Introduction to energy audit part 2
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The document outlines the approach and methodology for conducting energy audits, detailing the steps and preparation required for effective audits. It emphasizes the importance of understanding energy input and output, measuring existing energy performance, and identifying energy-saving measures. Additionally, the document provides insights into data collection techniques and operational management of energy facilities.
Introduction to energy audit part 2
- 1. By ZAINI ABDUL WAHAB ENERGY AUDIT : APPROACH & METHODOLOGY (PART 2) 1 ENERGY EFFICIENCY INFORMATION SHARING SERIES
- 2. Outline & Content PART 1 • Introduction to energy audit PART 2 • Energy Audit Approach • Steps In Energy Audit Process PART 3 • Energy Audit Report & Presentation 2
- 3. PART 2: Energy Audit Approach Steps In Energy Audit Process 3
- 5. 5 Preparation Finalize and agree on the terms of reference for energy audit team Objectives Expectations from the management Confidentiality Frequency of progress reporting and meeting Line of communication Introduction of energy audit team (consultant & in-house) Special briefing for external auditors on production, safety, health and environment requirements Briefing on energy audit activities and timeframe
- 6. 6 INTERNAL Energy manager Engineers Technical personnel •Process Technicians •Electrical Technicians • Boilerman EXTERNAL (Consultant) Chief auditor •Auditors (electrical, mechanical & etc) •Technicians Processes Operation Maintenance Accessibility Data required Measurement Data analysis Energy saving measures Calculations and verifications method Financial analysis ENERGY MANAGER/ CHIEF AUDITOR Overall Coordination Energy Auditing FACTORY/BUILDING MANAGEMENT •Commitment and Supports Personnel Input Energy Audit Organization
- 7. 7 Steps In Energy Audit Process
- 8. Prepare Energy Audit Report Define and confirm audit scope Analyze Feasibility And Viability Prioritize Proposed Measures Understand Processes And Requirements Obtain Data On Energy Input & Output Identify Existing Energy Performance Measurements and data analysis Identify Additional Data Analyse Energy Balance And Energy Performance Data Identify Energy Saving Measures Prepare A List of Energy Saving Measures Calculate Energy Saving Potentials Financial Analysis PLANNING AND DATA COLLECTION ANALYSIS AND REPORT PREPARATION PRESENT FINDINGS TO CONVINCE THE TOP MANAGEMENT FOR IMPLEMENTATION 8
- 9. 9 Define Audit Scope Type of audit Boundary Tasks involved Timeframe Expected output
- 10. 10 Understand Processes And Requirements • Processes and the requirements to maintain production output/services • Discuss with the site's senior management the aims of the energy audit and 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 • Site investigation accompanied by facilities/engineering/production personnel
- 11. 11 Obtain Data On Energy Input & Output Energy contracts and bills analysis Understand the energy bills Verify suitability of existing purchased energy (tariff, fuel prices) Verify accuracy of the bills received Options available for energy supply DESKTOP ANALYSIS (DOCUMENTATION) Electrical demand profile in kW for daily/weekly/monthly) Plant/Process line/Equipment/Machine Obtain actual quantity of energy using equipment in operation, on stand-by and unused) Prepare inventory list for: -each space and its purposes -energy related controls and operating hours -each equipment and its functions and location MEASUREMENT & SITE DATA COLLECTION
- 12. 12 Tips For Data Collection Easy to use and provide the information to the accuracy that is needed, not the accuracy that is technically possible Measurement equipment can be inexpensive (flow rates using a bucket and stopwatch) The quality of the data must be such that the correct conclusions are drawn (what grade of product is on, is the production normal etc) Define how frequent data collection should be to account for process variations Measurement exercises over abnormal workload periods (such as startup and shutdowns) Design values can be taken where measurements are difficult (cooling water through heat exchanger) DO NOT ESTIMATE WHEN YOU CAN CALCULATE DO NOT CALCULATE WHEN YOU CAN MEASURE
- 13. 13 Identify Existing Energy Performance Loads profile data Control systems available Functions and purposes The recent measured performance data/reports Process flow, technology related, etc Energy consumption figures of equipment/process/unit Production and operating schedules Best energy efficiency practices and latest technologies, etc As-built technical data and information Layout drawing of the plant Energy using equipment information •Name, type, location •Manufacturer, year produced and technical conditions •Production/Output capacity •Rated power and efficiency •Energy medium (fuel) and consumption •Operational mode conditions/performance •(full load/partial load) •Operational times 1. Desktop Analysis
- 14. 14 Identify Existing Energy Performance 2. Measurements and data analysis Measurement of process parameters and energy related parameters for all energy sources/utilities using portable instruments/plant instrumentation Conducting tests and trials on equipment/utilities to assess the performance wherever applicable Energy and performance related data Data on existing meters and sub-meters Temperature, humidity, pressure, flow rate, speed, efficiency level and etc.
