ENERGY AUDIT OF OLD

PRODUCTION BLOCK GROUND

FLOOR

MINOR PROJECT REPORT

SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENT OF THE

DEGREE OF

BACHELOR OF TECHNOLOGY
(Electrical Engineering)

Submitted By: Submitted To:

Sukhman Singh Virk Prof. Preetinder Singh Sidhu
URN: 2104297 Designation

Department of Electrical Engineering

Guru Nanak Dev Engineering College
Ludhiana, 141006
 Acknowledgement

I am highly grateful to the Director, Guru Nanak Dev Engineering College (GNDEC),
Ludhiana, for providing this opportunity to carry out the present minor project work.

The constant guidance and encouragement received from Dr. Kanwardeep Singh
H.O.D. Electrical Engineering Department, GNDEC Ludhiana has been of great help
in carrying out the project work and is acknowledged with reverential thanks.

I would like to express a deep sense of gratitude and thanks profusely to Project
Guide Prof. Preetinder Singh, without his wise counsel and able guidance, it would
have been impossible to complete the project in this manner.

I express gratitude to other faculty members of Electrical Engineering department of

GNDEC for their intellectual support throughout the course of this work.

Finally, I am indebted to all whosoever have contributed in this report work.

Sukhman Singh Virk

 Guru Nanak Dev Engineering College, Ludhiana

Certificate

I hereby certify that the work which is being presented in the minor project report
entitled “ENERGY AUDIT OF OLD PRODUCTION BLOCK GROUND FLOOR ”
by “SUKHMAN SINGH VIRK” in partial fulfillment of requirements for the award
of degree of B.Tech. (Electrical) submitted in the Department of Electrical
Engineering at GURU NANAK DEV ENGINEERING COLLEGE, LUDHIANA
under PUNJAB TECHNICAL UNIVERSITY, KAPURTHALA is an authentic record
of my own work carried out during a period from ______ to _______under the
guidance of PROF. PREETINDER SINGH. The matter presented in this project
report has not been submitted by me in any other University / Institute for the award
of any Degree or Diploma.

Signature of the Student

SUKHMAN SINGH VIRK (2104297)
- Sign

This is to certify that the above statement made by the candidate is correct to the best
of my knowledge.

Signature of the Minor Project Guide

PROF. PREETINDER SINGH
Designation (Electrical Engineering)
 Preface

Energy audit is a procedure for analysis of energy utilization of a plant or a site. An

energy audit helps energy conservation. Energy conservation is the energy demand
management aiming to increase efficiency of use. Audit allows to understand about
the ways in which different energy sources are used in an industry thereby identifying
the areas where waste can occur and providing the scope of improvement which my
be possible. Energy audit gives a positive approach to energy cost reduction,
preventing maintenance and quality control programme vital for production and
utilize activities. Energy audit try to balance total input of energy with its use.
Scope of an energy audit varies as per the facilities being audited. This is one of the
concepts used in energy management industries and it involves methodological
examinations and comprehensive review energy use. Energy audit is the starting point
of energy management plan. Energy audit results in energy conservation proposals or
projects thus, giving an outlook towards energy cost reduction. The energy
management and energy monitoring are the basic necessary steps for energy audit.

This report provides energy audit of old production block ground floor and looks into
the energy use scenario and patterns observed during the audit phase. The possible
energy management or conservation schemes are discussed along with possible areas
where various cost reduction proposals can be considered for better efficiency at the
workplace.
 Content
1 Introduction .................................................................................................................1
1.1. Need for Energy Audit ....................................................................................1
1.2. Type of Energy Audit ..................................................................................... 2
1.3. Reasons for Carrying out the Energy Audit ....................................................2
1.4. Goals of energy audit ......................................................................................2
2 About the Site ............................................................................................................. 3
3 Major Loads ................................................................................................................5
4 Energy Consumption and Cost Profile ....................................................................... 9
4.1. Best Practices Followed in the Organization ................................................11
5 Light Measurements ................................................................................................. 12
6 Recommendations for improving the energy efficiency and energy conservation in
the Organization ...........................................................................................................14
7 References .................................................................................................................15
 Page 1

1 Introduction

Energy Audit is the way to a systematic approach for decision-making in the area of
managing energy. It attempts to identify all the energy streams in a facility and
balance the total energy inputs with its use. Industrial energy audit is an effective tool
in defining and pursuing energy management programme.

