ENERGY MANAGER TRAINING COURSE (EMTC)

TC 6.0 – INTRODUCTION OF ENERGY

AUDIT
VER.2(2019)

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LEARNING OUTCOMES
At the end of the module, participants should be able to:

1. Describe the compliance to the specified requirement before conducting

the Technical Energy Audit in the facility
2. Explain the differences types of Technical Energy Audit, resources needed
and methodologies
3. Explain the differences between Certified Energy Manager (CEM) and
Energy Auditor’s roles and responsibilities
4. Propose an appropriate recommendation for Energy Conservation
Measures (ECM) implementation
5. Analyze and evaluate the results of Energy Audit report
SUSTAINABLE ENERGY MANAGEMENT
ROADMAP
Evaluation Energy Management Matrix

Energy Policy
Energy Committee
Organization
Preparation Set up EM Component
Awareness Training

Implementation of Detailed Energy Audit

Energy Select Energy Target & Plan
Conservation
Measures Set up SIT
Technical Training

Accreditation Scheme
System Integration
Integrate to ISO/ TPM
Procedural 3Training
Benchmarking in Building
WHAT IS BEI ? LABEL CONCEPT
• A benchmarking tool in monitoring building energy Star range:
performance by indicating the intensity of energy used per 1 Star: Highly inefficient
meter square area of the building 5 Star: Most efficient

• The Intensity is calculated by taking the ratio between

annual energy consumption of a building (kWh/year) and
nett floor area of the building (NFA)

Annual Energy Consumption (kWh) Building

BEI (kWh/m² /year) = categories:
NFA (m²) Building Energy
Office/ Intensity
Hospital/ Unit:
University/ kWh/m2/year
BEI LABELLING BENEFITS School &
etc.
Ascertains energy performance of Government
buildings

Accelerates efforts to make Government buildings

energy efficient through Government Lead By Example

Provides and disseminates information to building STAR BEI Range*

occupants on energy usage performance of the building 5-Star BEI ≤ 100
compared to energy efficient building
4- Star 100 < BEI ≤ 130
Creates healthy competition among building owners to
improve energy use 3- Star 130 < BEI ≤ 160
Helps the Government achieve national commitment 2- Star 160< BEI ≤ 250
to reduce GHG emissions intensity of GDP by 45% by 1- Star BEI > 250
2030
*BEI range for office building
Sample Benchmarking in Industry – Steel
Industry

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Tools for Energy Monitoring

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 Requirements need to comply
Primary
- Safety and legislations
General - Data confidentiality
- System and equipment standard
Rules - Competency of teams

Secondary
- Energy Efficiency
- Material Efficiency
- Manpower Efficiency
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Energy Audit Definition
• A systematic inspection and analysis of
energy use and consumption of audited
object(s) to identify energy flows, potential
opportunities and monitoring & verification
for improving energy performance and
reporting them.
• Objectives of Energy Audit
- To understand current energy management practices
- To reduce the energy consumption without
compromising safety, comfort, and quality of the
facilities
- To understand energy consumption in the
building/industry
- To establish baseline energy performance
- To identify area of energy wastage and potential
energy improvement 8
Energy Audit Needs and Types
Type Description
-Evaluating energy consumption in general
-energy bill analysis and determining EEI (BEI/SEC)
Walk-through/
-Identifying areas for potential savings in general using experience
Preliminary audit
and ‘rule of thumb’
-No systematic measurement
-Using input from preliminary audit
-Identification of energy sources and end-users and apportionment
-Determination of equipment and system performance
Detailed audit -Performance evaluation with reference to design/standards
-Investigation and measurement to identify potential savings
-Analysis of saving measures using and technical and economic
evaluation.
-Input from detail audit
-Involve high cost, complex system
Investment -Require financing
Grade Audit -Perform ROI, IRR and risk analysis
-Longer period for investigation and monitoring 9
Execution steps of preliminary energy
audit

• 1-2 days

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Execution steps of detailed energy
audit

