• Preheat combustion air with waste heat
  (22 0C reduction in flue gas temperature increases boiler efficiency by 1%).

• Use variable speed drives on large boiler combustion air fans with variable flows.

• Burn wastes if permitted.

• Insulate exposed heated oil tanks.

• Clean burners, nozzles, strainers, etc.

• Inspect oil heaters for proper oil temperature.

• Close burner air and/or stack dampers when the burner is off to minimize heat loss up the stack.

• Improve oxygen trim control (e.g. -- limit excess air to less than 10% on clean fuels).
  (5% reduction in excess air increases boiler efficiency by 1% or: 1% reduction of residual oxygen in stack gas increases boiler efficiency by 1%.)

• Automate/optimize boiler blow down. Recover boiler blow down heat.

• Use boiler blow down to help warm the back-up boiler.

• Optimize deaerator venting.

• Inspect door gaskets.

• Inspect for scale and sediment on the water side
  (A 1 mm thick scale (deposit) on the water side could increase fuel consumption by 5 to 8%).

• Inspect for soot, flyash, and slag on the fire side
  (A 3 mm thick soot deposition on the heat transfer surface can cause an increase in fuel consumption to the tune of 2.5%.)

• Optimize boiler water treatment.

• Add an economizer to preheat boiler feed water using exhaust heat.

• Recycle steam condensate.

• Study part-load characteristics and cycling costs to determine the most-efficient mode for operating multiple boilers.

• Consider multiple or modular boiler units instead of one or two large boilers.

• Establish a boiler efficiency-maintenance program. Start with an energy audit and follow-up, then make a boiler efficiency-maintenance program a part of your continuous energy management program.

• Fix steam leaks and condensate leaks
  (A 3 mm diameter hole on a pipe line carrying 7 kg/cm2 steam would waste 33 kilo liters of fuel oil per year).

• Accumulate work orders for repair of steam leaks that can't be fixed during the heating season due to system shutdown requirements. Tag each such leak with a durable tag with a good description.

• Use back pressure steam turbines to produce lower steam pressures.

• Use more-efficient steam desuperheating methods.

• Ensure process temperatures are correctly controlled.

• Maintain lowest acceptable process steam pressures.

• Reduce hot water wastage to drain.

• Remove or blank off all redundant steam piping.

• Ensure condensate is returned or re-used in the process
  (6 0C raise in feed water temperature by economiser / condensate recovery corresponds to a 1% saving in fuel consumption, in boiler).

• Preheat boiler feed-water.

• Recover boiler blowdown.

• Check operation of steam traps.

• Remove air from indirect steam using equipment
  (0.25 mm thick air film offers the same resistance to heat transfer as a 330 mm thick copper wall.)

• Inspect steam traps regularly and repair malfunctioning traps promptly.

• Consider recovery of vent steam (e.g. -- on large flash tanks).

• Use waste steam for water heating.

• Use an absorption chiller to condense exhaust steam before returning the condensate to the boiler.

• Use electric pumps instead of steam ejectors when cost benefits permit

• Establish a steam efficiency-maintenance program. Start with an energy audit and follow-up, then make a steam efficiency-maintenance program a part of your continuous energy management program.

• Check against infiltration of air: Use doors or air curtains.

• Monitor O2 /CO2/CO and control excess air to the optimum level.

• Improve burner design, combustion control and instrumentation.

• Ensure that the furnace combustion chamber is under slight positive pressure.

• Use ceramic fibers in the case of batch operations.

• Match the load to the furnace capacity.

• Retrofit with heat recovery device.

• Investigate cycle times and reduce.

• Provide temperature controllers.

• Ensure that flame does not touch the stock.

• Repair damaged insulation
  (A bare steam pipe of 150 mm diameter and 100 m length, carrying saturated steam at 8 kg/cm2 would waste 25,000 liters furnace oil in a year.)

• Insulate any hot or cold metal or insulation.

• Replace wet insulation.

• Use an infrared gun to check for cold wall areas during cold weather or hot wall areas during hot weather.

