WALCHAND COLLEGE OF ENGINEERING

SANGLI

An AUDIT REPORT
ON

Energy

Audit: Industry

As a Partial Fulfilment
Of
UTILIZATION OF ENERGY AND MANAGEMENT
By
B.Tech. ELECTRICAL ENGG.
BATCH-E3

ROLL NOs.
26, 27, 28, 33, 34, 37, 38, 45, 54, 58, 60

Under the guidance of

A. K. Thorbole
DEPARTMENT OF ELECTRICAL
ENGINEERING
2013-2014

Energy Audit: Industry

Audit done by: Final Year B. Tech. Electrical E3
Audit done for: ARNAV INDUSTRIES
Address:
Plot no. 13,
Behind Chakan Oil Mill,
Bapu Kaka Nagar,
Opposite MSEB,
MIDC, Kupwad
Area: 1200 sq.ft.
Period of Audit: January 2014
Temperature: 27 deg Celsius

Purpose
Gathering the right data, with the appropriate amount of detail, is a key component to
realizing the maximum savings from an energy audit. However, the process for audit
data collection is currently non-standardized, and crucial data can be overlooked or the
level of detail is insufficient for the required energy and financial analyses. To address
these issues, we have created these template data collection forms. The purpose of
these sample forms are to assist building energy auditors collect data required to
complete comprehensive energy and financial analyses of proposed modifications to
the building. These forms are best suited to Level II and Level III audits.
Energy conservation is the practice of decreasing the quantity of energy
used. It may be achieved through efficient energy use, in which case energy use is
decreased while achieving a similar outcome, or by reduced consumption of
energy services. Energy conservation may result in increase of financial capital,
environmental value, national security, personal security, and human comfort.
Individuals and organizations that are direct consumers of energy may want to
conserve energy in order to reduce energy costs and promote economic security.
Industrial and commercial users may want to increase efficiency and thus
maximize profitIn these guidelines an energy audit and an energy analysis mean
any comprehensive analysis related to energy conservation, which is performed at
an industrial site. An energy audit model means a procedure that is used to reflect
the extent of the auditing work, its performance and reporting. In Finland, audit
models have been developed for surveying objects of different type, size and age.
These guidelines apply to auditing models applicable in the industry sector. In
these guidelines the field of application is the foundry industry that represents an
energy intensive sector of industrial production. The guidelines for audits are to
be updated within this project.
Energy Audit Guidelines:
In general the guidelines for energy related audits are designed in three
stages. The first stage gives the general guidelines for energy-related audits
defining the general and administrative procedures.
The second level is composed of the performance and reporting guidelines,
developed, which include instructions and requirements tailored to fit a particular
auditing object and must be complied with taking into consideration the special
features of the particular object.
The third level is the Energy Auditors Manual that describes good auditing
practices, and provides instructions for performing the actual audit. This level is
the key issue in the publication containing production technology, maintenance,
building installations and constructions and gives practical guides to accomplish
auditing tasks and offers proper hints for auditor to create options of energy
savings.

Guidelines to Foundry Industry Audit Models :

All guidelines applicable to performing energy audits of industrial objects
are aiming to the demanding auditing where all the energy use is to be
investigated. The level of auditing is called here energy analysis unlike energy
surveys where all the unit parameters will not be completely opened. The field
studies are recommended to be carried out in two stages: firstly in more general
auditing level without reporting and secondly in deeper analysing level where all
energy use and unit processes have been investigated.
These model-specific guidelines to an industry audit contain:
A general part
A model table of contents of an industry audit report, with additional
guidelines to the contents of every section
Foundry Industry Energy Analysis :
A process industry energy analysis is a two-stage adaptation of the energy
analysis for the energy-intensive process industry. The work is primarily targeted
at mapping the any energy conservation possibilities in the production process.
Also the energy conservation potential in the in-house service systems and
equipment are investigated.
This industry energy analysis is designed for energy-intensive foundry
process plants. The objective is to establish the primary and secondary energy
flows of the entire auditing object as well as to map all possible energy
conservation alternatives. Production processes play a key role in the energy
analyses. The participation of the customers own production and maintenance
personnel is usually necessary in performing the analysis
Object and the Proposed Conservation Measures:
Auditing object :
A verbal description of the auditing object including, among other
information, a brief over-view of the production process and the key information.
Energy Management and Conservation Potential :
A verbal description of the consumption levels of the auditing object, any
conservation opportunities and the suggested measures to be taken are described.
Sub-headings may follow the basic distribution heat/electricity/water, or any other
distribution providing a clearly discernible distribution of the energy consumption
of the auditing object.

Basic Information of the Object :

Name
Address
By individual buildings
o Construction year(s)
o Year(s) of renovation and/or extension
o Construction types/ intended purpose
o Construction volumes
o Gross areas
o Time of use of the buildings (hours/year) and usage sequences
Line of Activities, Production Volumes and Staff :
The line of activity of the auditing object and a verbal description of the
operations: production, production volumes, staff, etc. The operation and main
processes of the production plant to be presented graphically in the direction of
their progression (raw materials -> processes -> final products).
raw materials for the production facility
principal processes and their order
key processes and process equipment from the energy consumption aspect
schematic description of the functioning of the process
products of the facility and their volumes
Access to Municipal Networks :
A description of the delivery / production of heat, electric power and water
at the auditing object
Operation, Servicing and Maintenance :
A description of the objects operational, servicing and maintenance
organisation, consump-tion monitoring and maintenance contracts. The report
must express a view regarding the adequacy of the current consumption
monitoring level and present the principles and oppor-tunities to improve
consumption monitoring at a general level.
Consumption and Cost of Energy and Water :
The total cost, cost distribution, unit cost as well as the development of
overall consumption, and costs in the past years. Also, any changes in the
structure of the production process shall be presented, as well as changes in
production volumes and the number of staff.