- 15. Measurement: Power Factor Profile & Analysis No. Landlord MSB Average Power Factor PF Req. ( >85% )On-Peak (0800-2200) Office Hour (0800-1800) 1 MSB/L1 (Tx2) 83.0% 82.8% < 85% 2 MSB/L1 (Tx3) 76.0% 78.1% < 85% 3 MSB/L16 (Tx6) 98.0% 97.5% > 85% 4 MSB/L16 (Tx7) 79.5% 89.4% > 85% 5 *MSB/AC (Tx4) 95.0% 95.0% > 85% 15
- 16. Measurement : Electrical System Analysis & Load Profile Parameters Lowest Highest Average Current Range (A) 46.75 305.16 168.16 Voltage (V) 411.19 426.37 418.96 Load (kW) 25.44 185.43 100.84 Load profile for MSB L1 TX2 from 12/10/12 to 18/10/12 16
- 17. Measurement : Building Monthly Load Profile (kW) from sub-metering 17
- 18. Baseline : Building monthly load profile(kW) for AHU from sub-metering 18
- 19. Measurement & Analysis: Chiller Plant Efficiency • Actual efficiency at about 0.98kW/RT for both chillers • Efficient chiller should be less than 0.65kW/RT Chilller Specs. Actual Chiller Plant 1 Capacity(RT) 800 600 Input Power (kW) 437 475 Delta T (F) 10 8 Plant Efficiency(kW/RT) 0.65 0.97 C.O.P 6.0 4.45 Chiller plant 2 Capacity(RT) 300 205 Input Power (kW) 171 162 Delta T (F) 10 7 Plant Efficiency(kW/RT) 0.65 0.98 C.O.P 6.0 4.44 19
- 20. Measurement & Analysis: Lighting System Performance No. Location Standard MS1525:2007 Actual (Average) 1 Main lobby 100 178 2 Cafe 200 166 3 Corridor 100 65 4 Lift lobby 100 111 5 Toilet 100 212 6 Car-park 50 130 7 Staircase 100 20 No. Location Power Density (W/m2) Max. Power Density (W/m2) (Standard MS1525:2007) 1 Main lobby 6.53 20 2 Cafe 7.84 15 3 Corridor 4.03 10 4 Lift lobby 3.67-5.03 20 6 Car-park 1.03-1.41 5 Lux level Power density 20
- 21. 21 Identify Existing Energy Performance 3.Observation of present operating practices & process parameters Review of operation and maintenance practices Interaction and discussions with heads of department, engineers, supervisors, operators
- 22. 22 Identify Additional Data Required And Measurements Needed • Use of measured data in monitoring and verification. Don’t measure something that we won’t use- wasting time and resources! • Obtain measuring equipment
- 23. 23 THERMAL MEASUREMENT • Thermometer • Thermocouple • & Indicator • Thermograph • Data-logger • Hygrometer MECHANICAL MEASUREMENTS Flow • Vane Anemometer • Ultra Sonic Flow Meter • Flow/Velocity • Temperature • Relative Humidity Pressure • Pressure Recorder • Leaks • Ultra Sonic Leak Checker Speed • Contact Tachometer Multifunction kit • Flow/Velocity • Pressure • Temperature • Relative Humidity • Sound • dB Meter • Time Stop watch Measuring tape CHEMICAL MEASUREMENT Flue Gas Analysis Flue Gas Analyzer • (CO2 & O2, • CO • Temp • Efficiency ELECTRICAL MEASUREMENT 3-Phase/ 1-Phase Power Analyzer Voltage, Current kVA, kW, kVAr Power factor Harmonics Lighting Lux meter Energy Audit Equipment
- 24. 24 Ultra-sonic Flow Meter • Application : Flow measurement of Liquids • Parameters : Velocity & Measured discharge of liquid flow • Make : Panametrics, Ireland • Range : 0.03 to 12.2 m/s (pipe size 2” to 24”)
- 25. 25 Non Contact Tachometer - Stroboscope • Application : Speed Measurements • Parameters measured : Speed of Rotating Element • Make : Testo, Germany • Range : 20 to 20000 rpm
- 26. 26 Digital temperature & humidity data logger • Parameters measured : Dry bulb temperature & humidity • Make : Gemini, USA • Range : -15 to 150oC and 0-99 % RH
- 27. 27 Non Contact Type Infrared Temperature Indicator • Application : Measurement of Surface Temperatures • Parameters measured : Surface Temperatures • Make : Raytek, USA • Range : -18 to 870oC
- 28. 28 Digital Temperature & Hygrometer • Application : Measurement of Temperatures & humidity • Parameters measured : Dry bulb temperature & humidity • Make : Center, Taiwan • Range : -20 to 60oC, 0 to 100% RH
- 29. 29 Flue Gas Analyzer • Application : Measurement of Flue Gas Parameters • Parameters measured : O2, CO, NO, NO2, SO2, Humidity • Make : TESTO, Germany • Range : 02-0 to 21%, CO-0 to 20000 ppm, • NO- 0 to 3000, No2-0 to 500 ppm, • Humidity- 0 to 100%
- 30. 30 3-Phase Power Analyzer • Application: Measures all Electrical and Harmonic Parameters • Parameters measured : V, A, PF, KW, kVA, kVAr, Hz, first 50 • Harmonics • Make : RCC Technologies, Canada • Range : 600V, 1000A
- 31. 31 Digital Lux Meter • Application : Measurement of Light Levels • Parameters measured : Light level in lux and/or foot-candles • Make : Physics • Range : 0 to 50000 lux
- 32. 32 Prepare Energy Balance Data And Information • Energy supply and consumption data • Apportioning of energy consumption by: Type of energy – fuel, electricity Equipment/system – production machinery, motor, air conditioning, lighting and etc. Applications – production facilities, offices, tenants
- 33. Load Distribution: Building End-use Breakdown(%) Cost(RM) Chiller 139821.00 35.08 51453.56 AHU 67740.47 16.99 24928.22 CoolingTower 10441.54 2.62 3842.44 CDWP 10321.21 2.59 3798.16 CHWP 15671.31 3.93 5766.98 Lighting 39068.12 9.80 14376.91 Others 115552.15 28.99 42522.72 Total 398615.80 100.00 146689.00 Energy Consumption (kWh) Air conditioning system consumed the biggest energy (61%)%) 33