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Determining type of audit needed
Question to help you determine your
audit needs
Do you want to evaluate the overall
opportunity potential in your facility?
Do you already have an energy audit
completed?
Have some energy efficiency projects
been installed?
Do you have limited funds to spent on
an audit?
Do you know what projects you want to
implement?
Do you plan to have comprehensive
energy target and plan for your facility?
Are you concerned about accuracy of
energy project savings and cost?
If your answer is “YES” the we If your answer is” NO” then we
recommend . . . recommend . . .
Detailed Energy Audit Walk-through/preliminary or selected
system/equipment energy audit
Walk-through/preliminary energy audit
Updated the latest data to get
project financing
Perform M&V to verify the actual Walk-through/preliminary energy audit
saving. If the energy target is not
achievable medium/high cost ECM
will be considered
Walk-through/preliminary energy Detailed Energy Audit
audit
Investment grade audit
Walk-through/preliminary energy
audit/detailed energy audit
Walk-through/preliminary energy audit
Detailed Energy Audit
Walk-through/preliminary
Detailed Energy Audit energy audit
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Resources needed for energy audits

Instruments
Permanent and portable
Auditors
Company staff or
external auditor

Energy records

Budget and time Computers

and
software tools
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Energy Audit Team

Energy end-user/client top management

Energy Service Companies/unit management

Overall co-ordination
and support

Audit expertise Process expertise

Energy Audit Team Building/Factory staff

Lead auditor (Management & Technical) Energy manager or counterpart

Auditor for mechanical and thermal Chief Engineer (case by case)
Auditor for electrical Technical personnel (case by case)
Competent person (chargeman) Other personnel (case by case) 14
 Energy Manager role to ensure
successful energy audit
Pre-Audit Phase During Audit Phase Post Audit Phase

• Desktop data collection • Kick-off meeting – key • Desktop data collection

• Arrange for key decision person, top • Report to the top
makers to be at the management management
meeting with the • Fulfil safety requirement • Propose and priorities
energy auditor & Permit To Work ESM to be inline with
• Identify scopes and • Prepare equipment organization/company
objectives standard and target & plan
• Identify EE project in specifications
the pipeline & future • Ensure equipment
• Provide relevant form to reliability
meet primary • Review energy audit
requirement i.e. safety, progress
NDA • Data collection and
analysis
• Review EA draft & final
report
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Roles and duties of energy auditor
• Plan and carry out energy audit based on agreed scope.
• Quantify energy consumption and establish base line energy
information.
• Construct energy and material balance.
• Perform efficiency evaluation of energy & utility systems.
• Compare energy norms with existing energy consumption levels.
• Identify and prioritise energy saving measures.
• Analysis of technical and financial feasibility of energy saving
measures.
• Recommend energy efficient technologies and alternate energy
sources.
• Report writing, Presentation and follow up for implementation

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Methods and
Approaches in
Energy
Auditing

Cont. 17
(1) Kick-off Meeting
 (1) Kick-off Meeting

• Objectives
• Scope / Boundary
Energy Audit Kick Off

• Team (Auditor & Facility)

Meeting Agenda

• Timeline
• Deliverable
• Report Format
• Requirement (Safety & Document Confidentiality)
• Contact Person
• Walk through audit to the facility
 Purpose of Kick-off meeting
The purpose of the kick off meeting is to:
• Brief the client about the audit process.
• Introduce energy auditing team members to the client and request members from
client side.
• Present to the client a list of document, manuals, records, drawings required for
conducting the desk-top data collection.
• Obtain permission for the team members to have access to the client’s facilities.
• Familiarize the audit team members with the client’s safety procedures.
• Agree on the process of coordinating the Energy Auditing team activities and data
collection. It is recommended to appoint one technical person from the client’s side
and one from the energy auditing team’s side to coordinate all auditing activities. This
would help to smoothen the Energy Auditing process.
• Provision of office area for the auditing team.
• Agree on a detailed time schedule for carrying various outside Energy Audit activities.
• Inspect the client’s facilities to establish strategies for field inspections, data collection
and measurements.
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(2) Desktop Data Collection
Desktop Data Collection
The purpose of desktop data collection is to minimize the field
energy related data collection by using all available facility
data. It would be advisable during the initial process to collect
preliminary building energy related data using a Facility Detail
Audit Form for better understanding for planning stage.
– E.g. Mechanical & Electrical Diagram, Architectural
drawings, Process flow diagram, Energy bill historical
data, lighting drawings, air conditioning system drawing
and design manuals, load control systems including
timers, automation System if any and others.