• Ensure that all insulated surfaces are cladded with aluminum

• Insulate all flanges, valves and couplings

• Insulate open tanks
  (70% heat losses can be reduced by floating a layer of 45 mm diameter polypropylene (plastic) balls on the surface of 90 0C hot liquid/condensate).

• Recover heat from flue gas, engine cooling water, engine exhaust, low pressure waste steam, drying oven exhaust, boiler blow down, etc.

• Recover heat from incinerator off-gas.

• Use waste heat for fuel oil heating, boiler feed water heating, outside air heating, etc.

• Use chiller waste heat to preheat hot water.

• Use heat pumps.

• Use absorption refrigeration.

• Use thermal

Electricity Distribution System

• Optimise the tariff structure with utility supplier

• Schedule your operations to maintain a high load factor

• Shift loads to off-peak times if possible.

• Minimise maximum demand by tripping loads through a demand controller

• Stagger start-up times for equipment with large starting currents to minimize load peaking.

• Use standby electric generation equipment for on-peak high load periods.

• Correct power factor to at least 0.90 under rated load conditions.

• Relocate transformers close to main loads.

• Set transformer taps to optimum settings.

• Disconnect primary power to transformers that do not serve any active loads

• Consider on-site electric generation or cogeneration.

• Export power to grid if you have any surplus in your captive generation

• Check utility electric meter with your own meter.

• Shut off unnecessary computers, printers, and copiers at night.

• Properly size to the load for optimum efficiency.
  (High efficiency motors offer of 4 - 5% higher efficiency than standard motors)

• Use energy-efficient motors where economical.

• Use synchronous motors to improve power factor.

• Check alignment.

• Provide proper ventilation
  (For every 10 oC increase in motor operating temperature over recommended peak, the motor life is estimated to be halved)

• Check for under-voltage and over-voltage conditions.

• Balance the three-phase power supply.
  (An imbalanced voltage can reduce 3 - 5% in motor input power)

• Demand efficiency restoration after motor rewinding.
  (If rewinding is not done properly, the efficiency can be reduced by 5 - 8%)

• Use variable-speed drives for large variable loads.

• Use high-efficiency gear sets.

• Use precision alignment.

• Check belt tension regularly.

• Eliminate variable-pitch pulleys.

• Use flat belts as alternatives to v-belts.

• Use synthetic lubricants for large gearboxes.

• Eliminate eddy current couplings.

• Shut them off when not needed.

• Use smooth, well-rounded air inlet cones for fan air intakes.

• Avoid poor flow distribution at the fan inlet.

• Minimize fan inlet and outlet obstructions.

• Clean screens, filters, and fan blades regularly.

• Use aerofoil-shaped fan blades.

• Minimize fan speed.

• Use low-slip or flat belts.

• Check belt tension regularly.

• Eliminate variable pitch pulleys.

• Use variable speed drives for large variable fan loads.

• Use energy-efficient motors for continuous or near-continuous operation

• Eliminate leaks in ductwork.

• Minimize bends in ductwork

• Turn fans off when not needed.

• Use smooth, well-rounded air inlet ducts or cones for air intakes.

• Minimize blower inlet and outlet obstructions.

• Clean screens and filters regularly.

• Minimize blower speed.

• Use low-slip or no-slip belts.

• Check belt tension regularly.

• Eliminate variable pitch pulleys.

• Use variable speed drives for large variable blower loads.

• Use energy-efficient motors for continuous or near-continuous operation.

• Eliminate ductwork leaks.

• Turn blowers off when they are not needed.

• Operate pumping near best efficiency point.

• Modify pumping to minimize throttling.

• Adapt to wide load variation with variable speed drives or sequenced control of smaller units.

• Stop running both pumps -- add an auto-start for an on-line spare or add a booster pump in the problem area.

• Use booster pumps for small loads requiring higher pressures.

• Increase fluid temperature differentials to reduce pumping rates.

• Repair seals and packing to minimize water waste.

