UNIT-5

ENERGY AUDITING

CONTENTS OF AN ENERGY AUDIT

• Energy management systems

review its compliance with national laws and regulations, the quality of its
systems and policies and compare production levels to energy savings.
• Consumption and flow of energy
accounts for energy input, storage, conversion, waste, sales and
consumption.
• Statistics
measures instruments, calibration, measuring rate, and instrument
management. This also includes the scope of energy report, frequency of

submission, breakdown level, depth of analysis, etc.

• Consumption indicators

only accounts for a company’s energy consumption, but not its energy
inputs.

• Operating efficiency of equipment

assesses to what extent company equipment makes efficient use of

energy.

• Energy consumption during manufacturing

includes consumption per unit of output value, per unit of product, direct
and indirect energy consumption and energy consumption per
comparable unit product
• Energy cost indicators

multiplies energy consumption by energy price.

• Energy savings

differentiates actual energy consumption and benchmark consumption.

• Economic analysis of energy-saving projects

makes a comparative analysis of energy costs for similar products and

conditions.
 KEY REASONS OF ENERGY AUDITING

CORPORATE ENERGY SAVING

ENERGY MEASUREMENT

ENERGY-CONSUMING EQUIPMENT
 KEY REASONS OF ENERGY AUDITING

CORPORATE ENERGY SAVING

• Electricity is the most commonly used form of energy. If the use of this is
managed correctly it can therefore help many companies cut their energy
consumption and costs.

• Lighting systems, electric motors and drive systems, and heating/cooling

systems are the three most commonly used energy consuming systems across
all industries, whether large or small. Thus, similar energy-savings strategies
can be applied to any size business.
 KEY REASONS OF ENERGY AUDITING

ENERGY MEASUREMENT

Measuring energy data is a key component for implementing an energy

management plan. To be done effectively a manager needs to:

• Establish an energy data measurement system;

• Designate staff in charge of monitoring energy use;

• Ensure proper use of energy measuring instruments and ensure safety of

meters; and

• Provide energy data in a complete and timely manner.

 KEY REASONS OF ENERGY AUDITING

S.NO Name Purpose

1 Power meter Measures power
2 Vortex flow meter measuring fluid flow rates in an enclosed
conduit.
3 Electromagnetic flow meter Measure flow of magnetic field

4 Turbine flow meter measure the velocity of liquids, gases and

vapors in pipes, such as hydrocarbons,
chemicals, water, cryogenic liquids, air, and
industrial gases.
 KEY REASONS OF ENERGY AUDITING

ENERGY-CONSUMING EQUIPMENT

• Energy managers should identify office and production equipment that

consume the most energy. According to the Principle for Equipping and
Managing the Measuring Instrument of Energy Units (GB17167-2006), these
pieces of equipment often consume power that is above the limit specified in
Table.
ENERGY MANAGAEMENT SYSTEM MODEL
ENERGY STRUCTURE
HOW TO SAVE ENERGY
 ENERGY AUDIT LAWS AND REGULATIONS
• Energy Conservation Law

• Program for Energy Saving of One Thousand Enterprises

• General Principles of Energy Audit on Industrial and Commercial Enterprise

(GB/T17166－1997)

• General Principles of Energy Monitoring Technology (GB/T15316)

• General Principles for Calculation of Thermal Efficiency of Equipment

(GB/T2588－1981)

• General Principles for Calculation of Comprehensive Energy Consumption

(GB/T2589－1990)

• Guideline on Measuring and Testing Energy Consumption (GB/T6422－1986)

• Energy Saving Calculating Methods (GB/T13234－1991)

• Guideline on Energy Management in Industrial Enterprise (GB/T15587－1995)

 ENERGY AUDIT LAWS AND REGULATIONS
• General Principles for Equipping and Management of Energy Measuring
Instruments in Energy-consuming Units (GB/T17167－2006)

• Technical guides for evaluating the rationality of heat usage in industrial

enterprise (GB/T3486－1993)

• Technical guides for evaluating the rationality of power usage in industrial

enterprise (GB/T3485
(GB/T3485－1993)
1993)

• Technical guides for evaluating the rationality of water usage in industrial

enterprise (GB/T7119－1993)

• Statistical method of energy balance in enterprises (GB/T16614－1996)

• Methods of drawing up energy balance table in enterprises (GB/T16615－1996)

• Methods of drawing energy network diagram in enterprises (GB/T16616－1996)

ENERGY DIAGNOSIS METHODS

CHECK
• Managers should identify whether their equipment is listed under the Guiding
Catalogue of Industrial Structure Regulation (2011) or the Outdated Mechanical
and Electrical Equipment (Products) with High Energy Consumption (first
batch).

• Many companies are unwilling to retire old and outdated equipment, especially
if it still works, not realizing that such equipment causes companies to incur
additional costs in the long run.

