energy audit data templates (doe-eere, 2014-02-25) - test
TRANSCRIPT
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8/12/2019 Energy Audit Data Templates (DOE-EERE, 2014-02-25) - Test
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Plant Energy Profiler
(Self-Assessment / Kuesioner Survey)
Detail PerusahaanA.1.1. Nama Perusahaan :
A.1.1.1. Sektor Industri :
A.1.1.2. Alamat Kantor Pusat :
A.1.1.3. Telepon / Facsimile :
A.1.1.4. E-mail / Website :
A.1.2. CEO / Managing Director :
A.1.2.1. Contact Person :
A.1.2.1. Posisi / Jabatan CP :
A.1.2.2. Telepon / Facsimile CP :
A.1.2.3. E-mail CP :
A.1.3. Pendapatan Kotor Tahunan : Rp. / US$
A.1.4. Jumlah Karyawan Total :
A.1.5. Jumlah Pabrik / Plant :
Site / Plant DetailsA.2.1. Nama Pabrik :
A.2.1.1. Alamat Pabrik :
A.1.1.3. Telepon / Facsimile :
A.2.2. Manajer Pabrik :
A.2.3. Manajer Energi :
A.2.3.1. Contact Person :
A.2.3.2. Posisi / Jabatan CP :
A.2.3.2. Telepon / Facsimile CP :
A.2.3.3. E-mail CP :
A. Informasi Perusahaan
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PT Panarub Industry
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Sistem Penggunaan Energi di Pabrik Checklist)A.3.1. Fasilitas industrial (lampu, HVAC, dan fasilitas pendukung lainnya)
A.3.2. Boiler dan instalasi steam
A.3.3. Refrigerasi dan pendinginan proses industrial
A.3.4. Pemanasan proses industrial
A.3.5. Compressed air
A.3.6. Proses elektrokimia
A.3.7. Fan dan blower
A.3.8. Pompa
A.3.9. Handling material
A.3.10. Pengolahan material
A.3.11. Combined heat and power (co-generation)
Data Operasional PabrikA.4.1. Tahun Operasional Pabrik :
A.4.2. Major Plant Expansions / Modifications / Retrofits
A.4.3. Plant Space and Volume:
A.4.3.1. Production Space / Volume m2
m3
A.4.3.2. Office Space / Volume m2
m3
A.4.3.3. Storage Space / Volume m2
m3
A.4.3.4. Total Plant Space / Volume m2
m3
A.4.4. Total Number of Employees
A.4.5. Production Time / Duration
Hours / Shift Shifts / Day Hours / Day
Days / Week Weeks / Year Days / Year
(add on separate sheets, if necessary)
Tahun Sistem / Instalasi Utama yang Diperluas / Dimodifikasi / Retrofit
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A.4.6. Plant Production Items (to be elaborated in Section H. Production Information)
No.
1.
2.
3.
4.
5.
Plant Performance Figures / Business Case for Energy Efficiency Last 3 Years Data)A.5.1. Total Annual Sales : Rp. / US$
: Rp. / US$
: Rp. / US$
A.5.2. Total Energy Cost : Rp. / US$
: Rp. / US$
: Rp. / US$
A.5.3. Total Cost of Production : Rp. / US$
: Rp. / US$
: Rp. / US$
A.5.4. Net Profit : Rp. / US$
: Rp. / US$
: Rp. / US$
B.1. Does your company have a formal written energy management plan?Yes No
B.2. Have you formed an energy management team at your plant?
Yes No
B.3. Does your company have a formal method of communication in place for employees to suggest
energy saving opportunities?
Yes No
Profit after all other costs,
amortization, depreciation of
assets, and payment of taxes
(refer to annual accounts)
B. General Energy Management
Total sales of products and
services during last three
consecutive / reference
years
Total cost of fuel, gas,
electricity, imported heat /
steam, etc. in the same years
Total annual production
costs (materials, energy,
labours), excluding
overhead, taxation, and
Total 100.0% 100.0%
Product Item% Share by Ton of
Production
% Share by Profit /
Sale Value
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B.4. Does your company use life cycle cost analysis to evaluate the economics of energy efficient
equipment when making new purchases of large systems?
