-gas emissions and climate change [2]. To prevent our living earth
from global warming, it is utmost importance to optimize the energy usage in our
home, offices, industries, institutions and other organizations. To save electrical
energy and resources for our future, energy audit is introduced. An energy audit
can be simply defined as a process of evaluating a building for the usage of
electricity and identifying the opportunities to reduce consumption. An energy
audit is a systematic approach that analyses the power flow and provides
suggestions for reducing the wastage of power. It is an inspection, review and
study of energy flows, for energy conservation in a building, process or system
to reduce the amount of energy input into the system without affecting the usual
works and its output [3]. In commercial and industrial real estate, an energy audit

8
is the first step in identifying opportunities to reduce energy expense and carbon
footprints. Energy management includes efficient planning and operation of
energy production and energy consumption units. The Objectives of energy
management are resource conservation, climate protection and cost saving and
energy saving while the users have permanent access to the energy they need. It
is connected closely to environmental management, production management,
logistics and other established business functions. Energy management is the
proactive, organized and systematic coordination of procurement, conversion,
distribution and use of energy to meet the requirements taking into account
environmental and economic objectives.

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 CHAPTER 2
DEFINATION

Definition of the Energy Audit

As per Indian 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.”

Energy audit is an effective tool in defining and pursuing comprehensive energy

management programmes. It has positive approach aiming at continuous
improvement in energy utilisation in contrast to financial audit which stresses to
maintain regularity. Energy audit provides answer to the question – what to do,
where to start, at what cost and for what benefits?

Energy audit helps in energy cost optimization, pollution control, safety aspects
and suggests the methods to improve the operating and maintenance practices of
the system. It is instrumental in coping with the situation of variation in energy
cost availability, reliability of energy supply, decision on appropriate energy mix,
decision on using improved energy conservation equipment, instrumentations and
technology.

It has been established that energy saving of the order of 15 to 30% is possible by
optimising use of energy by better housekeeping, low cost retrofitting measures
and use of energy efficient equipment at the time of replacements. Indian industry
consumes more energy as compared to its counter parts in the developed
countries.

10
 CHAPTER 3
Why the need for Energy Audit?

i. The three top operating expenses are energy (both electrical and thermal),
labor and materials.
ii. Energy would emerge as a top ranker for cost reduction.
iii. Primary objective of Energy Audit is to determine ways to reduce energy
consumption per unit of product output or to lower operating costs.
iv. Energy Audit provides a “bench-mark” (Reference point) for managing
energy in the organization.

In any industry, the top three operating expenses are energy, labor and minerals.
Among the three, energy ranks the top place, where there is an enormous amount
of energy is required and also more expense will be there and hence there is a
need for managing the energy. Energy Audit will analyze the energy consumption
thereby providing a path to identify the areas, where wastage of energy occurs
and provide the scope for reducing the wastage.

The Energy Audit would give a positive orientation to the energy cost reduction,
preventive maintenance and quality control programmed which are vital for
production and utility activities. Such an audit programmed will help to keep
focus on variations which occur in the energy costs, availability and reliability of
supply of energy, identifying energy conservation technologies etc. In general,
Energy Audit is the translation of conservation ideas into realities, by lending
technically feasible solutions with economic and other organizational
considerations within a specified time frame. The primary objective of Energy
Audit is to determine ways to reduce energy consumption per unit of product
output or to lower operating cost. Energy Management includes planning and

11
operation of energy production and energy consumption units. Objectives are
resource conservation, climate protection and cost savings, while the users have
permanent access to the energy they need. It is connected closely to
environmental management, protection management and other established
functions. The objective of Energy Management is to achieve and maintain
optimum energy procurement and utilization throughout the organization.