• Balance the system to minimize flows and reduce pump power requirements.

• Use siphon effect to advantage: don't waste pumping head with a free-fall (gravity) return.

• Consider variable speed drive for variable load on positive displacement compressors.

• Use a synthetic lubricant if the compressor manufacturer permits it.

• Be sure lubricating oil temperature is not too high (oil degradation and lowered viscosity) and not too low (condensation contamination).

• Change the oil filter regularly.

• Periodically inspect compressor intercoolers for proper functioning.

• Use waste heat from a very large compressor to power an absorption chiller or preheat process or utility feeds.

• Establish a compressor efficiency-maintenance program. Start with an energy audit and follow-up, then make a compressor efficiency-maintenance program a part of your continuous energy management program.

• Install a control system to coordinate multiple air compressors.
   

• Study part-load characteristics and cycling costs to determine the most-efficient mode for operating multiple air compressors.

• Avoid over sizing -- match the connected load.

• Load up modulation-controlled air compressors. (They use almost as much power at partial load as at full load.)

• Turn off the back-up air compressor until it is needed.

• Reduce air compressor discharge pressure to the lowest acceptable setting.
  (Reduction of 1 kg/cm2 air pressure (8 kg/cm2 to 7 kg/cm2) would result in 9% input power savings. This will also reduce compressed air leakage rates by 10%)

• Use the highest reasonable dryer dew point settings.

• Turn off refrigerated and heated air dryers when the air compressors are off.

• Use a control system to minimize heatless desiccant dryer purging.

• Minimize purges, leaks, excessive pressure drops, and condensation accumulation.
  (Compressed air leak from 1 mm hole size at 7 kg/cm2 pressure would mean power loss equivalent to 0.5 kW)

• Use drain controls instead of continuous air bleeds through the drains.

• Consider engine-driven or steam-driven air compression to reduce electrical demand charges.

• Replace standard v-belts with high-efficiency flat belts as the old v-belts wear out.

• Use a small air compressor when major production load is off.

• Take air compressor intake air from the coolest (but not air conditioned) location.
  (Every 50C reduction in intake air temperature would result in 1% reduction in compressor power consumption)

• Use an air-cooled aftercooler to heat building makeup air in winter.

• Be sure that heat exchangers are not fouled (e.g. -- with oil).

• Be sure that air/oil separators are not fouled.

• Monitor pressure drops across suction and discharge filters and clean or replace filters promptly upon alarm.

• Use a properly sized compressed air storage receiver. Minimize disposal costs by using lubricant that is fully demulsible and an effective oil-water separator.

• Consider alternatives to compressed air such as blowers for cooling, hydraulic rather than air cylinders, electric rather than air actuators, and electronic rather than pneumatic controls.

• Use nozzles or venturi-type devices rather than blowing with open compressed air lines.

• Check for leaking drain valves on compressed air filter/regulator sets. Certain rubber-type valves may leak continuously after they age and crack.

• In dusty environments, control packaging lines with high-intensity photocell units instead of standard units with continuous air purging of lenses and reflectors.

• Establish a compressed air efficiency-maintenance program. Start with an energy audit and follow-up, then make a compressed air efficiency-maintenance program a part of your continuous energy management program.

• Increase the chilled water temperature set point if possible.

• Use the lowest temperature condenser water available that the chiller can handle.
  (Reducing condensing temperature by 5.5 0C, results in a 20 - 25% decrease in compressor power consumption)

• Increase the evaporator temperature
  (5.50C increase in evaporator temperature reduces compressor power consumption by 20 - 25%)

• Clean heat exchangers when fouled.
  (1 mm scale build-up on condenser tubes can increase energy consumption by 40%)

• Optimize condenser water flow rate and refrigerated water flow rate.

• Replace old chillers or compressors with new higher-efficiency models.

• Use water-cooled rather than air-cooled chiller condensers.

• Use energy-efficient motors for continuous or near-continuous operation.

• Specify appropriate fouling factors for condensers.

