Appendix E

Energy Management Checklist

This document is intended to be used as a checklist for walk-through energy efficiency audits and assessments.

Steam Generators and Heat Transfer Fluid Heaters and Vaporizers

■  Use Fuel Flow/Air Flow Control with Oxygen Trim

■  Maintain Excess Oxygen Below 5%, Below 8% for Stokers

■  Reduce Stack Temperature to 330°F for Sulfur Bearing Fuels

■  Minimize Combustibles in Stack Gas and Ash

■  Burn the Lowest Cost Fuel

■  Apply the “Utilized Cost” of Coal

■  Minimize the Use of Stabilizing Fuel If It Is Expensive

■  Burn Non-hazardous Wastes in Boilers or Vaporizers

■  Check Casing and Flue Gas Ducts for Air In-leakage

■  Optimize the Soot Blowing Schedule

■  Keep Internal Tube Surfaces Free From Deposits

■  Check Boiler/Vaporizer Efficiency Regularly

■  Recycle Wastewater Streams for Ash Sluicing

■  Split Range Control of Fan Speed and Dampers

■  Control Oil Tank Temperature at Minimum

■  Automate Boiler Blowdown

■  Install Blowdown Heat Exchanger

■  Optimize Load Sharing Between Boilers and Vaporizers

■  Operate Boiler Feed Pumps at Minimum Discharge Pressure

■  Check Feedwater Heaters for Efficient Heat Transfer

■  Reduce Deaerator Vent to <O.1% Water Flow or <0.5% Steam Flow

■  Keep Steam Pressure and Temperature at Maximum If System Has Turbines

■  Lower Steam Header Pressure If There Are No Turbines

Steam Users

■  Eliminate or Find a Use for Vented Steam

■  Install Jet Compressor to Make Low Pressure Steam Useful

■  Shift Users to Lowest Header Pressure Possible

■  Optimize Steam Balance with the Right Combination of Motors and Turbines

■  Install Condensate Flash Tanks to Recover Low Pressure Steam

■  Reduce Pressure of Heating Steam During Warmer Weather

■  Use Turbines Instead of PRV’s to Reduce Steam Pressure

■  Adjust Steam Header Pressures to Maximize Turbine Work

■  Close Turbine Hand Valves

■  If Turbine Exhaust Must Be Vented, Vent Those Turbines to Atmosphere

■  Install Smaller Turbine Nozzles

■  Repair Steam Leaks

■  Isolate Unused Steam Lines

■  Eliminate Long Steam Lines with Low Flow

■  Establish an Effective Steam Trap Maintenance Program

■  Reduce Failed Steam Traps to <5% of Total

■  Ensure Bypass Valve Around PRV’s Is Not Leaking

■  Return All Condensate

■  Recover Waste Heat Wherever Possible

■  Replace Steam Vacuum Jets with Mechanical Vacuum Pumps

■  Be Sure Vacuum Jets Have the Correct Nozzle Size

■  Operate the Minimum Number of Vacuum Jets

■  Be Sure Vacuum Jets Have the Correct Steam Supply and Exhaust

■  Check Actual Steam Consumption Against Design

■  Check Turbine and Condenser Performance Regularly

■  Keep All Steam, Dowtherm, and Condensate Lines Properly Insulated

■  Provide New Heat Tracing as Electric, Not Steam

■  Conduct a PINCH Technology Survey

Electrical Loads

■  Buy New High Efficiency Motors Instead of Rewinding Failed Motors

■  Install High Efficiency Motors for New Applications

■  Change to Smaller Motors on Lightly Loaded Drives

■  Challenge the Need for Every Motor Running

■  Use Variable Frequency Drives If Flow Rate/Load Varies Widely

■  Use Daylighting Where Possible

■  Remove Lamps Where Illumination Is More Than Is Needed

■  Promote Turning Off Lights and PCs When Not In Use

■  Use Photocells, Timers, or Motion Detectors to Operate Lights

■  Replace Incandescent Lamps with Fluorescent, Sodium Vapor, or Metal Halide Fixtures

■  Replace Safety Shower and Fire Alarm Incandescent Lamps with Compact Fluorescent Lamps

■  Replace Fluorescent Ballasts and Lamps with High Efficiency Electronic Type Ballasts and T8 Lamps

