l@I Energy Cons. & Audit .

(MSBTE) 9-2 Energy Audit

9.1 Introduction :

•
~,~1;::::t~.r=r~~;ar• •
An energy audit is an introductory activity towards
organizing energy efficiency programs 1n .
an
establishment.
• Energy audit identifies conservation opportunities that
are basically important for the development of an
.
energy savings program.
• Energy Audit means a systematic procedure to identify.
1. Existing energy consumption
2. Sources of wastage
3. The saving measures
And then report the findings in buildings, sites, facility
etc.
• In the today's energy scenario energy auditing has
become a very important part of any industrial activity.
• An Energy Audit Study includes :
1. Helps an establishment to understand, verify and
analyze its energy consumption (any heat and
power generated).
2. General examination of work place (physical
condition of organization, all processes, occupancy
time, variations in ambient temperature, energy
consumption pattern etc.)
3. Measurement of all energy flows.
 Energy Audit
J Energy Cons. & Audit (MSBTE
) 9-3

an d es tim at io n of va lu e of en er gy usage.
4. Analysis
m an ag em en t pr oc ed ur es an d methods.
5. Energy
Id en tif y ar ea s w he re energy use can be reduced.
6.
m en da tio ns fo r en er gy ef ficiency measures.
7. Recom
paybacks.
8. Implementation costs and
Pl an an d pr actic e of achievable energy
9.
er va tio n m etho ds w hi ch will increase energy
cons
efficiency.
10. Reduces energy was
tage.

11. Reduces energy costs.

• The Energy Audit serves
To fin d al l th e en er gy input in a buildings, sites,
1.
establishment etc.
To re st ric t en er gy us ag e with its individual role
2.
input with its use.
3. To balance the total energy
it is th us th e ke y to a systematic approach
• Ener gy A ud
de cisi on -m ak in g 1n the ar ea of Energy
for
Management.
ud y is an ef fe ctive tool in explaining
• Energy A ud it St
Management
g ex te ns iv e En er gy
and followin
Programmed (EMP).
tif ie s w he re en er gy is being
• An energy au di t id en
d as se ss es en er gy sa vi ng opportunities -
consumed an
t to sa ve m on ey w he re it counts th e most.
so you ge
• an en er gy au di t in cr ea ses awareness of
In the factory,
es am on g pl an t pe rs on nel, making then1
ener gy issu
ow le dg ea bl e ab ou t pr op er practices th at will
more kn
e.
n1ake them more productiv
IWJ Energy Cons. & Audit (MSBTE) 9-4
Energy AUdit .

>·M
~{<..·"
an ag em en t syst~~ {
-· .-. .. ,

Evaluation
sav ing
methods . _ . ·I mplementatio
· ·--··- ·· ' • saving methondsol

Reporting

Fig. 9.1 .1: Energy audit connecti

ons
• An en er gy au di t is a "b as eli ne
" fo r tr ac ki ng yearly
pr og re ss ag ain st tar ge ts, an en
er gy au di t becomes the
be st fir st ste p to wa rd s sa vi ng mo
ne y in th e pl an t.
• Du rin g an nu al ev alu ati on of
fa cto ry pe rfo rm an ce
en er gy au di t as se ss es mo ne y
sa ve d th ro ug h energy
co ns er va tio n tec hn iq ue s .

_9_.2_ _E_n_e_rg
=-y=----F_
-- lo
_w_ D_i_a~g__:
ra:..:. .m
: .-=-=-s=--=a=-n.:..:d::_:_it=
:: s -=S=-=i~g~n:. if
: . .: . .ic
: ._-=-a_n_c_e_ :_ -- -
• En er gy flow di ag ra m of an y sy ste
m is a di ag ra m which
sh ow s en er gy di st rib ut io n of
th at sy ste m fron1 the
in pu t t o ou tp ut sh ow in g th e po in
ts of los se s in be tw een ,
• In co nte xt of en er gy au di t Sa nk
the en ey Diag-ran1 rep res en ts
er gy flow in a sy ste m wh os e
co nd uct ed. au di t is to be
~nergy Cons. & Audit (MSBTE) 9-5 Energy Audit

Internal distribution of energy to final consumption per

•
energy per energy system within, can be easily
understood with the help of Sankey Diagram.

• It is drawn after energy balance calculation .