Yes No
B.5. Does your company establish required payback periods for energy efficient improvement
projects?
Yes No
Resources, Roles, Responsibility and AuthorityC.1.1. Have the roles, responsibilities and authorities for energy management been defined and
documented?
Yes No In Progress (Scale 1 to 5):
C.1.2. Have a Management Representative and an Energy Management Team been designated?
Yes No In Progress (Scale 1 to 5):
C.1.3. Have the roles, responsibilities, and authorities for the Management Representative and Energy
Management Team been defined?
Yes No In Progress (Scale 1 to 5):
C.1.4. Have the required resources (e.g. personnel, technology, finance) for implementation and
control of the energy management system been provided by the management?
Yes No In Progress (Scale 1 to 5):
C.1.5. Does the personnel appointed in energy management have the competence required?
Yes No In Progress (Scale 1 to 5):
Energy PolicyC.2.1. Has the organization defined and documented its energy policy?
Yes No In Progress (Scale 1 to 5):
C.2.2. Is the energy policy appropriate to the nature and the scale of, and the impact on the
organization's energy use and consumption?
Yes No In Progress (Scale 1 to 5):
C.2.3. Does the policy include commitments to
a. Continual improvement of energy efficiency?
b. Compliance with applicable legislation and other requirements?
c. Support purchase of energy-efficient products and services?
Yes No In Progress (Scale 1 to 5):
C.2.4. Does the energy policy provide a framework for setting energy objectives and targets?
Yes No In Progress (Scale 1 to 5):
C.2.5. Has the energy policy been documented, implemented, maintained and communicated to all
persons working for or on behalf of the organization?
Yes No In Progress (Scale 1 to 5):
C.2.6. Has the energy policy been regularly reviewed and updated?
Yes No In Progress (Scale 1 to 5):
his part can be skipped if your company is not yet interested to achieve ISO 50001 standard compliance in near future
C. ISO 50001 / Energy Management Compliance Assessment
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Legal and Other RequirementsC.3.1. Has a procedure been developed and implemented to identify applicable regulatory, legal and
other requirements?
Yes No In Progress (Scale 1 to 5):
C.3.2. Has the organization identified, implemented, and access to the applicable legal requirements
and other requirements, which are related to its energy use, consumption and efficiency?Yes No In Progress (Scale 1 to 5):
C.3.3. Has the organization determined how the applicable legal requirements and other
requirements apply to its energy use, consumption and efficiency?
Yes No In Progress (Scale 1 to 5):
C.3.4. Are current copies of all applicable regulatory and other requirements accessible to personnel
as necessary?
Yes No In Progress (Scale 1 to 5):
Energy Review, Energy Baseline and Energy Performance Indicators EnPIs)C.4.1. Has a procedure been established, implemented and maintained to identify the energy baseline
and Energy Performance Indicators?
Yes No In Progress (Scale 1 to 5):
C.4.2. Has energy baseline related to potential significant energy use been considered in establishing
and implementing the EnMS?
Yes No In Progress (Scale 1 to 5):
C.4.3. Has the organization identified the areas of significant energy use?
Yes No In Progress (Scale 1 to 5):
C.4.4. Has the organization determined the current energy performance related to identified
significant energy uses?
Yes No In Progress (Scale 1 to 5):
C.4.5. Are all significant energy uses controlled by objectives, targets, and programmes, procedures
or monitoring?
Yes No In Progress (Scale 1 to 5):
C.4.6. Has the organization identified other relevant variables affecting significant energy uses?
Yes No In Progress (Scale 1 to 5):
Energy Objectives, Energy Targets and Energy Management Action PlansC.5.1. Have documented energy objectives and targets been established at relevant functions and
levels within the organization?
Yes No In Progress (Scale 1 to 5):
C.5.2. Are the energy objectives and energy targets specific, measurable, concrete and
understandable?
Yes No In Progress (Scale 1 to 5):
C.5.3. Are the objectives and targets consistent with the energy policy?
Yes No In Progress (Scale 1 to 5):
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C.5.4. Has an energy performance evaluation system been established to periodically review the
achievement of the objectives and targets?