• Do not overcharge oil.

• Install a control system to coordinate multiple chillers.

• Study part-load characteristics and cycling costs to determine the most-efficient mode for operating multiple chillers.

• Run the chillers with the lowest energy consumption. It saves energy cost, fuels a base load.

• Avoid oversizing -- match the connected load.

• Isolate off-line chillers and cooling towers.

• Establish a chiller efficiency-maintenance program. Start with an energy audit and follow-up, then make a chiller efficiency-maintenance program a part of your continuous energy management program.

• Tune up the HVAC control system.

• Consider installing a building automation system (BAS) or energy management system (EMS) or restoring an out-of-service one.

• Balance the system to minimize flows and reduce blower/fan/pump power requirements.

• Eliminate or reduce reheat whenever possible.

• Use appropriate HVAC thermostat setback.

• Use morning pre-cooling in summer and pre-heating in winter (i.e. -- before electrical peak hours).

• Use building thermal lag to minimize HVAC equipment operating time.

• In winter during unoccupied periods, allow temperatures to fall as low as possible without freezing water lines or damaging stored materials.

• In summer during unoccupied periods, allow temperatures to rise as high as possible without damaging stored materials.

• Improve control and utilization of outside air.

• Use air-to-air heat exchangers to reduce energy requirements for heating and cooling of outside air.

• Reduce HVAC system operating hours (e.g. -- night, weekend).

• Optimize ventilation.

• Ventilate only when necessary. To allow some areas to be shut down when unoccupied, install dedicated HVAC systems on continuous loads (e.g. -- computer rooms).

• Provide dedicated outside air supply to kitchens, cleaning rooms, combustion equipment, etc. to avoid excessive exhausting of conditioned air.

• Use evaporative cooling in dry climates.

• Reduce humidification or dehumidification during unoccupied periods.

• Use atomization rather than steam for humidification where possible.

• Clean HVAC unit coils periodically and comb mashed fins.

• Upgrade filter banks to reduce pressure drop and thus lower fan power requirements.

• Check HVAC filters on a schedule (at least monthly) and clean/change if appropriate.

• Check pneumatic controls air compressors for proper operation, cycling, and maintenance.

• Isolate air conditioned loading dock areas and cool storage areas using high-speed doors or clear PVC strip curtains.

• Install ceiling fans to minimize thermal stratification in high-bay areas.

• Relocate air diffusers to optimum heights in areas with high ceilings.

• Consider reducing ceiling heights.

• Eliminate obstructions in front of radiators, baseboard heaters, etc.

• Check reflectors on infrared heaters for cleanliness and proper beam direction.

• Use professionally-designed industrial ventilation hoods for dust and vapor control.

• Use local infrared heat for personnel rather than heating the entire area.

• Use spot cooling and heating (e.g. -- use ceiling fans for personnel rather than cooling the entire area).

• Purchase only high-efficiency models for HVAC window units.

• Put HVAC window units on timer control.

• Don't oversize cooling units. (Oversized units will "short cycle" which results in poor humidity control.)

• Install multi-fueling capability and run with the cheapest fuel available at the time.

• Consider dedicated make-up air for exhaust hoods. (Why exhaust the air conditioning or heat if you don't need to?)

• Minimize HVAC fan speeds.

• Consider desiccant drying of outside air to reduce cooling requirements in humid climates.

• Consider ground source heat pumps.

• Seal leaky HVAC ductwork.

• Seal all leaks around coils.

• Repair loose or damaged flexible connections (including those under air handling units).

• Eliminate simultaneous heating and cooling during seasonal transition periods.

• Zone HVAC air and water systems to minimize energy use.

• Inspect, clean, lubricate, and adjust damper blades and linkages.

• Establish an HVAC efficiency-maintenance program. Start with an energy audit and follow-up, then make an HVAC efficiency-maintenance program a part of your continuous energy management program.

• Use water-cooled condensers rather than air-cooled condensers.

• Challenge the need for refrigeration, particularly for old batch processes.