 To minimize energy codes or waste without affecting production and quality

 To minimize environmental effects

IMPORTANCE OF ENERGY AUDIT IN HOME

An energy audit is an analysis of a facility, indicating how and where that facility
can reduce energy consumption and save energy costs. Its insight to energy
efficiency and conservation can lead to significant saving on the company’s
utility bill. 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”
Implementation of recommended measures can help consumes to achieve
significant reduction in their energy consumption levels. In India, energy audit
doesn’t gain much value as much in other countries people are focusing. Even
though Government is doing multiple projects to increase the overall efficiency
but still most of people don’t know about it and thought that it is an unnecessary
and ineffective thing to do, and that’s not the truth. In fact, energy audits are first
and foremost step to increase the energy efficiency of our living place and save
more money than invested. Energy audits make the necessary benefits of:

 Lower Electricity Bills - guaranteed advantage you will get is in your electricity
bill. Most of improvement’s payback time is very less for themselves i.e.

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 Make an impact on our Environment - Energy audits are environment-friendly.
When our home consumes less energy, you are reducing your carbon footprint
and helping to decrease unnecessary waste and pollution.

A home energy audit helps individual homeowners find out their residential
consumption and energy flow. An audit is useful to determine areas of your home
where there is energy loss and by identifying where power usage may be curbed
to earn savings. The process involves conducting a walk-through or a visual
inspection of your home, and utilizing testing equipment to identify problems and
analyse energy flow.

An energy audit can be done either by you, you, or a professional energy auditor.
Depending on the size of your home, a typical energy audit can be completed in
an hour to several hours. If you’re unsure about investing in a professional energy
auditor, there are tools online that can help you conduct your own assessment.
While it may not be as thorough as a professional audit, it could provide you with
a basic understanding of the process. This can include a “do-it-yourself
assessment” where you inspect your home like a professional audit – looking at
copies of monthly utility bills to determine spikes and dips in energy expenditures
or potential issues with existing appliances and systems in your home.

13
 CHAPTER 4
TYPES 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, potential and magnitude of cost
reduction desired.
Thus, energy audit can be classified into the following types
 Preliminary Audit
 Detailed Audit (comprehensive)
 Targeted audit on energy systems
 Walk through audit
 Audits for investment in energy conservation technologies
Preliminary energy audit is a relatively quick exercise to:
 Establish energy consumption in the organization

Preliminary Energy Audit:

i. Preliminary energy audit uses existing or easily obtained data

ii. Find out the energy consumption area in the organization
iii. Estimates the scope for saving Identifies the most likely areas for attention
iv. Identifies immediate (no cost or low cost) improvements

v. Sets a ‘reference point’ Identifies areas for more detailed study/

measurement
Preliminary audit is carried out in the limited time say within 10 days and it
highlights the energy cost and wastages in the major equipment’s and processes.
It also gives the major energy supplies and demanding accounting. The
questionnaire containing the industrial details of energy consumption process

14
carried out, energy need to unit product; load data etc. must be completed before
the pre-audit visit.

The pre-audit visit is done, by the audit team/audit consultant, in the plant area
with the attention focused on the energy inputs, spots of wastage and available
energy conservation opportunities. The items for waste recycling opportunities
are identified. The data regarding energy inputs and outputs are collected for use
during preliminary audit.

During the visit, discussions with line supervisors and line technicians and joint
brainstorming may be necessary to acquire creative ideas and to know the
practical difficulties in carrying out the proposed energy conservation measures
(ECMs).

After the pre-audit visit, the work of energy audit is undertaken. In the
preliminary audit, low tech recommendations are preferred. High tech solutions
are given under detailed energy audit. Some of the low-cost recommendations
may be: Switching off lights when not required, replace incandescent lamps by
the fluorescent lamps, automatic thermostat control, use of solar water heating
panels etc.

The preliminary audit spots energy waste spots and recommend short,
intermediate and long-term solutions. It should adopt step by step and cautious
approach for improvements and new techniques of energy management and
control system.

15
Detailed Audit:

Detailed Energy Audit evaluates all systems and equipment which consume
energy and the audit comprises a detailed study on energy savings and costs.
Detailed Energy Audit is carried out in 3 phases.

 The Pre-audit Phase

 The Audit Phase

 The Post-audit Phase

Detailed energy audit, also known as comprehensive energy audit includes

engineering recommendations and well-defined projects with priorities. It
accounts for the total energy utilised in plants. It involves detailed engineering
for options to reduce energy consumption and also reduce cost. The duration of
such studies is generally from 1 to 10 weeks. The action plan in divided into short
term, medium term and long-term actions.