Energy Audit is defined as "the verification, monitoring and analysis of use of energy
including submission of technical report containing recommendations for improving
energy efficiency with cost benefit analysis and an action plan to reduce energy
consumption"[1].

1.1. Need for Energy Audit

In any industry, the three top operating expenses are often found to be energy (both
electrical and thermal), labour and materials. If one were to relate to the
manageability of the cost or potential cost savings in each of the above components,
energy would invariably emerge as a top ranker, and thus energy management
function constitutes a strategic area for cost reduction. Energy Audit help to
understand more about the ways energy and fuel that are used in any industry, and
help in locating the areas where waste can occur and where scope for improvement
exists. The Energy Audit would provide a positive orientation to the energy cost
reduction, preventive maintenance and quality control programme which are
important for production and utility activities. Such an audit programme will help to
keep focus on variations which occur in the energy costs, availability and reliability of
supply of energy, decide on appropriate energy mix, identify energy conservation
technologies, retrofit for energy conservation equipment etc. In general, Energy Audit
is the translation of conservation ideas into realities, by lending technically feasible
solutions with economic and other organizational considerations within a specified
time frame. The primary objective of Energy Audit is to determine ways to reduce
energy consumption per unit of product output or to lower operating costs. Energy
Audit provides a " bench-mark" (Reference point) for managing energy in the
organization and also provides the basis for planning a more effective use of energy
throughout the organization1[1].
 Page 2

1.2. Type of Energy Audit

The type of Energy Audit to be performed depends on:

- Type of industry and various function
- Degree to which final audit is needed, and
-Amount of desired cost reduction. Thus Energy Audit can be classified into the
following two types:
A. Preliminary Audit
B. Detailed Audit

1.3. Reasons for Carrying out the Energy Audit

An energy audit is carried out for the following reasons:

 To meet customer and shareholder demand
 To identify potential for using secondary energy supply technologies.
 To improve energy performance and minify the environmental impacts of the
organization’s operations.
 To inform a plan of action aimed at minimizing an organization’s carbon
footprint.
 To identify behavioral change opportunities by evaluating underway operations
and maintenance practices.
 To provide clear fiscal information regarding energy savings opportunities to
prioritize these items for the firm’s decision-making process.

1.4. Goals of energy audit

Major goals of energy audit are,

1) To reduce wastage of electrical energy of a particular building and site.
2) To find actual energy consumption of building.
3) To improve efficiency of electrical supply system of the under consideration site.
4) To improve execution of supply system of the building.
5) To minimize cost of the system.
 Page 3

2 About the Site

Old production block ground floor is the area of interest for the energy audit. The
site’s general layout with facilities visited during the audit are listed below:

S.No Sections Where Audit Conducted

1. Room G10
2. Room G11
3. Department Library
 Page 4

4,5,6 Faculty Offices P001, P002, P003

7. Metal Forming Lab(40*30 sq. Foot)
8. R&D Lab(40*50 sq. Foot)
9. Machine Tool and Machining Science Lab(40*30 sq. Foot)
10. G-11(a)
11. Office
12. Mechanical Measurement and Meteorology Lab(88 m2)
 Page 5

3 Major Loads

Equipment Rating(in Quantity Respective

kW) (Nos) loads
Room G11 A

Fans 0.08 6 0.48

Lights 0.04 4 0.16

Sockets(6A) 0.7 14 58.8

Socket(16A) 2 1 2

Faculty Office (P001)

Fans 0.08 1 0.08

Lights 0.04, 1 (each) 0.049

0.009
Sockets(6A) 0.7 6 25.2

Faculty Office (P002)

Fans 0.08 1 0.08

Lights 0.04, 1 (each) 0.049

0.009
Socket(6A) 0.7 6 25.2

Faculty Office (P003)