• Avoid oversizing -- match the connected load.

• Consider gas-powered refrigeration equipment to minimize electrical demand charges.

• Use "free cooling" to allow chiller shutdown in cold weather.

• Use refrigerated water loads in series if possible.

• Convert firewater or other tanks to thermal storage.

• Don't assume that the old way is still the best -- particularly for energy-intensive low temperature systems.

• Correct inappropriate brine or glycol concentration that adversely affects heat transfer and/or pumping energy.
  If it sweats, insulate it, but if it is corroding, replace it first.

• Make adjustments to minimize hot gas bypass operation.

• Inspect moisture/liquid indicators.

• Consider change of refrigerant type if it will improve efficiency.

• Check for correct refrigerant charge level.

• Inspect the purge for air and water leaks.

• Establish a refrigeration efficiency-maintenance program. Start with an energy audit and follow-up, then make a refrigeration efficiency-maintenance program a part of your continuous energy management program.

• Control cooling tower fans based on leaving water temperatures.

• Control to the optimum water temperature as determined from cooling tower and chiller performance data.

• Use two-speed or variable-speed drives for cooling tower fan control if the fans are few. Stage the cooling tower fans with on-off control if there are many.

• Turn off unnecessary cooling tower fans when loads are reduced.

• Cover hot water basins (to minimize algae growth that contributes to fouling).

• Balance flow to cooling tower hot water basins.

• Periodically clean plugged cooling tower water distribution nozzles.

• Install new nozzles to obtain a more-uniform water pattern.

• Replace splash bars with self-extinguishing PVC cellular-film fill.

• On old counterflow cooling towers, replace old spray-type nozzles with new square-spray ABS practically-non-clogging nozzles.

• Replace slat-type drift eliminators with high-efficiency, low-pressure-drop, self-extinguishing, PVC cellular units.

• If possible, follow manufacturer's recommended clearances around cooling towers and relocate or modify structures, signs, fences, dumpsters, etc. that interfere with air intake or exhaust.

• Optimize cooling tower fan blade angle on a seasonal and/or load basis.

• Correct excessive and/or uneven fan blade tip clearance and poor fan balance.

• Use a velocity pressure recovery fan ring.

• Divert clean air-conditioned building exhaust to the cooling tower during hot weather.

• Re-line leaking cooling tower cold water basins.

• Check water overflow pipes for proper operating level.

• Optimize chemical use.

• Consider side stream water treatment.

• Restrict flows through large loads to design values.

• Shut off loads that are not in service.

• Take blowdown water from the return water header.

• Optimize blowdown flow rate.

• Automate blowdown to minimize it.

• Send blowdown to other uses (Remember, the blowdown does not have to be removed at the cooling tower. It can be removed anywhere in the piping system.)

• Implement a cooling tower winterization plan to minimize ice build-up.

• Install interlocks to prevent fan operation when there is no water flow.

• Establish a cooling tower efficiency-maintenance program. Start with an energy audit and follow-up, then make a cooling tower efficiency-maintenance program a part of your continuous energy management program.

• Reduce excessive illumination levels to standard levels using switching, delamping, etc. (Know the electrical effects before doing delamping.)

• Aggressively control lighting with clock timers, delay timers, photocells, and/or occupancy sensors.

• Install efficient alternatives to incandescent lighting, mercury vapor lighting, etc. Efficacy (lumens/watt) of various technologies range from best to worst approximately as follows: low pressure sodium, high pressure sodium, metal halide, fluorescent, mercury vapor, incandescent.

• Select ballasts and lamps carefully with high power factor and long-term efficiency in mind.

• Upgrade obsolete fluorescent systems to Compact fluorescents and electronic ballasts

• Consider daylighting, skylights, etc.

• Consider painting the walls a lighter color and using less lighting fixtures or lower wattages.

• Use task lighting and reduce background illumination.

• Re-evaluate exterior lighting strategy, type, and control. Control it aggressively.

• Change exit signs from incandescent to LED.