The short-term action plan requires no capital investment or least investment to

avoid energy wastages and minimising non-essential energy uses and improving
the system efficiency through improved maintenance programme.

The medium-term action plan requires a little investment to achieve efficiency

improvement through modifications of existing equipment’s and other
operations.

The long-term action plan is aimed to achieve economy through latest energy
saving techniques and innovations. The capital investments are required to be
studied thoroughly while finalising the long-term action-plan.

The comprehensive (detailed) energy audit is a thorough and extensive energy

audit that analyses and quantifies the amount of energy consumption in each sub
system of the plant and compares the same with the target energy consumption.
Target per unit energy consumption is the optimum energy consumption per unit
product.

16
The comprehensive audit is quite exhaustive, and it is convenient
to split it into following sub parts:

Overall system audit:

This accounts for energy leakage/loss through the total system to the atmosphere.
The energy conservation measures to eliminate such leakages/loss are
recommended.

Functional audit:
It identifies the energy conservation measures in operation and maintenance of
each main plant and its subsystems and suggests ECOs is operation and
maintenance.

Utility Audit:
It identifies yearly/monthly/daily consumption of commercial secondary energy
(electricity/petroleum products/fuel etc.) and suggests ECOs.

Modernization audit:
It recommends major changes in the process requiring retrofitting.

The comprehensive energy audit report generally converts the

following:

(i) Energy conservation opportunities (ECOs)

(ii) Energy conservation measures (ECMs)

(iii) Projected investments for ECMs.

(iv) Projected annual savings of ECMs and pay-back period.

(v) Feasibility studies for retrofitting/modification work.

Energy Audit is defined as “the verification, monitoring and analysis of use of

energy including submission of technical report containing recommendations for

17
improving energy efficiency with cost benefit analysis and an action plan to
reduce energy consumption”.

We carry out energy audit to establish and quantify the cost of the various energy
inputs and consumption flows within an organization over a given period.

The primary objectives of energy audit are to identify and evaluate opportunities
to reduce energy consumption per unit of product output and reduce operating
costs through energy conservation and planning. Energy audit provides a “bench-
mark" for managing energy in the organization and also provides the basis for
planning a more effective use of energy throughout the organization. We carryout
Preliminary Audit, /Detailed Audit, Investment-Grade Energy Audit, Baseline
Energy Audit.

Detailed energy audit includes a complete description of the facility, including an

equipment inventory, an energy balance, detailed energy savings and costs
associated with each low-cost and not-cost measure, financial analysis of each
recommended measure, identification and rough estimates of capital project costs
and savings. Energy savings and economic feasibility are determined as
accurately as possible. The reports contain more detailed descriptions of the
measures.

The portable instruments, trend logs and data loggers are used in detailed
energy audits for assessing the current performance accurately. The scope of an
energy audit includes an examination of the following areas:

 Energy generation/conversions equipment’s like boilers, furnaces, Heaters,

pumps, fans, compressors, transformers etc.
 Energy distribution network of electricity, water, steam, condensate,
compressed air etc.
 Energy utilisation efficiency of all equipment and buildings.

18
  Efficient planning, operation, maintenance and housekeeping
 Management aspects of design and operating data collection, field
measurements, data analysis, and training

We conduct detailed audit in three phases’ namely Pre-audit, Detailed Audit and
post audit as per BEE’s 10step methodology for effective results

The Results

 Immediate savings through no-cost recommendations

 Expected reduction in utility costs from 10-30%
 Long-term roadmap for ongoing utility savings
 Compliance with benchmarking and regulatory/mandatory laws

Targeted Energy Audit:

It Identifies how energy is used and where the opportunities for savings can be
made various targeted energy efficiency audit forms, with guides, are included in
the resources to help organisations periodically review the compliance &
performance of their installations.

Walk through audit:

Walkthroughs are cradle-to-grave reviews of transaction cycles.