Fan 0.08 1 0.08

Lights 0.04, 1(each) 0.049

0.009
Sockets(6A) 0.7 5 3.5

Office

Lights 0.04 6 0.24

Fans 0.05 4 0.2

 Page 6

Air Conditioning Unit 1.6 1 1.6

Sockets(6A) 0.7 6 4.2

Socket(16A) 2 1 2

Room G10

Fans 0.08 5 0.4

Projector 230 1 230

Socket(6A) 0.7 4 16.8

Lights 0.04 4 0.16

Room G11

Fans 0.08 6 0.48

Projector 0.230 1 0.230

Lights 0.04, 2 (each) 0.98

0.009
Socket(6A) 0.7 1 0.7

Corridors/Hallways

Lights 0.009 3 0.027

Tube lights 0.04 2 0.08

Water Purifier 0.5 1 0.5

Machine Tool and Machining Science Lab

Fans 0.08 9 0.72

Lights 0.04 5 0.2

Sockets(6A) 0.7 7 4.9

Radial drilling machine 1.5 1 1.5

Tool and cutter grinder 0.850 1 0.850

Surface grinder 0.750 1 0.750

 Page 7

Pentograph 0.38 1 0.38

Capstan Lathe 1.5 1 1.5

General Purpose Lathe 1.5 2 3

Department Library

Fans 0.05 2 0.1

Air Conditioner(1.5 Ton) 1.5 2 3

Lights 0.04 8 0.32

Computers 0.2 4 0.8

Socket(6A) 0.7 26 18.2

Metal Forming Lab

Fans 0.08 9 0.72

Lights 0.04 7 0.28

Sockets(6A) 0.7 4 2.8

Metal Spinning Machine 2.2 1 2.2

Bar Pointing Machine 2.2 1 2.2

Compressor 0.75 1 0.75

Compressor 2.2 1 2.2

Descaling Machine 11 1 11

Wire Drawing Machine 15 1 15

Bar Drawing Machine 5.5 1 5.5

Bar Straightning Machine 1.5 1 1.5

Power Press 1.5 1 1.5

R&D Lab

Fans 0.08 15 1.2

 Page 8

Lights 0.04 11 4.4

Socket(6A) 0.7 24 16.8

Socket(16A) 2 4 8

Compressor 1.5 1 1.5

Abrasive Cutt off Machine 2.2 1 2.2

Air jet Erosion Teaster 1 1 1

Cryogenic Ball Milling 0.45 1 0.45

System
Metal Flow index tester 0.5 1 0.5

Metallurgical Microscope 0.05 1 0.05

Ultimaker 3D Printer 0.22 1 0.22

Universal Testing 1.5 1 1.5

Machine
Vacuum Oven 1.6 1 1.6

Vertical Milling Machine 0.75 1 0.75

Shieve Shaker 0.6 1 0.6

Vibratory Finishing 1.1 1 1.1

Machine
Vaccum Oven with Pump 3.8 1 3.8

Metallurgical Sample Saw 1.5 1 1.5

Double Disk Polishing 0.25 1 0.25

Machinne
Micro Vickers Hardness 0.05 1 0.05
Tester
Ultrasonic Cleaning Tank 2 1 2

U print 3D Printer 1.2 1 1.2

Differential scanning 0.3 1 0.3

 Page 9

Calorimeter

Office(R&D LAb)

Lights 0.04 2 0.08

Fans 0.08 1 0.08

Air Conditioning Unit 1.6 1 1.6

Socket(6A) 0.7 6 4.2

Mechanical Measurement and Metrology Lab

Lights 0.04 6 0.24

Fans 0.05 4 0.2

Air Conditioning Unit 1.6 2 3.2

Autocollimater (Nikon) 0.012 1 0.012

Roundness and 0.5 1 0.5

Cylindericity
Tester(Kudale)
Socket(6A) 0.7 8 5.6

4 Energy Consumption and Cost Profile

The organization works five days a week. Moreover the energy consumption is
dependent on the time table followed by the organization during that time. Two
sessions are observed during the year vis a vis January to June and August to
December. Considering the said remarks the following load duration observations are
seen:
S.NO. Description Details