• Optimize loading

• Use waste heat to generate steam/hot water /power an absorption chiller or preheat process or utility feeds.

• Use jacket and head cooling water for process needs

• Clean air filters regularly

• Insulate exhaust pipes to reduce DG set room temperatures

• Use cheaper heavy fuel oil for capacities more than 1MW

• Seal exterior cracks/openings/gaps with caulk, gasketing, weatherstripping, etc.

• Consider new thermal doors, thermal windows, roofing insulation, etc.

• Install windbreaks near exterior doors.

• Replace single-pane glass with insulating glass.

• Consider covering some window and skylight areas with insulated wall panels inside the building.

• If visibility is not required but light is required, consider replacing exterior windows with insulated glass block.

• Consider tinted glass, reflective glass, coatings, awnings, overhangs, draperies, blinds, and shades for sunlit exterior windows.

• Use landscaping to advantage.

• Add vestibules or revolving doors to primary exterior personnel doors.

• Consider automatic doors, air curtains, strip doors, etc. at high-traffic passages between conditioned and non-conditioned spaces. Use self-closing doors if possible.

• Use intermediate doors in stairways and vertical passages to minimize building stack effect.

• Use dock seals at shipping and receiving doors.

• Bring cleaning personnel in during the working day or as soon after as possible to minimize lighting and HVAC costs.

• Recycle water, particularly for uses with less-critical quality requirements.

• Recycle water, especially if sewer costs are based on water consumption.

• Balance closed systems to minimize flows and reduce pump power requirements.

• Eliminate once-through cooling with water.

• Use the least expensive type of water that will satisfy the requirement.

• Fix water leaks.

• Test for underground water leaks. (It's easy to do over a holiday shutdown.)

• Check water overflow pipes for proper operating level.

• Automate blowdown to minimize it.

• Provide proper tools for wash down -- especially self-closing nozzles.

• Install efficient irrigation.

• Reduce flows at water sampling stations.

• Eliminate continuous overflow at water tanks.

• Promptly repair leaking toilets and faucets.

• Use water restrictors on faucets, showers, etc.

• Use self-closing type faucets in restrooms.

• Use the lowest possible hot water temperature.

• Do not use a central heating system hot water boiler to provide service hot water during the cooling season -- install a smaller, more-efficient system for the cooling season service hot water.

• Consider the installation of a thermal solar system for warm water.

• If water must be heated electrically, consider accumulation in a large insulated storage tank to minimize heating at on-peak electric rates.

• Use multiple, distributed, small water heaters to minimize thermal losses in large piping systems.

• Use freeze protection valves rather than manual bleeding of lines.

• Consider leased and mobile water treatment systems, especially for deionized water.

• Seal sumps to prevent seepage inward from necessitating extra sump pump operation.

• Install pretreatment to reduce TOC and BOD surcharges.

• Verify the water meter readings. (You'd be amazed how long a meter reading can be estimated after the meter breaks or the meter pit fills with water!)

• Verify the sewer flows if the sewer bills are based on them

• Meter any unmetered utilities. Know what is normal efficient use. Track down causes of deviations.

• Shut down spare, idling, or unneeded equipment.

• Make sure that all of the utilities to redundant areas are turned off -- including utilities like compressed air and cooling water.

• Install automatic control to efficiently coordinate multiple air compressors, chillers, cooling tower cells, boilers, etc.

• Renegotiate utilities contracts to reflect current loads and variations.

• Consider buying utilities from neighbors, particularly to handle peaks.

• Leased space often has low-bid inefficient equipment. Consider upgrades if your lease will continue for several more years.

• Adjust fluid temperatures within acceptable limits to minimize undesirable heat transfer in long pipelines.

• Minimize use of flow bypasses and minimize bypass flow rates.

• Provide restriction orifices in purges (nitrogen, steam, etc.).

• Eliminate unnecessary flow measurement orifices.

• Consider alternatives to high pressure drops across valves.

• Turn off winter heat tracing that is on in summer.

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