green training audit_romano

7/31/2019 Green Training Audit_Romano

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GReening business through theEnterprise Europe Network

Energy audit

Renewable Energy Sources and

Rational Use of Energy Energy Labels

Venice, 30/11/2010


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Scope of an Energy Audit

Energy audit is a needed step in implementation of anydetailed and sizable energy efficiency project. Often

there will be the need for engineering design beforeimplementation/ construction of the project.

The major impetus behind an energy audit is that theanalysis of energy consumption and identification ofpotential conservation measures in facilities relate tovarious disciplines of engineering, that are oftenbeyond the expertise of one person or smallengineering firms.


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There are two ways to make an energy audit

There are two basic types of audits, walk-throughaudit and detailed audit, the latter consideredinvestment grade audit. Investment grade audit is

also called feasibility. An investment grade audit maybe a comprehensive audit that is intended to identifyall energy efficiency opportunities in a facility, or amore targeted audit which focuses on a specific piece

of equipment or process, e.g. lighting, a boiler, adrying process, compressed air system.


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First StepBefore you begin your walk-through of the industrial facility, a

meeting should be held with the appropriate plant personnel thatare familiar with the physical condition and day-to-day operationof the manufacturing equipment in the facility. The purpose of

the meeting is to determine which of the systems, technologies,and equipment listed below actually apply to the facility andwhere you should focus your attention during the walk-throughaudit.

Lighting Systems Steam Systems

Motors, Belts and Drives Refrigeration Systems

Hydraulic Systems Energy Management

Fans and Pumps Compressed Air Systems

Injection Molding or

Extrusion

Veneer Dryers


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Second Step

The next step is to go through the checklist of questions in a guidethat pertain to the facility. All of these questions may not beanswered in the meeting and, therefore, should be flagged tobe addressed during the walk-through. As you go through thechecklist of questions, this is a good opportunity to discuss any

concerns that the plant personnel may have with implementingthe energy saving measures corresponding with each checklistitem. This process will help you to determine the energy savingsmeasures that have already been implemented and those thatmay or may not be applicable to this facility. At this point you

should have a better sense of which areas in the facility to focusyour attention on during the walk-through and who shouldaccompany you.

Youll find more at:http://www.bpa.gov/Energy/N/industrial/audit/index.cfm
http://www.bpa.gov/Energy/N/industrial/audit/index.cfmhttp://www.bpa.gov/Energy/N/industrial/audit/index.cfmhttp://www.bpa.gov/Energy/N/industrial/audit/index.cfmhttp://www.bpa.gov/Energy/N/industrial/audit/index.cfmhttp://www.bpa.gov/Energy/N/industrial/audit/index.cfm


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Tools

ClipboardFlashlightCamera

Light MeterPhillips and StandardScrewdriversTrue RMS meter, if notavailable, a Clamp on Amp

Meter.


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Third step

The next step is to tour the facility with the appropriateplant personnel that are familiar with the variousareas that you will be auditing. As you tour the

facility, refer to the guide to ensure that you answerany remaining checklist questions. The back of eachpage can be used to record your observations, suchas equipment nameplate data, gage readings, meterreadings, and to make notes, such as areas thatrequire further study, equipment operators names,phone numbers, etc.


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Fourth step

After the tour is completed, a wrap upmeeting should be held to review your

findings. At this point, a list of potentialenergy saving opportunities that shouldbe considered for additional study can

be developed.


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Investment Grade Audits

A detailed or investment grade audit (whether comprehensive ortargeted) is a technical and economic analysis of potentialenergy saving projects in a facility that:

Provides information on current energy consuming equipmentoperations

Identifies technically and economically feasible energy efficiencyimprovements for existing equipment, and

Provides the customer with sufficient information to judge thetechnical and economic feasibility of the recommended projects.


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Investment Grade Audits

Detailed or investment grade audits are the basis for furtherengineering analysis and design, and investment in energyefficiency improvements by facility owners or third parties. Theycan be also the basis for performance contract agreements. An

accurate investment grade audit can result in identification ofhighly cost effective projects, and result in substantial cost/timesavings in realization of the projects, while a low quality auditwill result in unrealistic savings analysis, duplicate work in theengineering design process, and potential problems in

performance contract agreements. More importantly, becausesome of these energy audits may become a basis for investmentin, and establishment of distributed generation facilities in thepresent energy market, energy audit work may have significanteconomic repercussions.


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Investment Grade AuditsBe Careful!!!!!

a low quality audit will result in unrealistic savings analysis,duplicate work in the engineering design process, and potential

problems in performance contract agreements.

And.

More importantly, because some of these energy audits maybecome a basis for investment in, and establishment of

distributed generation facilities in the present energy market,energy audit work may have significant economic

repercussions.


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Some Energy audit Cases

The following reports were prepared by energy service companies(ESCos), and in a few cases by energy engineering consultants.The audits and reviews have been performed since July 2001after the peak of California energy crisis. The results from

review of ten comprehensive audit reports are presented in thefollowing table. The ten audits that are presented here weredone by seven firms, some of them with national operations.The table has three columns, showing the facility that the auditreport was prepared for, the recommended measures and themajor issues that were raised after careful review of the audit

reports.


