L i f e & E n e r g y A u d i t
210 ECOs
Boilers
Increase steam output through improved efficiency
Install economizer in Boiler for preheating feed water
Improve the efficiency of the boiler by soot blowing
Installation of Air preheater to the boiler
Convert the existing grate fired boiler to fluidized bed boiler
Blow down loss reduction
Usage of fuel oil additive for LSHS
To modify Burner in Boiler to improve combustion efficiency
Conversion of coal fired thermic fluid heaters to fluidized bed combustion heaters using bagasse
Install variable frequency (VFD) for FD fan of Boiler ƒ Use coal after drying in sunlight
Reduce of boiler pressure from 9.0 Kg/cm2 to 4.0 Kg/cm2
Replacing the boiler with a 25/HR boiler
Steam Systems
To provide separate line for condensate recovery
Replace existing electrical heating system by steam heating
Improve the efficiency of steam distribution system
Improvement of Efficiency of the turbine
Stop Steam condensate pump
Attend to steam leaks in steam lines and valves
Optimization of steam utilization
Install the right Steam Traps
Furnaces
Fuel efficiency Improvement in furnace
Minimize the heat loss through the exhaust fans
Replace present control panels by thyristor control panel
Interlock Operation of Exhaust Blowers with Door openings in PCO & WDO
Installation of Flux-maxiox in furnace oil supply line
Use LPG as fuel instead of Town gas
Improve the efficiency of dryer
To keep usage of holding furnace to the minimum possible to avoid energy loss
Shot Blast to remove the sand
Install ladle preheating for furnace
Loading the furnace to the full capacity
Re-scheduling the batch operations of furnace
Reduce the tapping temperature ƒ Minimize Pouring Time
Insulation & Refractory’s
Insulate the pipeline and equipments
Replace the existing refractory with ceramic wool ƒ To provide ceramic wool lining backed by rock wool
Insulating the uninsulated pipelines
Installation of polypropylene balls in the Electroplating baths
Minimizing the heat loss through insulated surfaces
Providing thermocole lid just on the surface of the hot baths
Insulate the bare steam lines in the identified areas
Install Covers for tanks with Heaters
Insulating Furnace Wall
Provision of lid for 2 T furnace and replace existing lid with Insulation in the barrels of all the Electrical heaters in Line A, B, C.
To insulate the barrels of all the Electrical heaters in lines.
Co-generation
* Replace the present condensing type turbine
Waste Heat Recovery
Utilize the heat generated through incineration
Operate the existing heat recovery system in Pot concentrator furnaces for recovering the waste heat
Thermic Fluid Heaters
To reduce excess air in the exit gas
Conversion of Electrically heated water baths
Performance improvement of thermic fluid heater
Conversion of electrical heating to thermic fluid heating
Installing a boiler working on thermic fluid heating
Improve the efficiency of Aquatherm
Optimization of thermic fluid heaters
Cooling Towers
Replace existing metal blades by FRP blades for C.T.’s
Install automatic temperature controller in the cooling tower systems
Centralization of utilities
Saving by water quality management
To install side stream fitters for Cooling Tower of power plant
Install cooling tower for radiator cooling.
Water Treatment
To revamp the existing cooling water treatment
Electrical Systems / Systems Study
Install harmonic filters and suppress waveform distortion
Install high-tension voltage stabilizer
Reallocate the loading pattern of transformers
Operate the two transformers in parallel
To lay additional runoff cable from substation
Install energy saver for welding transformer
Load management of electrical energy requirements
Improve the load factor
Optimization of energy cost by using fuel additive in HSD
Install 115 kVAR power factor correction capacitors
Install low tension voltage stabilizer
Use additive in lube oil
Reduce DG Set Frequency to 48.5
Reduce frequency of VFD of AHU
Reduce cable loss by reducing drop in voltage
Reduce Max demand
Replace Defective Capacitors
Optimization of UPS system
Provide captive power generation to obviate losses
Replace motor - generator sets with thyristor based welding sets
Reduce voltage by 5% at transformer
Use super kerosene as fuel for the DG sets
Install energy saver for DG sets
Improving the performance of DG set by fine tuning
Install electrical meters for power delivery network
Provision of capacitors across the terminals of A.C. welding transformers.
Re-engineering of the power delivery network.