- 35. 35 Analyse Energy Balance And Energy Performance Data • Energy and material balance & energy loss/waste analysis • Identify areas where energy is being or possibly wasted Energy Input Desired Product/ Service Level PROCESS (Equipment/ Operation) Energy loss (???) Energy loss (???) Output
- 36. 36 Identify Energy Saving Measures Conceptual ideas, develop and refine measures Review existing/previous ideas – brainstorming and value analysis Communication with manufacturers/technology experts for more efficient technologies solutions • Identification of energy saving measures to eliminate/minimize energy wastage to improve energy performance
- 37. Guidelines On Common Energy Audit Checklists 37
- 38. General management items 1. Energy management system • Organization • Energy conservation target and investment target • Medium-and-long term plans 2. Measuring and recording implementation status • Installation and operating status of measuring instruments • Implementation status of measurement control system 3. Maintenance of equipment • Periodic inspection and daily inspection • Repairing of leakage (water, air and steam) • Equipment cleaning (filters and strainers) 4. Management of energy consumption volume • Recording status of daily report • Daily consumption volume and daily load curve • Monthly consumption volume and graph for comparison to previous year 5. Energy unit consumption management • Unit consumption management 6. PDCA management cycle • PDCA management status 38
- 40. Energy Facilities of Buildings Air conditioners •Heat sources and transportation of heat •Air conditioners and ventilating facilities •Water supplies and water discharging facilities •Freezers, refrigeration and kitchen facilities •Power receiving and transforming facilities, lighting and electrical facilities •Elevators and building facilities 40
- 41. Air conditioning and ventilating facilities • Air conditioning operational management • Appropriate temperature and humidity settings • Inhomogeneous temperature distributions • Warming up operations • Review of operations • Termination of air conditioning for unused rooms • Exclusion of outdoor air intrusion • Management of air conditioning efficiency • Restriction of air conditioning sections • Utilization of outdoor air (outdoor air cooling) and night purge ventilation • Prevention of mixing losses • Water spraying on rooftops and outdoor units • Implementation of energy conservation equipment • Variable Air Volume and Variable Water Volume • Outdoor air introduction control systems (carbon dioxide controls) • Outdoor air cooling systems • Installation of total heat exchangers • Localized cooling and exhausting • Ventilation facility management • Appropriate ventilating frequency • Management of temperature (electric rooms and machine rooms) • Termination of ventilation for unused rooms • Ventilation controls of parking area (carbon dioxide concentration controls) • Speed controls of blower and ventilator (VAV and VWV) 41
- 42. Supply and discharge water, chiller, refrigeration and kitchen facilities • Water supply and discharge facilities management • Utilization of miscellaneous water (rain water and well water, etc.) • Water conservation measures (water saving top, automatic washers, onomatopoeic device for restrooms, water saving showers) • Supply water flow rates and pressures. • Reusing of discharged water • Management of chilling, refrigerating and kitchen facilities • Heat insulation and defrosting management • Opening and closing management of doors • Management of showcase • Increasing efficiency 42
- 43. Power receiving and transforming, lighting and electrical facilities • Operational management of power receiving and transforming facilities • Demand factors • Power factor management • Management of demand • Transformer capacities • Shut off for unnecessary transformers • Implementation of energy conservation equipment • Demand monitoring and control • Low-loss transformers • Operational management of lighting facilities • Management of appropriate light intensities • Extinguishing of light when not needed (use of daylight) • Light apparatus cleaning and apparatus replacement • Installation location of lighting and division of circuits • Dimming and/or extinguishing with dimming control system • Localized lighting 43
- 44. Power receiving and transforming, lighting and electrical facilities 4. Implementation of energy conservation lighting facilities • Adoption of highly efficient lamps • Adoption of highly efficient apparatuses • Inverter stabilizers • Implementation of Task Ambient method • Lighting switching control • Natural lighting systems 5. Management of OA equipment • Reduction of standby electric power • Shut off power when not required • Electric power conserving-type implementations 6. Vending machine management • Implementation of energy conserving-type equipment • Time controls 44