You start at the beginning of a transaction cycle (usually a source document) and
walk the transaction to the end (usually posting to the general ledger). The auditor
is gaining an understanding of how a transaction makes its way through the
accounting system and about related internal controls.
As we perform a walkthrough, we:
 Make inquiries
 Inspect documents

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  Make observations
By asking questions, inspecting documents, and making observations, we are
evaluating internal controls to see if there are weaknesses that would allow errors
or fraud to occur. Audit standards do not permit the use of inquiries alone.
Observations and inspections must also occur.
Some auditors believe that audit walkthroughs (or documentation of controls for
significant transaction cycles) are not necessary if the auditor is assessing control
risk at high. This is not true. While the auditor can assess control risk at high, she
must first gain an understanding of the cycle and the related controls. In other
words, the auditor can’t default to high. Risk assessment procedures are required.

What is not an Audit Walkthrough?

Following a transaction through the accounting system–without reviewing
controls–is not an audit walkthrough. We must examine controls to see if they
have been implemented and to see if they are properly designed.
Placing a copy of the operating and accounting system manual in the audit file is
not a walkthrough. While manuals tell you what the client intends to do, they
don’t tell you what is occurring. In other words, they don’t answer the
implementation question.

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Audits for investment in energy conservation technologies:
Energy audits assist industrial companies or facilities in understanding how they
use energy and help to identify the areas where waste occurs and where
opportunities for improvement exist. This guidebook provides step-by-step
guidelines that can be easily followed even by those who have not previously
conducted energy audits. These guidelines are developed in a manner that can be
used by both in-house auditors who are auditing their own plant and outside
consultants who are hired to do an energy audit. The Canadian Industry Program
for Energy Conservation (CIPEC) has published a guidebook titled Energy
Efficiency Planning and Management Guide (CIPEC 2002) which presents a
comprehensive discussion of the procedures for conducting an industrial energy
audit. CIPEC also has a more recent guidebook specifically for energy auditing
called the Energy Savings Toolbox – an Energy Audit Manual and Tool (CIPEC
2009). These two CIPEC guidebooks are two of the main references for Sections
1. to 4 of the guidelines presented here. Also, American Society of Mechanical
Engineers (ASME) has published energy assessment standards that cover the
assessment of pumping, compressed air, steam, and process heating systems. In
these standards the step-by-step procedure for measurement and assessment of
these systems are presented which are key component of any energy audit practice
and are highly recommended to energy auditors and mangers (ASME, 2009a,b,c,
2010).

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Establish energy consumption in the organization:
1. Shutdown your computer

Computers are some of the biggest energy users in office buildings. Turn your
monitor off at night and ditch the screensaver. Today's computers can be turned
on and off over 40,000 times. Opting to shut down over using a screensaver does
not affect your computer's lifespan. (Energy Star). So, power down!

2. Choose the right light

LED bulbs are the most energy efficient lighting option. LED bulbs use 75% less
electricity than incandescent bulbs (Energy Star). They also have no mercury, and
last about 25 times longer than traditional incandescent bulbs (DoE).

3. Eliminate vampire power: unplug idle electronics.

Devices like televisions, microwaves, scanners, and printers use standby power,
even when off. Some chargers continue to pull small amounts of energy, even
when plugged in (a good judge of this is if a charger feels warm to the touch). In
the US, the total electricity consumed by idle electronics equals the annual output
of 12 power plants (EPA).

4. Use a power strip to reduce your plug load.

To avoid paying for this "vampire power," use a power strip to turn all devices
off at once. Flipping the switch on your power strip has the same effect as
unplugging each socket from the wall, preventing phantom energy loss.

5. Turn off the lights

Just one switch and you're done!

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 CHAPTER 5

10 STEPS FOR DETAILED ENRGY AUDIT

Figure 5.1 Plan of Action (a)

Figure 5.2 Plan of Action (b)

23
 CHAPTER 6
Question that an energy auditor needs to ask

 What function does this system serve?

 How does this system serve its purpose?
 What is the energy consumption of this system?
 What are the indications that this system is working properly?
 If this system is not working, how can it be restored to good working
conditions?

 How can the energy cost of this system be reduced?