■  Request a Lighting Survey

■  Clean Light Fixtures to Improve Efficiency/Light Levels

■  Provide Electric Tracing Rather Than Steam Tracing

■  Provide Controls on Self-Limiting Electrical Tracing

■  Maintain Heat Tracing Thermostats and Controls

■  Do Not Provide Heat Tracing For Freeze Protection on Lines 6” or Larger

■  Keep Electrical Equipment Cool

Electrical Power Distribution

■  Buy All Electricity Under One Contract

■  Take Advantage of Utility Incentives for Demand Side Management

■  Request an Interruptible Electrical Contract

■  Have a Load Reduction Plan to Avoid Setting New Electrical Peaks

■  Take Advantage of Utility Incentives for Demand Peak Shaving

■  Use Diesel Generators to Shave Peaks

■  Increase Turbine Generator Load to Shave Peaks

■  Transfer Loads from Motors to Turbines to Shave Peaks

■  Avoid Setting Peaks by Cycling Nonessential Equipment

■  Run Nonessential Equipment and Batch Processes During Off Peak Hours

■  Delay Starting Motors Until a New Peak Can Be Avoided

■  Switch Large Motors Quickly to Avoid Setting a New Peak

■  Install a Power Monitoring System to Enable Load Management

■  Trend Plant Loads to Avoid Adding Unnecessary Distribution Equipment

■  Analyze Power Usage to Identify Energy Reduction Opportunities

■  Install Capacitors to Increase Power Factor

■  Install Solar Photovoltaic Systems for Small Remote Loads

■  Specify High Efficiency for New Power Transformers

Refrigeration

■  Allow Condenser Pressure to Drop With Reduced Cooling Water Temperature

■  Control Condenser Pressure to Reduce Horsepower

■  Vary the Hot Gas Bypass Control Set Point With Condenser Pressure

■  Monitor Energy Consumption Per Ton to Detect Poor Machine Performance

■  Increase Chilled Water Delta T Across Machines to Design Or Greater Values

■  Maintain Proper Amounts of Refrigerant Charge

■  Keep Condensers Clean

■  Avoid Liquid Refrigerant Carryover Into Compressor

■  Operate the Refrigeration Evaporator at the Highest Practical Temperature (Pressure)

■  Minimize or Eliminate Air In-Leakage to Refrigeration Machines

■  Operate the Minimum Number of Refrigeration Machines for the Load

■  Install Refrigeration Optimization Control System

■  Optimize Brine System Concentration

■  Install Thermal Storage to Shift Load Off-Peak

■  Use Absorption Refrigeration Driven by Low Level Heat

■  Shift Loads From Chilled Water to Cooling Tower Water When Feasible

■  Precool With Cooling Tower Water Before Applying Chilled Water

Cooling Towers

■  Run Minimum Number of Pumps

■  Throttle Flow in Plant to Get the Design Delta T Across the Tower

■  Select Fan Speed for Ambient Conditions

■  Install Adjustable Pitch Fan Blades

■  Maintain Correct Cycles of Concentration

■  Maintain Tower Equipment to Run at Design Conditions

Heating, Ventilating, and Air Conditioning (HVAC)

■  Heating, Ventilating, and Air Conditioning (HVAC) Control Systems

■  Use Exhaust Air to Heat or Cool Other Areas

■  Balance Air Flows to Meet Actual Loads

■  Ensure That Exhaust Flow Matches or Balances Conditioned Air Supply

■  Ensure That Duct Work is Free of Obstructions

■  Ensure That Terminal Diffusers and Ducts are Clean

■  Keep Coils Clean

■  Keep Air Filters Clean

■  Keep Fans Clean

■  Control Flow Through Air Washers Where Possible to Adiabatic Operation

■  Repair or Replace Air Washer Nozzles That Do Not Atomize Properly

■  Trim Impellers on Air Washer Pumps When Oversized or Install Smaller Impeller

■  Make Sure Control Valves to Coils Completely Shut Off When Not in Use

■  Make Sure Steam Traps on Heating Coils Function

■  Make Sure Dampers on Coil or Air Washer Systems Close Completely

■  Maximize Supply Air Temperature During Cooling Season and Minimize During Heating Season

■  Minimize Control of Humidity Consistent with Personnel and Product Needs

■  Minimize or Eliminate Heating and Cooling in Unoccupied Areas

■  Install Thermostats on Interior Walls

■  Calibrate and Eliminate Poor or Non-performing Controls

■  Install DDC Controls to Replace Pneumatic Controls

■  Install HVAC Management System

■  Utilize Water-Side Cooling Tower Economizer Systems in Winter Where Possible to Replace Chilled Water