- 46. Air Conditioning And Chilling Facilities •Operational management • Appropriate temperature & humidity settings • Reduce air intake from outdoor • Management of heat producing equipment • Chilled water outlet temperature settings • Scheduled operation • Outdoor air shutout and ventilation status •Energy conservation strategies • Enhance thermal building insulation • Waste heat recovery and utilization • Speed controls for pumps and blowers • Localizing cooling and exhausting •Operational management of cooling facilities • Operating power of chillers • Outlet & inlet pressure of refrigerant • Inlet & outlet temperature control and pressure control of chilled water •Operational management of auxiliary equipment • Operating power of cooling towers • Water quality management • Pump operating power(water quantity and pump head) •Cold temperature retention and chilling facilities • Management of incoming & outgoing through doors(door opening & closing period) • Management of temperature to increase efficiency 46
- 47. Pumps, Fans & Air Compressors •Operational management of pumps and fans • Open/close status of valves • Improvement of routing(piping &ducting) • Consumption flow rate & operating pressure • Check the actual against design performance • Speed and unit controls •Operational management of air compressors • Review types of air compressors(screw/reciprocating) • Matching of capacity & types 47
- 48. Boilers And Industrial Furnaces •Combustion management • Air ratios and exhaust gas management • Burners, fuels and air flow systems • Combustion control equipment • Regenerative type combustion system •Operational and efficiency management • Load factors, startup and stop status • Quantity control • Heat efficiency, heat balance and heat distribution • Water quality management and blow management •Thermal insulation, heat retention and heat radiation prevention • Temperature on outer surface of furnace walls and ducts • Thermal insulation materials (heat storage losses) • Sealing of opening and furnace pressure •Exhaust gas temperature management and waste heat recovery • Exhaust gas temperature • Heat recovery (air preheating) • Exhaust gas circulation 48
- 49. Steam Systems, Heat Exchangers, Waste Heat And Waste Water, Etc. •Operational management • Steam pressure and temperature settings • Steam flow rates •Leak and temperature retention management • Piping systems and tanks, etc. • Load facilities •Appropriate piping systems • Routing, differential pressures and piping sizes • Sorting unnecessary piping • Integration of multiple steam systems •Load leveling • Installation of accumulators • Countermeasures on side of load •Use of drain recovery • Steam trap management • Drain recovery locations and recovery systems • Flash steam utilization 49
- 50. Steam Systems, Heat Exchangers, Waste Heat And Waste Water, Etc. • Operational management of heat exchangers • Suitability of types • Suitability of usage and heat transfer media • Maintenance status (soiling and pressure losses) • Temperatures of heat transfer media and heated objects • Temperature effectiveness • Reduction of waste heat and waste water • Recovery of heat from hot water • Appropriate exhaust air duct • Recycling of cooling water • Management for concentrations of impurities in water • Excessive gas use • Use of excessive gases 50
- 51. Power Receiving And Transforming Electric Motors, Electric Heating And Lighting Facilities •Power receiving facility management • Management of load factors and power factors • Management of demand (monitor and control) • Electric power purchase contract details • Utilization of electric power during night •Transformer facility management • Transformer capacities, voltage and low-loss transformers • Demand factor/supply adjustment • Shut off for unnecessary transformers •Management of electric motors and electric heating facilities • Facility capacity, voltage and number of units • Rotational speed control • Termination of operation when unloaded •Lighting facility management • Adoption of highly efficiency lamps • Adoption of automatic extinguishing and localized lighting • Installation location of lighting and division of circuits • Management of appropriate illuminance • Extinguishing during unnecessary hours and use of daylight 51
- 52. 52 Prepare A List of Energy Saving Measures • Discuss and list down all energy saving measures and opportunities
- 53. 53 Calculate Energy Saving Potentials • Calculate projected energy saving potentials in energy unit and convert into RM! • Use data from measurements/manufacturers’ information/data analysis to estimate potential saving values
- 54. 54 Conduct Financial Analysis Conduct financial analysis for each measure Use method adopted by the company/organization including life cycle analysis Item for Investment Operating Cost/year Saving/year (in energy or other unit) Saving/year (RM) Equipment Instrumentation Civil works & others Purchasing cost Maintenance & repairs Labour Energy Depreciation Electrical energy Thermal energy Others (disposal, labour and etc.)