For a lot of New Jersey homeowners, the importance of saving on energy bills
grows ever present when winter approaches. Cold temperatures are already here,
and knowing which steps to take in order to ensure that heating bills don’t go
through the roof this winter is essential to moving forward in an intelligent
manner. The first step towards making changes is to conduct a home energy audit.

The importance of being prepared for your home energy audit simply cannot be
overlooked, and knowing which questions to ask are essential. Here are 5
questions worth asking, all of which can help to ensure that you don’t run into
confusion along the way.

1. What are the Specific Elements of the Inspection?

Everyone home energy audit consists of a number of different elements, and

knowing what they are ahead of time can be helpful. Ask about whatever specific
tests might be performed, details regarding inspections and how long the home
energy audit will last. Knowing this information ahead of time will give you a
much better idea of what to expect before things get underway.

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2. How will the Home Energy Audit Report Be Delivered and
Resulted?

The final step once a home energy audit has been conducted is for a report to be
resulted and delivered. You’ll want to ask how this will happen and what the
report will include, such as pictures, technical details, recommendations for home
improvements and comparisons to current standards. Each of these elements
helps to give you an idea as to where your home stands in the grand scheme of
things, which will help you to determine how to move forward.

3. Will the Results Include the Rebate Information?

For homeowners who are looking for a helping hand regarding financing a
project, knowing all of the details regarding rebate information is essential. With
this in mind, you should always ask whether the results of a home audit will
include information about the rebate you’re hoping to make use of, dispelling any
confusion that might exist. Tom Rostro Company has certified auditors who are
trained in our rebate process, ensuring you don’t have to worry about the details.

4. How will a Home Energy Audit Meet Our Needs?

The goal of any home energy audit is to put you on a path towards reducing your
energy bills and improving comfort levels within your home. It should also help
you to figure out what improvements need to be made and in what order through
a process of assessment, inspection and delivery of results. In other words, a home
energy audit is designed to help you move forward in reaching your energy
efficiency goals.

5. Are There Multiple Kinds of Home Energy Audits?

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While all home energy audits share the same end goal of helping you to streamline
your home’s energy efficiency, there may be differences between one form or
another that should be taken into consideration by the homeowner. Asking what
sort of HEA will be conducted at the inspection will help to square away any
remaining questions you may have about the process.

At Tom Rostron Company, we believe that the first step towards home
performance is conducting a home energy audit. Contact us today to learn more
about the process and how it can benefit you and your family.

Energy auditor responsibilities are to analyze energy bills including utility rates
or tariffs to gather historical energy usage data; calculate potential for energy
savings; collect and analyze field data related to energy usage; educate customers
on energy efficiency or answer questions on topics such as the costs of running
household appliances or the selection of energy efficient appliances; identify and
prioritize energy saving measures; inspect or evaluate building envelopes,
mechanical systems, electrical systems, or process systems to determine the
energy consumption of each system; perform tests such as blower-door tests to
locate air leaks; prepare audit reports containing energy analysis results or
recommendations for energy cost savings; prepare job specification sheets for
home energy improvements, such as attic insulation, window retrofits, or heating
system upgrades; quantify energy consumption to establish baselines for energy
use or need; recommend energy efficient technologies or alternate energy
sources; analyze technical feasibility of energy saving measures using knowledge
of engineering, energy production, energy use, construction, maintenance, system
operation, or process systems; compare existing energy consumption levels to
normative data; identify opportunities to improve the operation, maintenance, or
energy efficiency of building or process systems; measure energy usage with
devices such as data loggers, universal data recorders, light meters, sling
psychrometers, psychrometric charts, flue gas analyzers, amp probes, watt

26
meters, volt meters, thermometers, or utility meters; determine patterns of
building use to show annual or monthly needs for heating, cooling, lighting, or
other energy needs; oversee installation of equipment such as water heater wraps,
pipe insulation, weather-stripping, door sweeps, or low flow showerheads to
improve energy efficiency.