ASSESS
• Managers should also evaluate equipment that is not yet outdated to
determine its energy efficiency based on national and international standards.

ANALYZE
Low operating efficiency is caused by:
• Low quality equipment, including obsolete equipment that is listed in the
“Eliminated Products Catalog”;

• Improper service maintenance and operation; and

• Process requirements that render equipment less efficient.

SOLVE
To correct efficiency problems managers should:

• Replace obsolete equipment with new energy efficient models;

• Improve energy management, including the establishment of equipment

operation and maintenance policies; and

• Integrate energy-saving technologies into the manufacturing process at a

system level.
 ENERGY DIAGNOSIS OF POWER DISTRIBUTION SYSTEM
• A company’s distribution systems network carries electricity from the
transmission system and delivers it to its equipment and factories.

• Typically, the network includes low-voltage (less than 1 kV) distribution wiring
and medium voltage (less than 50 kV) power lines and transformers, which
engineers can regulate to reduce the voltage of power distribution to the
company. Enhancing equipment and distribution efficiency ensures higher
energy savings and reduces power used during the distribution process.
• The power factor is a number between 0 and 1. At 0, energy flows are entirely
• reactive, whereby stored energy returns to its source on each cycle. In contrast,
• when the power factor is equal to 1, all the energy is consumed by the load and
• none returns to the source, resulting in over-utilization of energy.
• » Technical apparatus can be used to test motors and circuits to determine the
• optimal power factor of each load.
• » The recommended power factor is below 0.95.
 ENERGY DIAGNOSIS OF POWER DISTRIBUTION SYSTEM

POWER FACTOR

• The power factor is a number between 0 and 1. At 0, energy flows are entirely
reactive, whereby stored energy returns to its source on each cycle.

• In contrast, when the power factor is equal to 1, all the energy is consumed by
the load and none returns to the source, resulting in over-utilization of energy.

• Technical apparatus can be used to test motors and circuits to determine the
optimal power factor of each load.

• The recommended power factor is below 0.95.

 ENERGY SAVING MEASURES FOR DISTRIBUTION SYSTEM

• Select cable sections according to the economic current density. The economic
current density is closely related to the annual operating hours of cables.
Considering the large amount of data and calculation required to determine the
economic current density, a comparison method is commonly adopted by
industrial companies.

• An increase of the operating voltage helps to improve power quality and

reduce line loss. By increasing voltage by 10 percent, a subsequent 18 percent
decline in line loss can occur.
 ENERGY SAVING MEASURES FOR DISTRIBUTION SYSTEM
• Reducing reactive currents and increasing the power factor of a line is an
effective way of reducing energy waste.

• At a constant voltage and current, the higher the power factor, the higher the
active power will be.

• A chemical factory, for instance, installed a 1,500 kVA transformer. The initial
requirements were 1,160 kVA with a power factor of 0.70. The load percentage
of the transformer was 78 percent (1160/1500=77.3%). To increase the load,
but avoid fines charged by the power agency, the factory needs to add 438kVAr
reactive power compensation to the motor load. This subsequently increased
the factor to 0.90 and reduced power to 900 KVA, which is the vectorial sum of
KW and KVAr.
 ENERGY SAVING MEASURES FOR DISTRIBUTION SYSTEM

TRANSFORMER

• Stick to the economic operation principle by selecting transformer capacities

according to the calculated capacity (this principle can be applied to new
factories or for expanding existing factories.)

• Adjust or replace transformers according to the actual load rate. The load rate of
a standalone transformer should be 70 to 80 percent. In the case of a transformer
network, some loads should be transferred and several transformers should be
stopped (this applies to existing factories.)

• Select energy-saving transformers (S11) to reduce the amount of no-load

currents and reactive power losses. It is better to maintain the temperature of the
distribution room at 60 °C by installing ventilation equipment.

• Since the load of the 1500KVA transformer is using only 60 percent of its
capacity, the factory can add more loads to the transformer in the future.
 ENERGY DIAGNOSIS- LIGHTNING SYSTEM

Problems frequently found in lighting systems include:

• Uninterrupted lightening:

In many cases, office buildings and manufacturing plants are illuminated

overnight and on weekends, and sometimes workers operate outdoor lighting
during the daylight.