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(3) Field Data Collection
List of activities during on-site survey

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(3) Field Data Collection
• Field Data Collection
– Completing the missing data, which the Auditor could not
find during the desktop data collection process
– Verifying the accuracy of desktop data
– Understanding closely the building operations, make
observations about energy wastes and building
maintenance status
– Carrying out load profiling and load apportioning
– Carrying out necessary field measurements required

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(3) Field Data Collection
1. Inspection of the energy and utilities supply system
– Walk through inspection, note the location of the system in the
layout plan to identify points where to conduct measurements
– List of process and utility areas to be checked and audited:
• Boiler house • Water supply and water treatment
• Energy intake stations for electricity facilities
and natural gas • Distribution systems for electricity,
• Compressed air stations steam compressed air and other
• Refrigeration systems media
• Lighting and large ventilation • Milling equipment/other
systems equipment
• Motors/Fans • Cooling tower

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(3) Field Data Collection
2. Inspection of the process units
– Draw a simple block diagram for each element of the process flow
(process unit). Then, identify material and energy flows during
the inspection tour.

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(4) Data Analysis & Finding
3. Cross Checking of Load Demand Data
– Energy management finding i.e Energy matrix
– Technical finding
• i.e. load apportioning, COP chiller, air ratio, steam trap
– Propose Energy Conservation Measures (ECMs)
– Financial plan
– Implementation plan

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Sample End-Load Apportioning
Annual Consumption (kWh)

Mechnical Pump UPS Chiller Plant

Ventilation 2.5% 2.4% 48.4%
5.6%
Others
13.7%

Lighting
13.9% AHU + FCU
13.5%
Sample of technical finding : Losses in
Process/System/ Equipment
-Steam System
Convection loss

Flue gas loss

Convection loss
Stack
Radiation and convection loss

Process

Air
Combustion loss

Fuel

Leakage loss
Blowdown loss Condensate loss
Types of energy saving measures
Measures Example

No cost • Fine-tuning of building services

• User awareness
• Repair leaks
• Reshedule load/usage
Internal
• Saving potential 3~10% initiatives
(SEM)
• Cooling system improvement
• Lighting system and technology improvement
Low cost • Building envelope
• Insulation
• Monitoring & Tergeting
• Housekeeping
• Saving potential 6~10%

• Equipment technology change

High cost • System change
Internal or
• Cogeneration with
• Fuel conversion ESCO
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• Saving potential 10~15%
(5) Energy Audit Reporting
Energy audit report should be based on actual historical and field collected data and any
recommendations should be supported by reliable engineering calculations.
The report should consists of several sections namely,
Executives summary – Highlight major findings
1. Introduction & scope of Works – Project background, scope, assumptions and limitations, Energy
Audit Process and Energy Audit Measurement Equipment
2. Operational Review of the Facility
– Site description – Audited site and description
3. Technological Description of the facility/processes
4. Energy supply and demand
– Baseline study – Energy consumption trend, EEI, specific consumption
5. Findings
– Energy Management
– Technical - Performance
6. Energy saving measures and recommendation - Type of Energy Saving Measures, estimated
saving in kWh and RM, assumptions, the implementation costs, Simple Payback Periods and some remarks
on the recommend measures.
7. Implementation plan
8. Sustainability Plan
9. Financial Plan.
10. References and appendices.
 How to review the energy audit
• Ensure accuracy of facility operating hours
• Ensure accuracy of each equipment operating hours
• Accuracy of energy and demand rates used in the energy audit
• Appropriateness of project recommendations for the facility
– Equipment complexity - can the new equipment be operated by your existing staff,
or is training needed?
– Equipment compatibility - is the new equipment compatible with existing systems?
– Equipment reliability - has the equipment had a proven track record?
– Operational cost - will the new equipment increase workload of your existing staff or
require the hiring of outside maintenance specialists?
• Accuracy of existing equipment identification in the energy audit
• Checking for Overestimating the Energy Savings -- interactive effects
• Use of appropriate simulation models and assumptions
• Project cost estimates (equipment, installation, engineering design, construction,
training, commissioning, permits and plan checks, contingency cost)

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 Energy review output
• Energy use and consumption
– current energy sources;
– past and present energy use and consumption analysis;
• Areas of significant energy use (SEU)
– identify the facilities, equipment, systems, processes and personnel working for, or on behalf
of, the organization that significantly affect energy use and consumption;
– identify other relevant variables affecting significant energy uses;
– determine the current energy performance of facilities, equipment, systems and processes
related to identified significant energy uses;
– estimate future energy use and consumption;
• Prioritized and recorded opportunities for improving energy performance.
• The energy review shall be updated at defined intervals, as well as in response
to major changes in facilities, equipment, systems, or processes.
• Energy baseline
• Energy performance indicators

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Guideline to Energy Manager to kick-start the
implementation
• Step 1 – Analyse & evaluate propose ECM
• Step 2 – Present to EMC to get approval
• Step 3 - Immediately implement no/low cost measures
• Step 4 – Consider EPC for high cost investment
• Step 5 – Perform M&V for pre and post retrofitting project
• Step 6 – Monitoring energy performance indicator and
reporting to EMC
• Step 7 – Management review for system and energy saving
achievement