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Audit Measures

Recommended

Issues Raised

Office BuildingSouthern CaliforniaFirm A

Retrofit part of the lighting systemHVAC system upgrade

Type of lamps and fixtures not identified, energysavings overestimated by about 40%HVAC system energy savings overestimated byabout 50% (methodology problem)Various measures not identified:VFD* for chilled water and condenser pumpsVFD for cooling tower fansVFD for return fansProper control of supply fan VFDVarious control issues

Office BuildingCentral Valley, CA

Firm B

Installation of a New 400 Ton Variable SpeedChillerUpgrade Existing Partial Thermal EnergyStorage SystemInstall VSD* on Pumps and FansEnergy Management Hardware and SoftwareRetrofit Lighting

No energy or demand balance presentedUtility rate schedules were not identifiedDOE-2 simulation had been used but noinput/output data were presentedIt is not clear how cooling tower fans arecontrolled

Office BuildingSan Francisco Bay Area, CAFirm A

Installation of VFDs on the Supply and returnFans.Installation of CO2 Controls on the Return AirFans.Installation of Damper Control.

Measured power of the motors is based oncurrent measurement, lacks power factormeasurementFan curves have been used for VFD justification,not clear if flow and pressure were measured orassumed, fan curves are sensitive to bothNumerical errors in power savings calculationsresulted in overestimation of savings by 50%It is not clear why installation of CO2 sensorsare recommended and how it will result in anyenergy savings, maintenance cost savings, etc.

Automating the on/off of the HVAC system notidentified, while it is done manually now


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Audit MeasuresRecommended

Issues Raised

PrisonCentral Valley, CAFirm D

Lighting RetrofitEnergy Management SystemVariable Air Volume HVACBoiler Economizers and Fan VSDsTransformer SubstationCogeneration Replacement

Assumed plug load without justificationNo details of the HVAC system to be controlledby the EMS has been presentedMeasurement data for boiler not presented, butvarious measures recommendedThe basis for choosing the kW rating of thecogen is not clear

FERCs criterion forcogen not clarified

Vocational InstitutionCentral Valley, CAFirm D

Lighting RetrofitThermal Energy StorageProgrammable Timeclocks and ThermostatsBoiler Economizer and Fan VSDsDairy Chiller Heat RecoveryNew Water Booster PumpCogeneration

Rate schedules not identifiedBoiler measurements not includedBoilers optimization not taken into considerationCogen calculations do not include actual plant

data

Office Building

Southern CaliforniaFirm D

Lighting Retrofit

EMS Controls ModificationsVSDs for Pumps and Chillers

Window FilmThermal Energy Storage

The schedule of operation of HVAC system and

building temperature control (chillers included)are not clear.The specs for the HVAC system are notprovided.The DOE-2 simulation has not been properlycalibrated. There is a discrepancy of upto 50% indemand estimation


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EXPECTATIONS FROM AN INVESTMENT GRADE AUDIT

The final product of an investment grade audit (the audit report) needs to at leastaddress the following issues:

Clear operating hours per department (and equipment in the case of majorenergy users)

Clear inventory of energy consuming equipment including their nominal ratings

and capacities Energy rate/cost per unit of energy usage and for different types of energy

(electricity, natural gas, etc.). In the case of electricity the customer may bepaying for electrical demand too. In such a case, the demand cost and its basisshould be clearly identified

Analysis of at least one year (as the base year) of energy consumption by typeof energy/fuel

Energy balance of the plant per type of fuel and preferably per meter based onrating, operating hour, utility factor and load factor of equipment. Utility factor isthe ratio of the operating hours of a piece or group of equipment to the totaloperating hours of facility or department. Load factor is the ratio of the actualdraw of equipment to the nominal rating of equipment, usually determined frommeasurement


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Clear identification of major energy consuming processes andequipment in the whole facility

Analysis of major energy efficiency measures identified in the audit

process, which at least includes source of energy saving, amount andtype of energy saved, cost savings, implementation cost and a pay-back analysis, as well as any major assumptions made in the analysis.In the case of computer simulation, a clear and succinct input/out putfor computer programs needs to be included.

Clear identification of the retrofit or control scheme/technology, and

inclusion of cut sheets of the proposed equipment Clear identification of the measures that may have potential in similar

facilities that do not exist or are not economical in the audited facility


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It is expected that investment grade energy auditsinclude realistic assumptions on the conservativeside; be complete, self sufficient, and a clear guide toimplementation, and serve as a roadmap to anyfuture energy efficiency retrofit work in the facility.Assuming that an identified measure is chosen, andthe detailed design is done, no more detailed energy

consumption analysis should be needed to designand construct the measures.


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Check List

The following can serve as a checklist for preliminary screening of adetailed/investment grade energy audit:

Are the energy rates based on historical (or projected) energyconsumption and current (or projected) energy rates?

Has energy usage (and demand in the case of large electricity users)been balanced for at least one full year of energy data, separately fordifferent fuels and preferably per meter? The preferred forms ofpresentation is graphical (e.g. pie chart) or tabular.

