This a compilation of the overall process in conducting energy audit based on my personal experiences, training that I attended in Malaysia, India and Japan and information sharing between fellow EE practitioners.Not to forget references from books and internet. I believe this would benefit to those who wants to understand what is energy audit all about for beginners to become an energy auditor and to facilities owners to assess the need to conduct energy audit and energy audit proposals submitted by consultants

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

4. 4
ENERGY AUDIT APPROACH

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

34. 34
Loads Distribution-Factory

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

39. Building Facilities
39

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

45. Manufacturing Facilities
45

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

63. zainiabdulwahab@yahoo.com
019 2152700
www.goingee.blogspot.com.my
www.facebook/zaini.abdulwahab1 63
THANK YOU!