Energy Audit,

Management and
Conservation
 Chapter 2:
Energy audits procedure of
buildings and multi-criteria
analysis
Second Semester 2024/2025

Eng. Asma’ shara’b PTUK

 Energy Management &Audit
Definition & Objectives of Energy Management
• The fundamental goal of energy management is to produce goods and provide services with the
least cost and least environmental effect.

• The strategy of adjusting and optimizing energy, using systems and procedures so as to reduce
energy requirements per unit of output while holding constant or reducing total costs of producing
the output from these systems.

• Effective use of energy aims to maximize profits (minimize costs) and enhance competitive
positions.

• The objective of Energy Management is:

1. To minimize energy costs / waste without affecting production & quality
2. To minimize environmental effects.

Eng. Asma’ shara’b PTUK

 Energy Audit :Types & Methodology
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.
Need for energy Audit
• In any industry, the three top operating expenses are often found to be energy (both electrical and
thermal), labor and materials.
• Energy Audit will help to understand more about the ways energy and fuel are used in any
industry, and help in identifying the areas where waste can occur and where scope for
improvement exists.
• The Energy Audit would give a positive orientation to the energy cost reduction, preventive
maintenance and quality control programmers' which are vital for production and utility activities.

Eng. Asma’ shara’b PTUK

• Energy Audit provides a " bench-mark" (Reference point) for managing energy in the organization
and also provides the basis for planning a more effective use of energy throughout the organization.
• Type of Energy Audit
Energy Audit can be classified into the following two
types.
i) Preliminary Audit
ii) Detailed 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

Eng. Asma’ shara’b PTUK

Preliminary Energy Audit Methodology
Preliminary energy audit is a relatively quick exercise to:
• Determine energy consumption in the organization.
• Estimate the scope for saving.
• Identify the most probably (and the easiest areas for attention).
• Identify direct improvements/ savings (especially no-/low-cost) .
• Set a 'reference point’.• Identify areas for more detailed study/measurement.
• Preliminary energy audit uses existing, or easily obtained data.

Eng. Asma’ shara’b PTUK

The preliminary audit or simple audit or walk through audit is the simplest and quickest type of
audit.
It involves
• minimal interviews with site operating personnel.
• a brief review of facility utility bills and other operating data.
• a walk through of the facility to become familiar with the building operation and to identify any
glaring areas of energy waste or inefficiency.
• Only major problem areas will be covered during this type of audit.
• The results are:
• Briefly described of corrective actions.
• quick estimates of implementation cost.
• potential savings in operating cost.
• simple pay back periods are provided.
Preliminary analysis aims to simple, low cost improvements and a list of energy conservation and
measures to orient the future detailed audit.

Eng. Asma’ shara’b PTUK

This phase is based on
• visual verifications,
• study of installed equipment
• operating data
• detailed study and analysis of recorded energy consumption collected.
Note: This level of detail, while not enough for reaching a final decision on implementing proposed
action.
➢ it is adequate to prioritize energy efficient projects and to determine the need for a more detailed
audit.

Eng. Asma’ shara’b PTUK

Detailed Energy Audit:
• A comprehensive audit provides a detailed energy project implementation plan for a facility, since
it evaluates all major energy using systems.
• This type of audit offers the most accurate estimate of energy savings and cost.
• In a comprehensive audit, one of the key elements is the energy balance.
• This is based on an
• inventory of energy using systems.
• study of current operating conditions.
• calculations of energy use.
• This calculated energy use is compared to utility bill charges.

Eng. Asma’ shara’b PTUK

 Detailed energy auditing is carried out in three phases:
• Phase I - Pre Audit Phase
• Phase II - Audit Phase
• Phase III - Post Audit Phase
• A comprehensive ten-step methodology for conduct of Energy
Audit at field level is presented next.

Eng. Asma’ shara’b PTUK

Phase I -Pre Audit Phase Activities
A structured methodology to carry out an energy audit is necessary for efficient working. An initial
study of the site should always be carried out, as the planning of the procedures necessary for an
audit is most important.
Initial Site Visit and Preparation Required for Detailed Auditing
An initial site visit may take one day and gives the Energy Auditor/Engineer an opportunity to meet
the personnel concerned, to familiarize him with the site and to assess the procedures necessary to
carry out the energy audit.
❖ During the initial site visit the Energy Auditor/Engineer should carry out the following actions: -
• Discuss with the site's senior management the aims of the energy audit.
• Discuss economic guidelines associated with the recommendations of the audit.
• Analyze the major energy consumption data with the relevant personnel.
• Obtain site drawings where available - building layout, steam distribution, compressed air
distribution, electricity distribution etc.