Understanding written sentences and paragraphs in work related documents,

Giving full attention to what other people are saying, taking time to understand
the points being made, asking questions as appropriate, and not interrupting at
inappropriate times, Using logic and reasoning to identify the strengths and
weaknesses of alternative solutions, conclusions or approaches to problems,
Considering the relative costs and benefits of potential actions to choose the most
appropriate one, Talking to others to convey information effectively.

I have the ability to listen to and understand information and ideas presented
through spoken words and sentences, read and understand information and ideas
presented in writing, communicate information and ideas in writing so others will
understand, tell when something is wrong or is likely to go wrong. It does not
involve solving the problem, only recognizing there is a problem, apply general
rules to specific problems to produce answers that make sense.

The knowledge of materials, methods, and the tools involved in the construction
or repair of houses, buildings, or other structures such as highways and roads,
principles and processes for providing customer and personal services. This
includes customer needs assessment, meeting quality standards for services, and
evaluation of customer satisfaction, the structure and content of the English
language including the meaning and spelling of words, rules of composition, and
grammar, arithmetic, algebra, geometry, calculus, statistics, and their
applications, machines and tools, including their designs, uses, repair, and
maintenance.

27
 CHAPTER 7

INDUSTRIAL FORMAT OF ENERGY AUDIT REPORT

Figure 7.1 Detailed Format

Energy audits identify energy consumed by a facility and locate energy

conservation measures or projects. Typical audits start with a walkthrough and
checklist and progress to monitoring and metering for information on real-time
energy consumption. More intricate audits involve economic calculations, such
as internal rate of return that are used to obtain funding for conservation projects,
code compliance and development of an equipment maintenance schedule.

Lay out the audit specifics in an executive summary that will take about five
minutes to read. Keep the summary concise but meaningful. Begin by stating,
"An energy audit was conducted on July 13, 2011 at ABC facility." State in the
second sentence the dollar amount of potential electricity cost savings from
identified conservation measures. Continue to detail current annual electricity
costs, as calculated from utility bills, and qualifiers as to whether detailed
economic evaluations were conducted during the audit.

28
Describe the overall purpose of the facility, hours and days of operation and any
energy conservation devices in use. Include specifics on overall square footage
and details on users. For example, describe a multi-use building’s resident on the
upper floors, retail space on the main floor and a laundry room in the basement,
all of which use the facility and energy, at different times of day with different
load demands.

Fill out energy accounting forms, which account for energy use at a facility by
tracking kilowatt hours and British thermal units as consumed by equipment, as
determined by sensors or meters or extrapolated from utility bills. Create a unique
picture of use at the facility by illustrating demand factor, which is the peak power
used over a small interval of time, perhaps an hour, and load factor, the ratio
between average demand and peak demand; both factors affect utility rates.

Review the accounting forms to calculate the base load, the consistent amount of
energy used over a 12-month period, such as 20 million Btu, and break the base
load into individual units. Identify consumption patterns for HVAC, lighting and
public laundry areas so you can suggest conservation measures, such as installing
energy efficient washing machines.

Explain accounting methods and include charts that reflect consumption patterns
and energy costs so decision makers can understand conservation options.
Describe how you determined electricity consumption: whether you used utility
reports and extrapolated or ammeters that measured electric current from an
outlet.

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 CHAPTER 8

Energy Auditing Instruments

An energy audit is a systematic analysis of energy use and consumption. It is

important to map all major energy in an energy audit and identify the energy loss
area and saving potential. For accurate and quantified identification of energy loss
or estimation of saving potential, it is important to have some of the important
instruments during an energy audit.

Figure 8.1 Instruments

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We have identified some of the important instrument required
during energy audit: -

I. Electrical measurements and Instruments

II. Lighting measurement Instruments
III. Chemical measurements Instruments
IV. Mechanical measurements Instruments
V. Humidity measurements Instruments
VI. Temperature measurements Instruments

Electrical measurements and Instruments

I. Voltmeter and ammeter to measure voltage & current.

Figure 8.2 – Voltmeter

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 Figure 8.2 - Ammeter

II. Power factor meter to measure power factor

Figure 8.3 – Power Factor Meter

III. Power analyzer to gives a continues measurement and record of real power
(KW), apparent power (kVA), voltage, current and power factor.

