Energy Audits — Electrical & Thermal
An energy audit seeks to document things that are sometimes ignored in the plant — such as the energy being used on site per year, which processes use the energy, and the opportunities for savings. In so doing, it assesses the effectiveness of management structure for controlling energy use and implementing changes.
The energy audit report establishes the needs for plant metering and monitoring, enabling the plant manager to institutionalize the practice and hence, save money for the years to come. The energy audit action plan lists the steps and sets the preliminary budget for the energy management program.
Four Step Energy Audit Methodology
Our structured four-step energy audit process identifies where energy is used, opportunities for savings, cost-benefit analysis, and a clear action plan for implementation.
Step 01
Analysis of Energy Use
Identifying where energy is used is useful because it identifies which areas the audit should focus on and raises awareness of energy use and cost. Sub meters are installed in different plant locations to pinpoint actual energy usage per area — creating spreadsheet data and charts useful for analysis. Key data includes operating hours, duty cycles, and actual power consumed via 3-phase current/voltage readings or power analyzer measurements.
Step 02
Identification of Energy Projects
Opportunities for energy savings can range from the simplest — such as lighting retrofits — to the most complex such as the installation of a cogeneration plant. We focus on major energy users and areas, always applying the 80/20 rule: focus on opportunities that provide 80% of the saving but require only 20% input. After preliminary identification, we focus on those with shorter payback periods.
Step 03
Cost Benefit Analysis
The identified energy conservation opportunities are analyzed in terms of the costs of implementing the project versus the benefits that can be gained. We calculate the total cost of installation and compare it with the savings derived — for example, installing a heat plate exchanger to recover waste heat. The project proceeds only where there is a net positive benefit.
Step 04
Action Plan & Implementation Priority
After passing the cost benefit test, an action plan is developed to ensure that all identified opportunities are implemented. The action plan includes all major steps, the people responsible, and a plan for monitoring the results — enabling the plant manager to institutionalize energy management and save money for years to come.
Important Points When Collecting Site Load Data
Accurate site load data is the foundation of a reliable energy audit. Our team collects and verifies three critical data points at every site.
Operating Hours
Gathered from plant personnel — it is essential to ensure the accuracy of this data because much of the potential for energy savings lies in the correct estimation of the equipment's operating hours. Inaccurate operating hours lead to incorrect energy calculations and missed savings opportunities.
Duty Cycle
Machines such as large electric motors have varying loads and hence different power requirements. The duty cycle — how much of the time a machine operates at full load versus partial load — is critical for accurate energy consumption calculations and identifying variable speed drive opportunities.
Actual Power Consumed
For electric power users, this is based on either 3-phase current/voltage readings or power analyzer measurements — such as direct kW readings which incorporate power factor. For fuel users, tank readings of monthly consumption, flow meters, and totalisation are used as measurement sources.
Two Types of Energy Audit
The type of energy audit to be performed depends on the function and type of industry, the depth to which the final audit is needed, and the potential and magnitude of cost reduction desired.
Preliminary Audit
A preliminary energy audit is a quick, low-cost assessment of a facility's energy consumption — used to identify obvious opportunities for savings and to determine whether a more detailed audit is warranted.
Detailed Audit
A detailed energy audit is a comprehensive, in-depth assessment of all energy-consuming systems — providing precise data on energy use, losses, and savings opportunities with full cost-benefit analysis.
The Type of Audit Depends On:
Function and type of industry — manufacturing, commercial, institutional, or infrastructure facility
Depth to which the final audit is needed — preliminary walkthrough or comprehensive detailed study
Potential and magnitude of cost reduction desired — scale of savings expected from the programme
25+
Years Experience
30%
Avg. Energy Savings
500+
Projects Completed
100%
Client Satisfaction
Energy Saving Opportunities We Uncover
Opportunities for energy savings can range from the simplest to the most complex. We focus on major energy users and areas — always applying the 80/20 rule to maximise returns for minimum input.
Lighting Retrofits
Replacement of inefficient lighting systems with LED technology — one of the simplest, fastest payback energy conservation opportunities in any facility.
Motor & Drive Systems
Identification of oversized motors, inefficient drives, and opportunities for Variable Frequency Drive (VFD) installation — typically the largest electrical energy users in industrial plants.
Waste Heat Recovery
Installation of heat plate exchangers and heat recovery systems to capture and reuse thermal energy — turning wasted heat into productive energy with strong financial returns.
Cogeneration Systems
Evaluation of cogeneration plant installation feasibility — simultaneous generation of electricity and useful heat from a single fuel source for maximum energy efficiency.
Power Factor Correction
Installation of capacitor banks and power factor correction systems — reducing kVA demand charges and improving the efficiency of the electrical distribution system.
SEEM Certified Energy Auditors
Yash Energy is registered with SEEM (Society of Energy Engineers and Managers) and has 25+ years of experience conducting electrical and thermal energy audits for industrial, commercial, and government clients across India.
Why Yash Energy for Your Energy Audit
SEEM Certified Auditors
Our energy auditors are registered with the Society of Energy Engineers and Managers (SEEM) — ensuring all audits are conducted to the highest professional standards.
Industrial & Commercial Experience
25+ years of energy audit experience across manufacturing plants, commercial buildings, hospitals, government facilities, and infrastructure projects across India.
Comprehensive Audit Reports
Detailed, actionable audit reports with energy baseline, identified opportunities, cost-benefit analysis, payback periods, and a prioritised implementation action plan.
Implementation Support
Unlike consultants who only deliver a report, Yash Energy provides full implementation support — designing, procuring, and installing the recommended energy conservation measures.
Monitoring & Verification
Post-implementation monitoring and verification of energy savings — confirming that the identified savings have been achieved and providing ongoing energy management support.
Ready for an Energy Audit?
Talk to our certified energy auditors about an electrical or thermal audit for your facility — identify savings, reduce costs, and cut emissions.