Eng. Asma’ shara’b PTUK

• To identify the main energy consuming areas/plant items to be surveyed during the audit.

• To identify any existing instrumentation/ additional metering required.

• To decide whether any meters will have to be installed prior to the audit eg. kWh, steam, oil or
gas meters.
• To identify the instrumentation required for carrying out the audit.

• To plan with time frame

• Tour the site accompanied by engineering/production

Eng. Asma’ shara’b PTUK

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Phase II- Detailed Energy Audit Activities
Depending on the nature and complexity of the site, a comprehensive audit can take from several
weeks to several months to complete. Detailed studies to establish, and investigate, energy and
material balances for specific plant departments or items of process equipment are carried out. The
information to be collected during the detailed audit includes:-
1. Energy consumption by type of energy, by department, by major items of process equipment.
2. Material balance data (raw materials, intermediate and final products, recycled materials, use of
scrap or waste products, production of by-products for re-use in other industries, etc.)
3. Energy cost and tariff data
4. Process and material flow diagrams5. Generation and distribution of site services (eg.
compressed air, steam).
6. Sources of energy supply (e.g. electricity from the grid or self-generation)
7. Potential for fuel replacement, process modifications, and the use of co-generation systems
(combined heat and power generation).
8. Energy Management procedures and energy awareness training programs within the
establishment.

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Draw process flow diagram and list process steps; identify waste streams and obvious energy wastage

Eng. Asma’ shara’b PTUK

Eng. Asma’ shara’b PTUK
Example: A flowchart of Penicillin-G manufacturing is given in the next slide.
• Note that waste stream (Mycelium) and obvious energy wastes such as condensate drained and
steam leakages have been identified in this flow chart
• The audit focus area depends on several issues like
➢ consumption of input resources,
➢ energy efficiency potential,
➢ impact of process step on entire process.
➢ intensity of waste generation and energy consumption.

In the above process, the unit operations such as germinator, pre-fermentor, fermentor, and
extraction are the major conservation potential areas identified.

Eng. Asma’ shara’b PTUK

Eng. Asma’ shara’b PTUK
 Identification of Energy Conservation Opportunities
Fuel substitution: Identifying the appropriate fuel for efficient energy conversion
Energy generation :Identifying Efficiency opportunities in energy conversion equipment/utility such
as captive power generation, steam generation in boilers, thermic fluid heating, optimal loading of
DG sets, minimum excess air combustion with boilers/thermic fluid heating, optimizing existing
efficiencies, efficient energy conversion equipment, biomass gasifiers, Cogeneration, high
efficiency DG sets, etc.
Energy distribution: Identifying Efficiency opportunities network such as transformers, cables,
switchgears and power factor improvement in electrical systems and chilled water, cooling water,
hot water, compressed air, etc.
Energy usage by processes: This is where the major opportunity for improvement and many of
them are hidden. Process analysis is useful tool for process integration measures.
Technical and Economic feasibility The technical feasibility should address the following issues :
• Technology availability, space, skilled manpower, reliability, service etc.
• The impact of energy efficiency measure on safety, quality, production or process.
• The maintenance requirements and spares availability

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The Economic viability often becomes the key parameter for the management acceptance. The
economic analysis can be conducted by using a variety of methods. Example: Pay back method,
Internal Rate of Return method, Net Present Value method etc.
For low investment short duration measures, which have attractive economic viability, simplest of
the methods, payback is usually sufficient. A sample worksheet for assessing economic feasibility is
provided below:

Eng. Asma’ shara’b PTUK

 Classification of Energy Conservation Measures
Based on energy audit and analyses of the plant, a number of potential energy saving projects
may be identified. These may be classified into three categories:
1. Low cost - high return.
2. Medium cost - medium return.
3. High cost - high return.

Energy Audit Reporting Format

After successfully carried out energy audit energy manager/energy auditor should report to the top
management for effective communication and implementation. A typical energy audit reporting
contents and format are given below.