■  Reduce Preheater Set Point

■  Install Adequate Insulation on Chilled Water Systems

■  Use Primary-Secondary Circuits and Variable Flow Chilled Water Systems Where Applicable

■  Replace Worn or Loose Belts on Fans

■  Install Waste Heat Recovery Where Applicable

■  Install or Switch to Variable Air Volume Air Distribution System

■  Use an Infrared Survey to Locate Heat Loss

Building Envelope

■  Install Tight Sealing Doors and Windows to Minimize Infiltration

■  Install Hanging Door Seals in High Traffic Areas

■  Use Ceiling Fans to Eliminate Stratification of Air in High Ceiling Areas

■  Install Adequate Building Insulation

■  Install Roof Spray Systems to Minimize Heat Gain

■  Utilize Advanced Window Treatments to Minimize Heat Gain

■  Where Appropriate, Re-Roof with Light Colored Roofing Materials

■  Ventilate Attic Space

■  Install Adequate Wall Insulation

■  Insulate Partition Walls Between Conditioned and Unconditioned Spaces

■  Keep Garage and Warehouse Doors Closed

■  Use Self Closing Doors

■  Recaulk Doors and Windows and Install Weather-Stripping

■  Replace Broken Windows

■  Install Vestibules to Prevent Excessive Air Infiltration

■  Close Abandoned Stacks

Compressed Air

■  kW/100 scfm Should Be <19 for 100 psi and <24 for 160 psi

■  Intercool Between Compressor Stages

■  Keep Intake Filters Clean

■  Cool Air Intake Where Possible

■  Monitor Stage Temperatures and Pressures to Detect Problems

■  Use Inlet Guide Vanes for Control of Centrifugal Compressor Output

■  Control Antisurge Valves with Flow Rather than Pressure

■  Keep Antisurge Valves Closed

■  Base Load Centrifugals and Carry Swings on Reciprocating Compressors

■  Optimize Load Sharing Between Compressors

■  Reduce the System Pressure to the Minimum Needed

■  Use a Booster Compressor for Small High Pressure Loads

■  Use Air Blower Instead of Compressed Air

■  Do Not Use Compressed Air for Cleaning or Agitation

■  Eliminate Air Trap Leakage

■  Repair Air Leaks

■  Shut Off Compressed Air to Equipment That Is Down

■  Replace “Heatless” Air Dryers with “Heated

■  Eliminate Pressure Regulators That Bleed Air

■  Monitor Compressed Air Use to Detect Abnormal Changes

Fans

■  Use Adjustable Speed Drives

■  Reduce Speed with Sheave-Change to Minimize Damper Throttling

■  Control Fan Output with Inlet Guide Vane Control to Reduce Throttling Loss

■  Keep Fan Belts From Slipping

■  Size Ductwork to Give Minimum Static Pressure Loss

■  Minimize Duct Leakage

Pumps

■  Reduce System Pressure to Minimum Needed by the Users

■  Substitute Gravity Flow Where Possible

■  Use a Booster Pump for a Small High Pressure Demand

■  Connect Heat Exchangers in Series to Reduce Cooling Water Flow

■  Operate the Minimum Number of Pumps for the Load

■  Install Smaller Impellers to Avoid Throttling Loss

■  Maintain Pumps to Produce Design No-Load Discharge Pressure

■  Use a Variable Frequency Drive To Control Discharge Pressure

General

■  Reuse Water Wherever Possible

■  Use Untreated Water Instead of Filtered Water

■  Control Water Flow to Coolers and Condensers at Optimum Rate

■  Keep All Instrumentation Calibrated

■  Measure and Record All Utility Consumption and Analyze Performance and Trends

■  Operate the Minimum Amount of Equipment to Satisfy System Loads

■  Use DCS and Energy Optimization Systems to Control Efficiently

■  Use All Utilities at the Most Economical Temperature and Pressure

■  Optimize Piping Systems for Minimum Life Cycle Cost

■  Isolate All Unused Energy Consuming Equipment

■  Insulate Heated Tanks

■  Use Suction Heaters Instead of Heating Entire Tanks

■  Repair Hot Water Leaks

■  Run Hot Water Heaters at Minimum Temperature Required

■  Keep Heat Exchanger Surfaces Clean

■  Purchase Only Energy Efficient Equipment

■  Use Heat Pumps to Supply Hot Water and Refrigeration

■  Operate Internal Combustion (I/C) Engines Only When Necessary

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