Classrooms
 Page 10

S.NO. Description Details

1. Total no of class rooms 3

2. Yearly Occupancy Rate 6 hrs

3. Total Electricity Consumption(Yearly Avg.) 200-250 units

Offices

1. Total number of offices 5

2. Yearly occupancy rate 2hrs

3. Total Electricity Consumption(Yearly avg.) 800-1000 units

Laboratories

1. Total Elecricity Consumption( Yearly Avg) 1300-1700 units

Total Consumption 2300-3000 units

 As per Tariff structure for FY 2023-24 provided by Punjab State Electricity

Regulatory Commission(PSERC)[2], the unit cost for non residential supply are
6.96/kVah.
 Average energy cost for the site lies between Rupees 16,008-21,000.
 Salvage value of equipment if replaced: Fans-Rs 45-55/kg
 Page 11

4.1. Best Practices Followed in the Organization

 Major appliances are protected by circuit breakers and keeping awareness boards
on ‘dangers’ and ‘warnings’.
 In most the places sign boards of ‘SWITCH OFF THE APPLIANCE BEFORE
LEAVING’ are kept towards saving energy measure to the stake holders.
 Installed roof top solar plant
 NEMA certified motors are used where possible.
 Page 12

5 Light Measurements

Equipment Measured Recommended Value/Range*

Value(Lux)
Laboratories 300-500-750

Metal Forming Lab

Metal Spinning 120 200(Bench work, scribing, pressing,

Machine punching, shearing, spinning, folding)
Cupping Test 90 700(inspection work)
Machine
Sheet Rolling 90

Bar Pointing 90

Wire Pointing 100

Descaling Machine 150

Wire Drawing 160

Machine
Bar Drawing 100
Machine
Bar Straightening 80
Machine
Power Press 30

R&D Lab

Extruder Machine 60 300-500-750(coarse work)

500-750-1000(medium work)
Metal Flow Indexer 50
750-1000-2000(fine to minute work)
Abrasive Cut Off 60
Machine
Gear Head 90
Universal Milling
Machine
 Page 13

Universal Testing 60
Machine
Machine Tool And Machining Science Lab

Radial Drilling 60 150(Rough bench and machine work)

Machine 300(medium bench and machine
Tool and Cutter 40 work,ordinary automatic machine,rough
Grinder grinding,medium buffing and polishing)
Surface Grinder 40 700(Fine bench and machine work,medium
grinding,fine buffing and polishing, fine
Pentograph 50
automatic machine)
Capstan Lathe 60

General Purpose 100

Lathe
Mechanical Measurement and Metrology Lab

General 220 300-500-700

Lecture Halls/Teaching Spaces(Average with lights on)

Room G11(A) 83 200-300-500

Room G11 190

Room G10 135

Department Library

General 120 200-300-500

Bookshelves 150 150

Reading Tables 160 200

Faculty Offices

P 001 96 200-300-500(General)

P 002 80

P 003 70
 Page 14

P 004(R&D Lab) 96

Office 120

Stairs 96 100

* Values Based on IS 3646(1992); CODE OF PRACTICE FOR INTERIOR

ILLUMINATION[3]

6 Recommendations for improving the energy efficiency and energy

conservation in the Organization

The energy audit suggests following recommendations:

 Sub-meters are recommended for energy monitoring so that energy load required
and energy consumption may be noted.
 There are fans of older generation and non energy efficient which can be phase
out and replaced with new energy efficient fans.
 Maintain appliances and replace old appliances in all laboratories
 Turn off equipment when not in use.
 Regular monitoring of equipment in all laboratories and immediate rectification
of any problems.
 Continuous monitoring and analysis of energy consumption by dedicated teams
may be planned within the campus.
 Page 15

 Upgrading existing lights and fixtures with led’s instead of cfl’s and fluorescent
tubes. Hence, allowing reduction in energy consumption along with better
illumination.
 Replacing windows with clear float glasses and maximize utilization of natural
lighting
 Replacing faulty lights, tubes and fixtures.

7 References

[1] Energy Management and Audit Available: https://beeindia.gov.in>files

[2] Punjab State Electricity Regulatory Commission Available:
https://pserc.gov.in>pages
[3] IS 3646(Part 1):1992 Code of practice for interior illumination, Bureau of Indian
Standards.