Industrial Energy Audit Guidebook: Guidelines for ...

1 LBNL-3991E. ERNEST ORLANDO LAWRENCE. BERKELEY NATIONAL LABORATORY. Industrial Energy Audit Guidebook: Guidelines for Conducting an Energy Audit in Industrial Facilities Ali Hasanbeigi, Lynn Price China Energy Group Energy Analysis Department Environmental Energy Technologies Division October 2010. This work was supported by the China Sustainable Energy Program of the Energy Foundation through the Department of Energy under Contract No. DE-AC02-05CH11231. The Government retains, and the publisher, by accepting the article for publication, acknowledges, that the Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for Government purposes.

2 Disclaimer This document was prepared as an account of work sponsored by the United States Government. While this document is believed to contain correct information, neither the United States Government nor any agency thereof, nor The Regents of the University of California, nor any of their employees, makes any warranty, express or implied, or assumes any legal responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights.

3 Reference herein to any specific commercial product, process, or service by its trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof, or The Regents of the University of California. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof, or The Regents of the University of California.

4 Ernest Orlando Lawrence Berkeley National Laboratory is an equal opportunity employer. i Industrial Energy Audit Guidebook: Guidelines for Conducting an Energy Audit in Industrial Facilities Ali Hasanbeigi, Lynn Price China Energy Group Energy Analysis Department Environmental Energy Technologies Division Abstract Various studies in different countries have shown that significant Energy -efficiency improvement opportunities exist in the Industrial sector, many of which are cost-effective. These Energy -efficiency options include both cross-cutting as well as sector-specific measures.

5 However, Industrial plants are not always aware of Energy -efficiency improvement potentials. Conducting an Energy Audit is one of the first steps in identifying these potentials. Even so, many plants do not have the capacity to conduct an effective Energy Audit . In some countries, government policies and programs aim to assist industry to improve competitiveness through increased Energy efficiency. However, usually only limited technical and financial resources for improving Energy efficiency are available, especially for small and medium-sized enterprises.

6 Information on Energy auditing and practices should, therefore, be prepared and disseminated to Industrial plants. This guidebook provides Guidelines for Energy auditors regarding the key elements for preparing for an Energy Audit , conducting an inventory and measuring Energy use, analyzing Energy bills, benchmarking, analyzing Energy use patterns, identifying Energy -efficiency opportunities, conducting cost-benefit analysis, preparing Energy Audit reports, and undertaking post- Audit activities. The purpose of this guidebook is to assist Energy auditors and engineers in the plant to conduct a well-structured and effective Energy Audit .

7 Ii Table of Contents 1. Introduction to Industrial Energy auditing .. 1. Definition of Energy auditing .. 2. objectives .. 2. Types of Energy audits .. 2. Overview of Energy Audit procedures .. 3. 2. Preparation for the Energy Audit .. 5. Defining the Audit criteria .. 5. Defining the Audit scope .. 5. Selection of Energy Audit 5. Making an Audit plan .. 6. Preparing an Audit 6. Conducting the initial walk-through 6. Collecting Energy bills and available data and information .. 7. Conducting the preliminary analysis.

8 7. 3. Analyzing Energy 9. Electricity bills .. 9. Natural gas bills .. 10. Coal and fuel oil bills .. 10. Graphical analysis of historical Energy use .. 11. 4. Inventory and measurement of Energy use .. 13. Electrical load inventory .. 13. Thermal Energy use inventory .. 13. Energy system-specific measurements .. 14. Energy balance .. 15. 5. Analyzing Energy use and production patterns .. 16. Load/Demand profile .. 16. Scatter diagram for presenting the dynamics of the Energy -production relationship .. 18.

9 Interpretation of Energy -production data pattern on a scatter diagram .. 19. 6. Benchmarking and comparative Energy performance analysis .. 21. 7. Identifying Energy efficiency and Energy cost reduction opportunities .. 23. iii Electrical demand control .. 23. Cross-cutting Energy -efficiency improvement options .. 24. Energy -efficiency improvement opportunities in electric 24. Energy -efficiency improvement opportunities in compressed air systems .. 27. Energy -efficiency improvement opportunities in pumping systems.

10 30. Energy -efficiency improvement opportunities in fan systems .. 34. Energy -efficiency improvement opportunities in lighting system .. 35. Energy -efficiency improvement opportunities in steam systems .. 37. Energy -efficiency improvement opportunities in process heating systems .. 42. Sector-specific Energy -efficiency improvement opportunities for selected Industrial sectors .. 43. 8. Cost-benefit analysis of Energy -efficiency opportunities .. 45. Life-cycle cost analysis (LCCA).. 45. Life cycle cost (LCC) method.