- 55. Example :Energy Cost Savings for Air Conditioning System at a Building NO. Item MOTOR RUNNING NORMAL MODE ENERGY SAVING MODE ( Rated kW ) ( Running kW ) kWh/Year Rate/Year (RM) Amount (kWh) Rate/Year (RM) SAVING (%) SAVING (RM/Year) 1 CHWP 1 18.5 19.1 165,024 70,960 107,266 46,124 35% 24,836 Old Block Chiller Room 2 CHWP 2 18.5 19.0 164,160 70,589 106,704 45,883 35% 24,706 New Block Chiller Room 3 CDWP 1 15 13.3 114,912 49,412 82,737 35,577 28% 13,835 Old Block Chiller Room 4 CDWP 2 18.5 15.3 132,192 56,843 95,178 40,927 28% 15,916 New Block Chiller Room Sub-Total 67 576,288 247,804 391,884 168,510 32% 79,294 No Item Rated (kW) Actual kW Normal kWh/Year Saving Mode kWh/Year Saving % Saving kWh Saving (RM/Year) 1 Chiller – Old Blk 210 128 1,105,920 995,328 10% 427,991 47,555 2 Chiller– New Blk 210 115 993,600 914,112 8% 393,068 34,180 Sub-Total 420 243 2,099,520 1,909,440 9.1% 821,059 81,734 TOTAL HVAC SAVING 161,028 55
- 56. 56 Analyze Feasibility And Viability • 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 • Analyze and confirm feasibility and viability of each measure from technical and financial point of view
- 57. 57 Prioritize Proposed Measures List proposed measures according to its priority for implementation and its implementation plan Easy step Energy management at operational management level No/low cost Measuring, operation tuning, resetting, minor repairs Can be carried out with ideas or ability of the operators with advice from energy manager/engineer By small group activities at operational level-workers Middle step Technical improvement, medium scale investment, replacement of old equipment with higher efficiency technologies Can be carried out engineers, partly by small group High step Improvement with large scale of investment New process line or new plant Require detailed financial assessment (payback, ROI, life-cycle analysis) As project, task-force level-Top management
- 58. 58 Energy Saving Measures(ESMs)Summary Table Energy saving measure Type of option (No- cost/low cost/high cost) Saving/year (in energy) Saving/year (RM) Investment value (RM) Payback period (Year) Priority (High/Low)
- 59. 59 MEASUREMENTS & VERIFICATION OF SAVINGS Propose parameters and values to be used as a baseline for each measure Propose measurement, data collection method and calculation to be used to produce baseline value and result after the implementation. Get agreement on the baselines to be used for verification of results A TOOL TO CONFIRM THE ACTUAL RESULTS OF EACH IMPLEMENTED ENERGY SAVING MEASURE
- 60. Example: Energy saving calculated by the difference between a baseline year and a subsequent year from electricity bill(kWh) 60
- 61. Example: Savings calculated based on actual measurement from sub-meters 61
- 62. Options For Energy Baseline & Savings Calculation Method Advantages Disadvantages Utility billing history Low cost •Effects of weather , occupancy, other changes may mask savings •May be unreliable unless savings are significant compared to normal bill variation Data already available Independent data Represent all effects of ESMs Account for interactive effects System/Equipment sub-metering Isolate effects of ESMs •Higher cost •Misses interactive effects Very accurate for lighting measures Results are more predictable(low risk) 62