• These diagrams quantifies Outflows, Inflows of the
system in proportion to total energy inflow
o Energy Losses - Outflows
o Energy Gains - Inflows
o Useful ·energy in every energy system
This is done using,
o Data of energy bills
o Data from invoices
o Calculations
o Measurements in system
• Visual representation of energy flow helps to
I

o Find out critical energy consumption points of the

unit under study.
o Identify the sources of energy losses
This lead us to
More accurate evaluation of system behaviour
Decide a strategy to schedule energy saving
measures
• Henc~ using these diagrams energy manager can focus
on pnority to be given for improvement finding.
92
· ·1 Energy Flow for Induction Motor :
• The diagram 18
· fl ·.
energy ow diagram for induction
motor.
•
The electrical energy 18
(St . .
· d r
app ie to the induction motor.
ator w1nd1ng)
lcl3i Energy Cons. & Audit (MSBTE) 9-6 Energy Aud!t

ele ctr ica l lo ss es ta ke pl ac e in th e windings,

• Some
(e.g. copper losses)
• Electrical en er gy is co nv er ted
into magnetic energy. Electrical
. energy
Magnetic en er gy lin ks wi th
•
sta tio na ry as well as ro ta tin g
str uc tu re of th e in du cti on
motor.
··Magnetic
se s ta ke pl ac e in
• Mag ne tic los energy
ai r as well as in m ag ne tic
material. (e.g. hy ste re sis , ed dy
cu rre nt )
• Magnetic ·e ne rg y is co nv er ted
into mechanical energy.
• Mechanical losses ta ke pl ac e .
(e.g. friction, windage)
.
Fi na lly th e _ou tp ut Ill
ab le
mechanical en er gy form is av ail
r.
at th e sh af t of th e induction moto
Fig. 9.2.1
d th ei r use :
9.3 Energy Audit Instruments an

any lr instrument require ·to carry out energy audit

Q. LI$t ® t fol
procedure lri chemical fact()fy WitR fun
ction in brief. llfJ
9.3.1 ts:
Electrical Measuring Instrumen
• au di to r sh ou ld be we ll familier with
An en er gy
su rin g in str um en ts in or de r to ha ve knowledge of
mea
particular
~urchase, re nt an d most im po rta nt us e of
in strument.
 E
9-7
r11 y cons. & Audit (MSBTE) nergy Audit
IW:-. Energ
~ need to obta.in th e useful m ea su re m en t da ta for
Basic
is pr op er se le ct io n an d use of th e
' energy audit
instrument.
st ru m en ts ar e us ed for m ea su ri ng major
These in
lta ge , cu rr en t, kVA,
' electrical parameter s su ch as vo
uency etc.
kW, kVAR, power factor, freq
su re m en t ca n also be do ne us in g some of
Harmonic m ea
' ic meter.
the instruments like Harmon
ca n be us ed on -li ne i.e. w it ho ut
ts
• Some instrumen
switching off the process.
m en ts co ul d be us ed for in st an t
• Hand-held instru
measurements.
type s of in st ru m en t ca n be us ed for
• Some advanced
read ing as w ell as pr in tout of th e readings at
taking
required intervals.
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Fig. 9.3.1
lc\31 Energy Cons. & Audit (MSBTE) 9-8 Energy Audit

1. Tri Vector meter:

• Tri vector meter is a multip urpose meter.
• It has severa l functions.
• It replac es variou s equipm ents for meteri ng
energy param eters.
• It is light, compact and highly reliabl e.
• It can be used for uni-di rection al or bi-dire ctiona l
meteri ng, TOD (Time - of - Day) meteri ng, and for
energy manag ement .
• It is availab le for both HT and LT applic ations .
• Some of the meters availa ble can be progra mmed
to display maxim um 350 param eters that includ e
per phase RMS voltages and curren ts, kW, kVA,
kVAr, kWh, kVAh, kVArh+, kVArh-, PF,
Frequency, Phase sequen ce, real time clock,
MDs', Rising deman d with elapse d time, high
resolu tion energies, tampe r details etc.