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 Figure 8.4 – Power Analyzer
IV. Multimeter

Figure 8.5 - Multimeter

V. Synergy meter is used to measure and records current, voltage, power

factor, frequency, kWh and kVAh.

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 Figure 8.6 – Synergy Meter

Lighting measurement Instruments

Usually a substantial portion of electrical energy requirements of a plant are for

illumination. A lux meter is a very convenient instruments to measure the level
of illumination.

Figure 8.7 – Lux Meter

Chemical measurement Instruments

A flue gas analysis is an essential part of energy audit in a plant emitting flue
gases. The instruments used for flue gas analysis are:

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 I. Dragger
It indicates the degree of combustion in a boiler especially the extent of
carbon monoxide (CO) in the flue gases.

Figure 8.8 - Dragger

II. Fyrite Kit

This kit is used to measure percentage of Co2 and O2 in the flue gases.

Figure 8.9 – Fyrite Kit

Mechanical measurement Instruments:

I. Flow

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The instruments for flow measurement are anemometer to measure air
velocity and flow in a duct, pitot tube to measure pressure and gas flow
rate in big ducts and chimneys, electronic air flow meter to measure
velocity and pressure of air, impact tube to measure high air velocity in
small tubes and smoke pellet to measure low air velocity in a room.

Figure 8.10 - Anemometer

Figure 8.11 – Pitot Tube

Figure 8.12 – Impact Tube & Smoke Pellet

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 II. Pressure
The instruments used for pressure measurement are absolute pressure
manometer, diaphragm gauge, barometer, manometer, micromanometer,
draft gauge, Bourdon tube and pressure transducer. Many pressure gauges
available now days have digital display.

Figure 8.13 – Diaphragm Gauge

III. Speed
Non-contact tachometer and contact tachometer.

Figure 8.14 - Tachometer

IV. Steam trap testing

Engineers stethoscope and electronic steam tester.

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 Figure 8.15 – Steam trap testing

V. Leaks
Ultrasonic leak checker. It operates by generation of ultrasonic
psychrometer, dew point hygrometer, electrical conductivity humidity
meter, electrolytic hygrometer.

Figure 8.16 – Ultrasonic leak meter

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 Figure 8.17 - Dew Point Hygrometer

Humidity measurement Instruments:

The instruments available are psychrometer, dew point hygrometer, electrical

conductivity humidity meter, electrolytic hygrometer.

Figure 8.18 - Psychrometer

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 Figure 8.19 - Electrolytic Hygrometer

Temperature measurement Instruments:

I. Glass stem thermometer

Figure 8.20 – Glass stem thermometer

II. Thermocouple transducers

Figure 8.21 – Thermocouple Transducers

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III. Resistance thermometer

Figure 8.22 – Resistance Thermometer

IV. Bimetallic transducer

Figure 8.23 – Bimetallic Transducer

V. Optical pyrometer

Figure 8.24 – Optical Pyrometer

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VI. Radiation pyrometer

Figure 8.25 – Radiation Pyrometer

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 CHAPTER 9
Identification of energy conservation factors & areas

Steps for conserving energy can be taken if we know the correct factors and areas to
be studied and also details of fuels used. These can be:
• ENERGY GENERATION
• ENERGY DISTRIBUTION
• ENERGY USAGE BY PROCESSES
• FUEL SUBSTITUTION

Energy conservation is the effort made to reduce the consumption of energy by

using less of an energy service. This can be achieved either by using energy more
efficiently (using less energy for a constant service) or by reducing the amount of
service used (for example, by driving less). Energy conservation is a part of the
concept of Eco-sufficiency. Energy conservation measures (ECMs) in buildings
reduce the need for energy services and can result in
increased environmental quality, national security, personal financial
security and higher savings.[1] It is at the top of the sustainable energy
hierarchy.[2] It also lowers energy costs by preventing future resource depletion.[3]

Energy can be conserved by reducing wastage and losses, improving efficiency

through technological upgrades, and improved operation and maintenance. On a
global level, energy use can also be reduced by the stabilization of growth. Energy
can only be transformed from one form to another, such as heat energy to motive
power in cars, or kinetic energy of water flow to electricity in hydroelectric
power plants. However, machines are required to transform energy from one form
to another. The wear and friction of the components of this machine while running
cause losses of very high amounts of energy and very high related costs. It is
possible to minimize these losses by adopting green engineering practices to
improve the life cycle of the components.