Are operating hours for different areas in the facility clearly identified andtaken into consideration?

Are major energy consumers clearly identified, and taken intoconsideration in the energy balance?

Are the bases for implementation costs clearly identified?

If a modeling software has been used, are the inputs and outputs clearlyidentified, so that another expert can repeat the work?


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Check List

For the proposed measures, is it clear why energy will be saved?

Is it clear what form of retrofit is proposed and what are the advantages?

Is it clear where the retrofit should take place?

Have all potential energy efficiency measures been addressed?

Lack of consistency in energy cost, demand cost, operating hours ofvarious area of the facilities; often the basis for the considered demandcost is not clear

Lack of energy balance, which often results in overestimation of the costsavings

Lack of a clear description of the energy rate schedules, annual energyanalysis, so that the customer is not really provided with a clear picture ofhow they are charged.


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Major shortcomings you can usually meet in audit reports

Lack of consistency in energy cost, demand cost, operating hours ofvarious area of the facilities; often the basis for the considered demandcost is not clear

Lack of energy balance, which often results in overestimation of the costsavings

Lack of a clear description of the energy rate schedules, annual energyanalysis, so that the customer is not really provided with a clear picture ofhow they are charged.

Lack of equipment inventory and their ratings

Lack of clear description and identification of retrofit scheme

Overestimation of savings due to lack of consistency

Lack of consideration of the latest retrofit technology

Lack of pointing out the measures that may exist in similar facilities but donot exist in the surveyed facility


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Overall, while the comprehensive detailedenergy audit reports are supposed to provide a

clear picture of the energy supply andconsumption in the facility, and act as aroadmap for improvement of the energy

utilization and cost reduction, often they lacked

some key components to serve the ultimatepurpose.

Major shortcomings you can usually meet in audit reports


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Some of the perceived causes of deficiencies in the audit

reports seem to stem from

Lack of expertise of people who do the surveys, and moreimportantly those who prepare the report. Although takinginventory of equipment is fairly straightforward (filling out a sitesheet), it often takes a clear understanding of complicated

systems (e.g. a multiple-chiller system) to offer any meaningfulenergy efficiency improvements.

Lack of basic knowledge of the fundamental engineeringprinciples. Energy efficiency work is multidisciplinary, whichnecessitates a strong knowledge of fundamentals of mechanical

and electrical engineering. It is always advisable to have aprofessional engineer oversee comprehensive energy auditprojects.


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Lack of training in application of sophisticated simulationsoftware. Very sophisticated computer programs can produceincorrect results if they are not fed with the proper data (e.g.operating hours, load factors, etc.), and properly applied to thespecific situation.


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Conflict of interest Often the firm that conducts the survey andprepares the audit report, is the same or affiliated with the firmthat will do the engineering design and implementation (such asfull energy service companies). There may be cases that are not

directly leading into a profitable project and get omitted, or somerequired steps and information are overlooked in the interest ofgreen lighting a project. An example is when a firm is hired todo a comprehensive energy audit, but fails to take inventory ofall equipment and evaluate them, in the interest of an attractive

lighting retrofit project. Other examples are consideration ofunrealistic operating hours, utility factors, load factors of theequipment. An oversized 50 hp fan motor may operate at 50%of its load, but it will not be known in the plant audit if its powerdraw is not measured!


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MORE COMPLICATED ENERGY AUDIT CASES

Comprehensive energy audit of manufacturing facilities requires significantly higher

expertise than commercial and institutional facilities. While there are tens ofenergy saving opportunities in commercial facilities, there are hundreds ofenergy efficiency opportunities in industrial facilities.

It is not uncommon to identify 10-30% energy efficiency

opportunities with simple paybacks of zero to a few years inindustrial facilities.


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Some specific issues in audit of manufacturing facilities are

A much wider scope of measures and advanced technologies (inclusive of thosefor commercial facilities) can be identified in industrial facilities.

While there are significant commonalties between industrial facilities with

different processes, most facilities may have their unique energy efficiencymeasures that can be identified and analyzed based on fundamentalengineering principles.

Load measurements are required for major energy consuming devices. Someequipment may go through significant load variations.

Energy usage in most industrial facilities are highly product and production

dependent, and much less dependent on ambient conditions. Taking a detailed inventory (which includes the rating, usage pattern, loading) of

energy consuming equipment is an essential component of a comprehensiveenergy audit of industrial facilities.


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Energy Effciency in figures

Sector Parameters Consumptive

High Energyconsumption

Heavy Industries

SavingInvestment

Payback time

32 M95 M3 years

Middle energyconsumption

Mechanical sector

SavingInvestment

Payback time

0.2 M0.7M

2.7 years

Low energy

consumptionDwellings

Saving

InvestmentPayback time

3 M

8M3.5 years

www.mwhglobal.com


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Which are the main internal Barriers to reach energy

efficiency???

PRIORITY

PAYBACK

NARROW MIND

CHANGE RISK


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And the externalone.

INSTITUTIONS

INVESTMENTFOUNDS

TECHNICALEXPERTISES

CULTUTRE


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Thank you!!

Romano Selva

Sogesca srl

www.sogesca.it

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