Replace single welder type welding transformers with double welder type
Motors
Install Auto Delta-Star Controller for under loaded motors
Installation of soft starters for selected e quipments
Replace fluid coupling drives by variable frequency drives
Install variable speed drives for cooling blower
To provide interlock system for the main mill section
Replace V-Belt drives by Flat Belt Drives
Replace Metal cooling fans of indicated motors by plastic fans
Replace under loaded motors
Install VSD for motor of pump
Installation of cyclic load energy savers
Install shunt capacitors across the terminals of induction motors
Conversion of lightly loaded Delta conversion motors to permanent star connection
Periodical motor load survey
HVAC & Refrigeration
Replace the existing A/c units with VAM
Utilize the waste heat for VAM
Replace the window air conditioners by FCU’s
Provide ventilation by roof extractors
Install Mega saver units for air conditioning system
Fix Sun Film Control For Windows
Use 250 TR Unit Instead of Air Cooled 60 TR Units
Optimize Operation of HVAC’s
Install Conquest Energy Saver
Reduce RPM of AHU Fans in the Office Building
Install Loading and Unloading Mechanism for Chiller Compressors
Install motorized dampers to the air conditioning ducts
Install Energy Efficient Refrigeration Compressor
Convert water cooled A/c to Air cooled A/c system
Install Automatic Loading System in Refrigeration Compressor
Provide false ceiling in all the sections of the plant
Pumps
Optimization of Chilling Plant circulating pump operation
Improve efficiency of Pump
Operate two Pumps instead of three pumps
Install Right Size Pump for Water Supply
Install Lower Size Impeller for Water Pumps
Reduce pressure drop in the water supply header
To stop the Continuous Hardening Furnace Quenching oil pump
Savings obtained by Lowering the Steam Pressure in the Boiler
To optimize the cooling tower pump operation
Segregate high and low water pressure users
Erect overhead tank for water supply
Install water level controller to over head tank
Trim impeller of water pump
Install VFD for the process pump
Install soft starters for pumps
Fans and Blowers
Replacement of Inefficient fans
Performance testing of fans
Interconnection of Blowers in the plant
Replacement of inefficient blower
Down size the Air Supply Blower
Stopping of Exhaust Fans
Reducing the Speed of Blower
SECTOR WISE
Cement Industry
Saving by Reducing air flow in Kiln
Saving by Reducing air flow in discharge circuit
Speed reduction in Bag Filter fans
To reduce the pressure drop the Preheater
Arresting Air ingress by installing a Nose Ring Seal
Conversion of Worm gear drives to Helical gear drives
Conversion from Pneumatic Conveyor
Elimination of Coal mill Booster fan
Reduce the peak hour consumption by staggering running of raw mill
Textile Industry
Replace Aluminium Blade by FRP blades for Humidification
To provide False Ceiling for all the sections of the plant
Installation of Solid State Controller for Ring Frames
Use plastic type Aerofoil Louvers
Changeover from Spray to Cell type air washer
Reduce the Spindle Wharves Diameter in Ring Frame
Use Synthetic spindle oil for all Ring Frames
Use vacuum cleaner and eliminate use of compressed air
Use pneumofil fans of aluminium
Install Power Planner for Blow room
Install Schlaforst 338 for auto coner Building and Commercial
Provision of venetian blinds for windows
Install ‘Occupancy Sensor’ for Lighting in the Halls
Replace the D/C driven motor of the lift by A/C drives
Switching off the computers during lunch time
Fertilizer Industry
Replace the feed conveyor by a duct in the DAP conveyors system Chlor Alkali
Reduce electrical joint resistance
Lighting Systems
Replace incandescent lamps
To utilize natural light by installing translucent sheets
Install Photo Electric Controls to control artificial lighting
Install solar energy systems
To provide Reflectors in light Fittings
Installation of Energy Saver in Lighting Circuit
Replace Electromagnetic Ballasts by Electronic Ballasts
Replace Standard Lamps by Compact Fluorescent Lamps
Provide Day Light Switches to control lamps
Replace Slim Tube Fluorescent Lamps by Philips Trulite
Conversion to High pressure sodium vapour lamp
Install Lighting Transformers In Lighting Feeders ƒ Switch Off Lights in Identified Areas
Replace Filament Indication Lamps in Control Panels with LED Lamps
Replace machine spot lights with CFLS
Replace reflectors of tube light fittings
Replace of 50 Nos. of FT lamps with LED lamps
Balancing of electrical loads on 3 phase LT lighting feeder
Reduce input voltage to the lighting loads
Replace FT lamps with LED Lamps
Compressed Air System
Reduce the temperature inside the compressor house
Install Refrigeration dryers in Compressed Air System
Saving by arresting Leakages
Avoid use of compressed air for other purposes
Replace single stage compressor by double stage compressor
Use Transvector Nozzle for cleaning
Interconnect Suction of Blowers
Install Ejector instead of flash gas compressor
Optimize compressed air by usage of Nitrogen and smaller rating compressor
Stop 200 cfm Compressor
Optimize the usage of compressed air
To reduce the pressure loss in the compressed air pipe lines
Reduce Compressed air Pressure
Conversion of pneumatic conveying system to mechanical system for transportation of cement
Change lube oil of the compressors by Shatex Syn lube compressor oil - XSE
Conversion to electrical grinding