Supply of Energy and Water:

A more detailed verbal description of the acquisition of the various forms
of energy and their production.
Total Consumption, Cost and Unit Cost :
A numeric and graphic presentation, information from a number of years if
available. In pro-duction buildings unit costs are calculated per production unit.
The choice of the unit cost object (production unit) shall be agreed upon with the
customer in advance.
Heat
Electric power
Water
Other overall consumption and cost
Distribution of Energy Consumption :
Distribution of Energy Consumption is presented numerically by itemizing
the systems/equipment groups the share of which of the total consumption
exceeds 5 %. Numeric values can be based either on measurements or on
calculations.
1.1.2.2.4 Energy Balance Sheet
The Energy Balance Sheets include a graphic (Sankey diagram or similar)
and numeric presentation of the primary and secondary energy flows of the entire
auditing object reflecting the ways the energy flows. The shares of energy forms
exceeding 5 % shall be itemised. The balance sheets shall be drawn by subprocess, by process equipment or by production line presented under Section 6.
The following distribution shall be adhered to in presenting the energy flows:
buildings (in-house equipment and structures)
factory service systems (itemised)
production processes
i. main processes (production lines)
ii. sub-processes
iii. principal process equipment
ELECTRICITY SUPPLY:
Electricity supply may occur entirely as a purchase (or part of it) or it can
be produced on site. Purchase points or purchase tariffs may be numerous. The
subscriber of the energy audit may acquire only a part of the energy (for example,
the property electricity) and renters (such as business apartments) can buy directly
from the energy supplier only the electricity energy consumed in the apartment.
These things have to be presented in a clear report.
The total energy audit is reviewed in order that the whole energy use of the
audit site and all costs of electricity consumption are taken into account. The
power supply and costs will be precisely described in the report. To do this, the
cost of electric consumption can be calculated correctly and the different impacts

of the saving actions in energy supply can be taken into account with accurate
costs. It is important to know who is responsible for which energy cost and to aim
the proposal and saving actions correctly. Of particular importance, is to know
and to include in the energy audit report, the rate of electricity use for different
times of the audit site (different usage targets) and to calculate the savings actions
with real energy prices (taking into account also the other electrical consumption
components, among others reactive power demand charges).
If the electricity supply of the audit site has been competed in the market,
and it is not possible to display the real purchase price in the report, the accurate
prices should, however, be presented (preferably close to the real situation) at
different times. Cost and savings calculation are based on these prices. These
savings calculation can then be specified with correct price information at the
audit site. Also, this issue has to be clearly presented in the report. If the price
competition in the market is carried out for example, yearly, the price will vary
from year to year. The real price for cost savings of saving actions, therefore,
does not exist.
In the electricity supply part of the audit report will be presented at least the
following: an annual average price from the energy charges of electricity use in
the audit site (excluding the fixed charges), an average energy price at different
times (dates are determined in accordance with definition of tariffs), power
charges in the effect tariff site and their determination and an annual average
price of electricity supply including power charges.
In reporting the prices, it must be clearly remembered to tell whether they
are value-added taxes or tax-free prices.
If the electricity supply price of the audit site varies at different times, it is
not enough that average prices are observed in the savings calculation. For
example, the cost impact of energy use and savings calculation from different
devices or device groups can be noted the following:
Energy consumption of outdoor lighting is scheduled mostly during the
wintertime when the electricity cost is calculated using wintertime prices.
After this audit, you have 18 months to make some or all of the upgrades
your energy advisor recommends. After completing the work, you need a postretrofit audit. Here is the actual audit specifying Appliances, Wattage and Total
KWh :-

Machine Load:
SR.
NO.

NAME OF
APPLIANCE

QUANTITY

WATTAGE
(W)

OPERATIONAL
HOURS (APPROX)

TOTAL
KWh

1
2
3
4

Machine 1
Machine 2
Machine 3
Compressor

1
1
1
1

26110
14920
2238
3730

0.75
0.8
2
0.7

19.58
11.94
4.476
2.59

Total Units Consumed per day by machine load = 38.11

Lighting Load:
SR.NO NAME OF
APPLIANCE

QUANTITY

WATTAGE(W) OPERATIONAL
HOURS
(APPROX)

TOTAL
KWh

Printer

100

0.1

A.C.

1800

7.2

CFL

40

1.4

Fan

60

1.44

Computer

120

1.92

Total Units Consumed per day by Lighting load = 12.06

Total Units Consumed in a month (27 days including 4 days of vacation)
= 50.17*27=1354.57
Energy charges = 5.06 as it comes under LT V-Industrial (0-20 KW)
Total Cost per month= 1354.57*5.06 = Rs.6854.12
Demand Charges = Rs.190
Other charges and taxes = Rs. 865.92
Total Cost = Rs (6854.12 + 190 + 865.92) = Rs. 7910.04
In actual Total Bill = Rs. 7930.00