Fig. 9.3.2
 l
9-9 Energy Audit.
~ cons. & Audit (MSBTE)

~ • I
combustion ana yzer :
2,

Fig. 9.3.3: Electronic Combustion Analyser

• Latest combustion analyze rs are portabl e

electronic instrum ents used for the measur ement
of combustion efficiency of boilers, furnace s.
• Combustion analyzer is essentia l to ensure the
optimum ratio of air to fuel used.
• Electronic combustion analyze r includes many
measurements in one unit, mostly battery
powered and digital display with keypad for user.
• A basic analyzer support s measure ment of
o Flue/ Stack gas tempera ture
o Combustion Air Temper ature
o Oxygen Level
o Carbon monoxide Level
• Typical combustion analyze r is shown in figure
useful for testing boilers, plant heating
equipments and some process combustion
systems, etc.
_j
 <

IW1 Energy Cons. & Audit (MSBTE) 9-1 O

Energy Audit

ate rs, Bot Water

• Ap pl ica tio ns - Boilers, Un it He
ocess furn
heaters, He ati ng as well as pr aces
etc '
Process ovens, dryers, Pr eh ea ter s,
have features of
• Advanced meters of th es e ki nd s
integration With
alarms, multiple gas analysis,
printers, etc.

3. Fuel efficiency monitor:

oxygen and
• This in str um en t m ea su re s
temperature of the flue gas.
ar e fed into the
• Calorific values of common fuels
th e combustion
microprocessor, which calculates
efficiency.

Fig. 9.3.4

4. Flue gas analyzers: (Fyriter)

flue gas sample
• A hand bellow pump draws th e
into the solution inside the fyrite.
liquid volume
• A chemical reaction changes th e
revealing the amount of gas.
0 and CO2
• A separate fyrite can be used for 2
measurement.
 dit (MSBTE) 9-11 Energy Audit
~1 :n er g Y Cons. & Au
ldit
p
-
r.;..

s,

if
l

Fig. 9.3.5

5. Thermometers :
e ar e tw o ty p es o f th er m o m et er s :
T h er
er
(a ) C on ta ct T he rm om et
et er
(b ) In fr ar ed T he rm om
•• T he se a re
T h er m o m et er
(a ) C o n ta ct
w hi ch m ea su re s fo r ex am pl e flue
th er m o co u p le s,
-. ai r, an d h o t w at er te m p er at u re s by
g as , h o t
p ro b e in to th e st re am . F o r su rf ac e
in se rt io n o f
af ty p e p ro be is u se d w it h th e
te m p er at u re , a le
sa m e in st ru m en t.

Fig. 9.3.6
 7 11&1
l<l3! Energy Cons. & Audit (MSBTE} 9-12
Energy Audit

(b) Infrar ed Therm ometer : This is a non-contact

type measur ement which when directed at a heat
source directly gives the temper ature read out.
This instrum ent is useful for measur ing hot spots
in furnace s, surface temper atures etc.

Fig. 9.3.7

6. Airflow measurements :

• Airflow measur ements are very necessa ry to

analyze the HVAC and exhaus t systems .
• Accura te airflow measur ement is normally
difficul t and it demand s the specialized
instrum ents. Some of the simple to operate
instrum ent for basic energy audit are,

1. Digita l vane Anemo meter :

• It employ s a rotatin g vane whose speed
varies directly with the air speed.
• Use of this instrum ent is restrict ed because
its size which impose s difficul ty in putting
the sensor in the air stream to be measured.
'
• Not suitable for In-Duc t measur ements .
rd . ·y cons. & Audit (MSBTE) 9-13
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2• Digital Thermo Anemometer-
·
IIot wire is cooled in the air stream · Th IS
•
temperature of wire is sensed to sense the
speed.

• Suitable for ducts .

a. Pi tot Tube an d manonteter-

for
• This is the most versatile instruments
airflow measurement.
ble
• Handheld digital manometers are availa
ed
having da ta logging functions for advanc
applications.
va nta ge
• Pit ot tub e - Ma no me ter offers the ad
ssu re
of me asu rem en t of ne ces sar y pre
req uir ed for ass ess me nt of power.

7. Water flow meter:

ice usm g
• This non-contact flow me asu rin g dev
Doppler eff ect / Ul tra sonic principle.
• There is a tra nsm itte r and
receiver, which are
positioned on opposite sides

•
of the pipe. The me ter
directly gives the flow.
wa ter and other fluid flows 'iii ;
c•F•• •·r:;" -
can be easily measured with
this me ter. Fig. 9.3.8

8. Speed measurement :
n1easure
• Tachometer is used by energy auditor to
the speed of Motor of Driven device.
 -
kfi Energy Cons. & Audit (MSBTE) 9-14 Energy Audit

• In any aud it exercise speed me asu rem ent s are

critical as the y ma y cha nge wit h frequency, belt
slip and loading.
• Contact Type :
o A simple tac hom ete r is contact type. It is
use d wh ere direct access is possible.
o It is connected at the end of rota ting shaft.
o Can also be connected aga ins t the conveyor
bel t to det erm ine line ar speed.
• Non Contacting Type:
o More sophisticated and saf er ones are non-
contact ins trum ent s.
o It throws a light bea m on rota ting shaft
which is reflected off from a reflective patch
on the shaft.
• To compare the act ual performance of fan,
compressor, pum p wit h tha t specified on the
nam epl ate speed me asu rem ent is an important
aspect.