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 Sample of GOOD Report by ESCO
1. Energy Audit Report follow
Format provided in Technical
Specification
2. Complete information provided in
report
3. Good analysis and findings
4. Recommendation provided with
clear explanation and required
action or guidance to client on
how to implement the
recommendation
5. Availability of Implementation of
Action Plan, Priority, Schedule,
Sustainability and Financial Plan
in the report
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Sample of Propose ECM by ESCO

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Sample Reporting Format to Energy
Management Committee

By ESCO Monitoring

** ECMs selected based on suggestion by the ESCO in the executive summary

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Energy Audit Equipment
Motors & drives Multi-power meter
Power analyzer
strobo-tachometer

Illumination Illuminance meter

Air velocity meter
air leakage indicator
Air Flow, compressed air pressure meter

Steam distribution systems Ultrasonic steam trap tester

Ultrasonic flow meter
Thermometer
Temperature and Humidity infrared pyrometer
Infrared camera
TDS meter Humidity/temp. meter
Combustion Systems true-spot smoke meter
boilers & kilns
combustion analyzer
Pressure meter Multi-channel data logger
Auxiliary equipment Digital camera
Note book computer
Basic Equipment for Measurement and
Monitoring
Equipment How it look Function Application
Hygrometer Measure relative To measure relative
humidity and humidity and
temperature temperature for air
conditioning

Lux Meter To measure To measure illumination

illumination levels in offices, factories
(light) levels. etc.

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Basic Equipment for Measurement and
Monitoring
Equipment How it look Function Application
Portable To measure Measure electrical
Energy electrical parameter in any electrical
Analyser parameters installation

Flowmeter To measure liquid Aircond systems, pumping

flowrate system, piping

Combustion To analyse Stack gas

Gas Analyser combustion gas

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Sample of CLIENT Information Survey

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Sample of CLIENT Information Survey

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What is Energy Performance Contracting
(EPC)?
• Financing tool for energy efficiency project
• Profit gain through cost saving from the project
• Transfer the risk from the building owner to Energy Service
Company (ESCO) based on the performance guarantee of the
energy efficiency project
• Service contract provided by the ESCO to the client to implement
energy efficient project
• The service inclusive of consultation, energy audit and project
implementation
• Appointment of ESCO based on the competency, expertise,
technical and financial capability
How EPC Works for ECMs implementation?

To engage the service of an

ESCO;

To perform energy audit to

evaluate the ESM and level of
savings;

ESCO offer to implement and

finance the project.
Sharing of cost savings through EPC Concept

Electricity Bil,
RM
RM 100,000 baseline
Payment to ESCO Savings to Owner
(RM 20,000) (RM 20,000)
80,000kwH

Electricity Bil Amount

Reduction in Reduction in
Electricity Bil Electricity Bil

Timeline
0 Before During 5 year After
(Years)
implementation implementation implementation
of EPC of EPC of EPC
(Subject to the same Tariff)
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Sharing of cost savings through EPC Concept

Electricity Bil,
RM Baseline

Savings for Government

Savings for Electricity
Payment to ESCO government
bill saved

Electricity Bill before

EPC implementation Lower Electricity Lower Electricity
Bill Bill

time
Before implementation of During implementation of After implementation of (year)
EPC EPC EPC

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Benefits of EPC to the Company/Industry

NO UPFRONT COST to the Owner

ESCO will finance and implement the Energy Saving
Measures.
Saving achieved without compromising user’s comfort

ESCO install & maintain the E.E equipment involved

ESCO payment based on actual savings achieved in electricity
bill
All equipment's installed become the property of the Owner
after the contract period ended
 References
• Energy Manager Training Course (EMTC) under AEMAS
• Electrical Energy Audit Guidelines for Building by Suruhanjaya
Tenaga
• Energy Efficiency in the Japanese Steel Industry by The Japan Iron
and Steel Federation
• Malaysian Industrial Energy Audit Guidelines by Pusat Tenaga
Malaysia
• National Building Energy Intensity (BEI) Labelling for Government
Building under Suruhanjaya Tenaga
• Energy Audit Conditional Grant (EACG) under RMK 11 Malaysia
Plan
• Garis Panduan Pelaksanaan Kontrak Prestasi Tenaga under
Suruhanjaya Tenaga
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End of Session

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