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 CHAPTER 10
Technical & Economic Feasibility factors

Figure 10.1 Worksheet

ENERGY COSTS IN INDIAN SCENARIO

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)
UNDERSTANDING ENERGY COSTS

Figure 10.2 Energy Bill

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 CHAPTER 11
Benchmarking

Benchmarking can be a useful tool for understanding energy consumption

patterns in the industrial sector and also for taking requisite measures for
improving energy efficiency.
FACTORS INVOLVED: –
 Scale of operation
 Use of technology
 Raw material specifications and quality
 Product specifications and quality
BENCHMARKING FOR ENERGY PERFORMANCE
Internal Benchmarking
Historical and trend analysis
External Benchmarking
Across similar industries
The scale of operation, use of technology, raw material specification and quality
and product specification and quality
BENCHMARKING FOR ENERGY PERFORMANCE
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
BENCHMARKING PARAMETER
Gross production related e.g. kWh/MT clinker or cement produced (Cement
plant) e.g. kWh/MT, kCal/kg, paper produced (Paper plant)

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Equipment / utility related e.g. kWh/ton of refrigeration (on Air conditioning
plant)
MEASURING ENERGY PERFORMANCE

MAXIMIZING SYSTEM EFFICIENCIES

 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

MATCHING ENERGY USAGE TO REQUIREMENT
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, etc.

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OPTIMISING ENERGY INPUT REQUIREMENT

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

IDENTIFICATION OF ENERGY CONSERVATION OPPORTUNITIES

ENERGY MONITORING & TARGETING IMPORTANCE

An effective monitoring & implementing system with adequate technical ability
for analyzing energy saving options is key to ENERGY MANAGEMENT.
Energy monitoring and targeting is primarily a management technique that uses
energy information as a basis to eliminate waste, reduce and control current level
of energy use and improve the existing operating procedures. These techniques
cover all plant and building utilities such as fuel, steam, refrigeration, compressed
air, water, effluent, and electricity are managed as controllable resources in the
same way that raw materials, finished product inventory, building occupancy,
personnel and capital are managed. It Becomes the “Energy Cost Centers.”
ELEMENTS OF MONITORING & TARGETING SYSTEM
 Recording - Measuring and recording energy consumption

47
 Analyzing - Correlating energy consumption to a measured output, such as
production quantity
 Comparing -Comparing energy consumption to an appropriate standard
benchmark
 Setting Targets -Setting targets to reduce or control energy consumption
 Monitoring - Comparing energy consumption to the set target on a regular
basis
 Reporting -Reporting the results including any variances from the targets
which have been set
 Controlling - Implementing management measures to correct any
variances, which may have been occurred

Particularly M&T system will involve the following:

Checking the accuracy of energy invoices
Allocating energy costs to specific departments (Energy Accounting Centers)
Determining energy performance/efficiency
Recording energy use, so that projects intended to improve energy efficiency
can be checked Highlighting performance problems in equipment or systems

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 CHAPTER 12
Conclusion & Reference

The implementation of a structured energy audit offers numerous benefits

to the enterprises including:

Improved energetic efficiency;

Reduced energy bills;
Reduced environmental impact;
Reduced maintenance costs;
Improvement of working conditions and safety
Greater organizational involvement and competency concerning energy issues.
The main condition for the success of the energy audit is the commitment of the
top management. In addition to the evident and immediate benefits of the energy
audit, there are also other success factors that can motivate the top management
to implement energy efficiency measures:

 The need to gain competitiveness by reducing production costs.

 The increase of energy prices.
 The opportunity represented by the diffusion of new and more efficient
technologies.

 New legislation and regulations that incentivize energy saving

interventions.
REFRENCE:
[Link]
[Link]
[Link]
rvation_Audit_in_Industry_Sector

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