Fig. 9.3.9

9. Leak detectors :

• Ultrasonic ins tru me nts are ava ilab le which caJl

be use d to det ect lea ks of com pre sse d air lllld
rt1 energy cons. & Audit (MSBTE) 9_15 Energy Audit

~ other gases, which are normally not poss1"ble to udit

detect with human abilities. ' ts)

When gas is forced through a small opening _ a
• leak in a pressure or vacuum system - an ar
ultrasonic sound is created.
Directionality of this sound is used to locate the
• source of leak.
• The ultrasonic leak detector is sensitively tuned
to this frequency of sound. I

• Strength of leak signal is indicated by a display.

Adjustable sensitivity helps to pinpoint the leak
j
location
• Figure shows ultrasonic leak detector with the
ultrasonic transmitter. This is appropriate to
check the air leaks around the door and window
seals and gaskets, water leak in roof and leaks of
vacuum vessels.
Applications : · d. · · System
Refrigeration and Air Con 1t1onmg
• Heating System, Compressed Air Systems, etc. ,

F" "th fra11s01itter

tg. 9.3.10 : Ultrasonic Detector wi ' ·
 r-r $$i $\'YJ"11j

\(l3\ Energy Cons. & Audit (MSBTE) 9-16

Energy Audit

1O. Lux meters :

• Illumination levels are measured with a lux

meter. It consists of a photo-cell which se.:1ses the
light output, converts to electrical impulses which
are calibrated as lux.
• It proves useful for comparing the actual lux level
with the recommended standards for particular
areas.
• A basic Lux meter is as shown in figure. It has
features such as,
o Measurement from O to 50,000 lux
o It has sensor in a separate unit from
display, connected with flexible cord.
o It gives accuracy near about 5 %
o Automatic Zero Adjustment
o Battery Operated.
• Along with these a very useful feature of analog
output function for recording.

:Fig. 9·3·11 : Basic Light l\tleter

11
· Loud Analyzer :
• It is used t .
o measure audio signals.
 Audit (MSBTE) 9-17 Energy Audit
~ Energy Cons. &

l m e a su re m e n ts a re m ad e ~ 1 10 r se v er a1 Udit
Au d io si g n a
•
p u rp o se s. ts)
th e p er fo rm an ce o f eq u ip m en t.
• It is u se d to ch ec k w o rk in g
t th e e q u ip m e n t is
th a
It is u se d to ch ec k
ar
• th e g iv en sp ec if ic at io n .
ac co rd in g to
re th a t th e cu m u la ti v e d ef ec ts o f
• It is u se d to e n su
d io si g a n a ls a re w it h in li m it s.
a n au
a w a y th a t is

j
re th e sy st em in
• It is u se d to m e a su
h ea ri n g .
re la te d t o h u m a n
sti o n na ir e for Energy Audit
9.4 Pre pare Que
Pro jects :

~~ ~ ; } ~ H ~ , ~ ene;gy au;.FI
Q. State any touf~
. •,L/r' :JY!*s(.;;s·:~Ss.,;<• J.·. ·•.·
ti o n n ai re 1s to collect th e
th e q u es
• T h e m a in a im o f
an iz at io n .
b as ic d a ta o f a n o rg fo rm at io n o f th e
e ca n g a th e r th e in
• In q u es ti o n n ai re w
n o rg an iz at io n .
d if fe re n t p a rt s o f a
• It w il l sh o w : n 's in fr as tr u ct u re .
io n o f o rg an iz at io
1. P re se n t co n d it
u rc e.
2. P re se n t le v el o f re so
t le v el o f re so u rc e co n su m p ti o n.
3. P re se n
v es al re ad y p e rfo rm ed t ow ar d s
4. T h e v a ri o u s in itia ti
g y co n se rv a ti o n a n d m a n a g e m e n t.
en er
h el p a n o rg an iz at io n for 1n ak in g
w il l
• T he q u es t io n n ai re sp ec ific n ee d s.
es a cc o rd in g t o
or fi tt in g th e serv ic
es ti o n n a ir e is g iven for st u dy
qu
• H er e o n e ty p ic al
p u rp o se .