• Over-illumination in office buildings due to poor lighting system design;

• Under-illumination due to dusty light bulbs, lamp shades or poor quality lighting
design and selection;

• Insufficient use of natural light; and

• Use of low-efficient light bulbs

 ENERGY DIAGNOSIS- LIGHTNING SYSTEM

Energy efficiency can be achieved by:

• Improving lighting management: Identify the best ways to use illumination,

either through improving the location or the number of hours that illumination is
required or find ways to make better use of natural lighting (See figure 3-3
below);

• Improving energy-saving processes, by determining the best location for lighting

in factories, offices or unoccupied areas; and

• Selecting equipment that offers maximum energy savings. For example, a

company C throughout the year.
 ENERGY DIAGNOSIS- LIGHTNING SYSTEM

MEASURES FOR ENHANCING ENERGY SAVINGS IN THE

LIGHTING SYSTEMS

Step 1: Decide on the luminance, which measures the luminous flux spread

over a given area.

» Corridor and walkways: 80-120 lux

» Work areas used intermittently: 150-200 lux

» Office areas: 200-250 lux

» General inspection areas: 350-450 lux

» Continuously occupied areas used for the inspection of small parts: 500-600 lux
 ENERGY DIAGNOSIS- LIGHTNING SYSTEM

Step 2: Based on decisions made in Step 1, determine the desired power levels,
lighting layout and methods for lighting equipment. Add additional
lighting when an luminance of over 500 lux is required.

» Corridor and walkways: 80-120 lux

» Work areas used intermittently: 150-200 lux

» Office areas: 200-250 lux

» General inspection areas: 350-450 lux

» Continuously occupied areas used for the inspection of small parts: 500-600 lux
 ENERGY DIAGNOSIS- LIGHTNING SYSTEM

Step 3: Use energy-saving lighting equipment and controls

1. LED, T5 are more efficient than previous forms of lighting.

 ENERGY DIAGNOSIS- LIGHTNING SYSTEM

Step 3: Use energy-saving lighting equipment and controls

1. LED, T5 are more efficient than previous forms of lighting.

 ENERGY DIAGNOSIS- LIGHTNING SYSTEM

2. Install reflecting covers (in instances where luminance levels are insufficient,
but would be excessive with an additional lamp). Reflective covers can reflect
light from a lamp to other areas where lighting is needed, increasing
luminance by 25 percent and reducing the number of lamps needed.
Furthermore, reflecting covers have a long product life and no adverse effects.
 ENERGY DIAGNOSIS- LIGHTNING SYSTEM

• Step 4: Management methods include:

» Lighting controls to eliminate unnecessary lighting

» Cleaning dirty lamps to improve light efficiency

» The use of as much natural light as possible

ENERGY DIAGNOSIS- AIR CONDITION SYSTEM
 ENERGY DIAGNOSIS- AIR CONDITION SYSTEM
• The power consumption of a central air-conditioning system is the sum of the
power consumption of the compressor, the chilled water pump, the indoor heat
exchanger’s fan, the cooling tower’s fan, and the cool water pump.

• The power consumption of a split-type air conditioner is the sum of power

consumption of compressor, indoor heat exchanger fan, and outdoor heat
exchanger fan.
 ENERGY DIAGNOSIS- AIR CONDITION SYSTEM

 Many companies have a central air-conditioning system that consumes a lot

of power. The following measures can be taken to reduce power
consumption.

 » Install an appropriate chilled/cooling water pump. Pump parameters need

to be decided according to the actual conditions of the system. Excessively high
parameters may result in hidden waste.

 » Check the efficiency of the cooling tower regularly. Generally, the

temperature drop of. a cooling tower is about 5 degrees, and the outlet
temperature is one to two degrees higher than the ambient temperature
(evaporation rate being 1.5 percent).

 Maintenance or cleaning work will be necessary if the cooling efficiency is

lower than the above-mentioned values.
 ENERGY DIAGNOSIS- AIR CONDITION SYSTEM
• Ensure good insulation of chilled water pipe.

• Check the efficiency of the three heat exchanging devices regularly; keep the
surface of heat exchanger clean; and clean filters regularly.

• Make sure that there is a switch in each independent room, which can be used
to turn off the fan of the heat exchanger.

• A central air-conditioning system is suitable for cooling a relatively large area

but not for achieving a reduced temperature in a small space (such as areas
that need to be maintained at 22 degrees Celsius or lower). For the low-
temperature cooling of a small area, use a cabinet-type air conditioner.

• Set the chilled water outlet temperature at nine degrees Celsius to increase the
chiller's energy performance.
 ENERGY DIAGNOSIS- AIR CONDITION SYSTEM

 Energy-saving solutions for split-type air conditioners

• Select frequency conversion air conditioners with a high-energy performance

ratio.

• Decide the power of the air conditioner according to desired cooling

requirements.

• The setup temperature should not be lower than 26 degrees Celsius. If the air
outlet faces worker areas directly, the setup temperature can be 28 degrees
Celsius.

• Turn off air conditioners 30 minutes before the close of the business day (Never
let air conditioners run overnight). Avoid positioning outdoor units in direct
sunshine and ensure uninterrupted airflow. Place a protective covering over the
unit if it is not to be used for a long time..