Eng. Asma’ shara’b PTUK

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 Understanding Energy Costs
• In many industries sufficient meters may not be available to measure all the energy used.
• In such cases, invoices for fuels and electricity will be useful.
• In later years invoices can be used to quantify the energy and cost savings made through energy
conservation measures

Eng. Asma’ shara’b PTUK

 Fuel Costs
A wide variety of fuels are available for thermal energy supply:
• Fuel oil
• Low Sculpture Heavy Stock (LSHS)
• Light Diesel Oil (LDO)
• Liquefied Petroleum Gas (LPG)
• COAL
• LIGNITE
• WOOD ,,,,,,etc.
• Understanding fuel cost is fairly simple and it is purchased in Tons or Kiloliters.
• The main three factors that should be considered while purchasing are
Availability, cost and quality .
The following factors should be taken into account during procurement of fuels for energy efficiency and
economics.
➢ Price at source
➢ transport charge
➢ type of transport
➢ Quality of fuel (contaminations, moisture etc.)
➢ Energy content (calorific value)

Eng. Asma’ shara’b PTUK

 Power Costs
Unfortunately the different forms of energy are sold in different units e.g. kWh of electricity, liters of fuel oil, tons
of coal. To allow comparison of energy quantities these must be converted to a common unit of energy such as
kWh, Giga joules, kCals etc.

➢ Electricity (1 kWh) = 860 kCal/kWh (0.0036 GJ)

➢ Heavy fuel oil (Gross calorific value, GCV) =10000 kCal/litre ( 0.0411 GJ/litre)
➢ Coal (Gross calorific value, GCV) =4000 kCal/kg ( 28 GJ/ton)

Eng. Asma’ shara’b PTUK

 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. Some commonly used

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 Combustion Analyzer
This instrument has in-built chemical cells
which measure various gases such as O 2,
CO, NOX and SOX.

Fuel Efficiency Monitor

This measures oxygen and temperature of
the flue gas. Calorific values of common
fuels are fed into the microprocessor
which calculates the combustion
efficiency.

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 Contact Thermometer
These are thermocouples which
measures for example flue gas, hot air,
hot water temperatures by insertion of
probe into the stream. For surface
temperature, a leaf type probe is used
with the same instrument

Infrared Thermometer
This is a non-contact type measurement
which when directed at a heat source
directly gives the temperature read out.
This instrument is useful for measuring
hot spots in furnaces, surface
temperatures etc

Pitot Tube and manometer

Air velocity in ducts can be
measured using a pitot tube and
inclined manometer for further
calculation of flows.

Eng. Asma’ shara’b PTUK

 Water flow meter
This non-contact flow measuring device using
Doppler Effect / Ultra sonic principle. There is a
transmitter and receiver which are positioned on
opposite sides of the pipe. The meter directly gives
the flow. Water and other fluid flows can be easily
measured with this meter.
Tachometer Stroboscope Speed Measurements
In any audit exercise speed measurements are
critical as they may change with frequency, belt slip
and loading.
A simple tachometer is a contact type instrument
which can be used where direct access is possible.
More sophisticated and safer ones are non contact
instruments such as stroboscopes.

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 Leak Detectors
Ultrasonic instruments are available which
can be used to detect leaks of compressed
air and other gases which are normally not
possible to detect with human abilities.

Lux meters
Illumination levels are measured with a lux
meter. It consists of a photo cell which
senses the light output, converts to
electrical impulses which are calibrated as
lux.

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 Smart Energy Meters
The term smart meter usually refers to
electric meters which keep detailed
statistics on usage ,but it can be used for
fuels or water applications as well
performing the same job. The primary
purpose of smart meters is provide
information on how end users use their
electricity on real- time basis . The smart
energy meters use a wireless
communication to help to help track the
electricity consumption and thus save
both electricity and money . It can be easily
installed and gives an accurate reading
of electricity consumption which can also
be monitored/ controlled through mobile or
internet .

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Fuel substitution: Substituting existing fossil fuel with more efficient and less cost/less polluting fuel
such as natural gas, biogas and locally available agro-residues
Fuel substitution has taken place in all the major sectors of the Indian economy.
Kerosene and Liquefied Petroleum Gas (LPG) have substituted soft coke in residential use.
Few examples of fuel substitution
• Natural gas is increasingly the fuel of choice as fuel and feedstock in the fertilizer, petro
chemicals, power and sponge iron industries.
• Replacement of coal by coconut shells, rice husk etc.
• Replacement of LDO by LSHS

Few examples of energy substitution

➢ Replacement of electric heaters by steam heaters
➢ Replacement of steam based hot water by solar systems

Eng. Asma’ shara’b PTUK

Eng. Asma’ shara’b PTUK