Yes No In Progress (Scale 1 to 5):
C.5.5. Have action plans including the following items for the achievement of energy objectives and
targets been established and implemented?
a. Designation of responsibility for achieving objectives and targets at each relevant function
and level of the organization;
b. The means and time-frame by which the programmes are to be achieved;
c. The statement of the method by which an improvement in energy performance shall be
verified; and
d. The statement of the method of verifying the results of the action plans.
Yes No In Progress (Scale 1 to 5):
C.5.6. Have the action plans been documented and updated at defined intervals?
Yes No In Progress (Scale 1 to 5):
Competence, Training, and AwarenessC.6.1. Are all the personnel, related to significant energy uses, competent on the basis of appropriate
education, training, skills or experience?Yes No In Progress (Scale 1 to 5):
C.6.2. Have training needs associated with the control of its significant energy uses and the operation
of its EnMS been identified?
Yes No In Progress (Scale 1 to 5):
C.6.3. Have procedures been established to assure that all the personnel working for or on behalf of
the organization are aware of:
a. The importance of conformity with the energy policy, procedures and the requirements of
the EnMS?
b. Their roles, responsibilities and authorities in achieving the requirements of the EnMS?
c. The benefits of improved energy performance?
d. The impacts, actual or potential of their activities and how their activities and behaviour
contribute to the achievement of energy objectives and targets and the potential
consequences of departure from specified procedures?
Yes No In Progress (Scale 1 to 5):
C.6.4. Are training records, certificates and licenses maintained to demonstrate the competence?
Yes No In Progress (Scale 1 to 5):
CommunicationC.7.1. Does the organization communicate internally with regard to its energy performance and the
EnMS?
Yes No In Progress (Scale 1 to 5):
C.7.2. Are procedures maintained for communication of energy issues between various levels of the
organization?
Yes No In Progress (Scale 1 to 5):
C.7.3. Has the organization established and implemented a process by which any person working for,
or on behalf of, the organization can make comments or suggestions to EnMS?
Yes No In Progress (Scale 1 to 5):
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Internal AuditC.15.1. Have internal audit procedures been developed and implemented?
Yes No In Progress (Scale 1 to 5):
C.15.2. Has the internal audit schedule been developed?
Yes No In Progress (Scale 1 to 5):
C.15.3. Are the internal audits conducted to ensure that the EnMS:
a. Conforms to planned arrangements for energy management according to ISO 50001
standard requirements?
b. Conforms with the energy objectives and targets established?
c. Is effectively implemented and maintained, and improves energy performance?
Yes No In Progress (Scale 1 to 5):
C.15.4. Are audit reports and records documented?
Yes No In Progress (Scale 1 to 5):
C.15.5. Are the auditors conducting the audits competent and in a position to conduct the audits
objectively and impartially?
Yes No In Progress (Scale 1 to 5):
Nonconformity, Corrective Action and Preventive ActionC.16.1. Have procedures been established to define the responsibility for handling, investigating and
controlling, and mitigating nonconformity?
Yes No In Progress (Scale 1 to 5):
C.16.2. Does the organization address the actual and potential nonconformities by making corrections,
and by taking corrective and preventive actions with the following elements?
a. Reviewing nonconformities or potential nonconformities;
b. Determining the causes of nonconformities or potential nonconformities;
c. Evaluating the need of action to ensure that nonconformities do not occur or recur;
d. Determining and implementing the appropriate action needed;
e. Maintaining records of corrective and preventive actions; and
f. Reviewing the effectiveness of the corrective and preventive actions taken.
Yes No In Progress (Scale 1 to 5):
C.16.3. Are procedures changed and / or updated as a result of corrective action and preventive
action?
Yes No In Progress (Scale 1 to 5):
Control of RecordsC.17.1. Have procedures been established and implemented for the identification, retrieval and
retention of records?Yes No In Progress (Scale 1 to 5):
C.17.2. Are records legible, identifiable and traceable to the relevant activities?
Yes No In Progress (Scale 1 to 5):
C.17.3. Does the organization address the actual and potential nonconformities by making corrections,
and by taking corrective and preventive actions with the following elements?
a. Training records;
b. Audit results;
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c. Management review records;
d. Information on applicable energy laws and other requirements;
e. Inspection, maintenance and calibration records;
f. Information on significant energy use and energy performance indicators;
g. Procurement records;
h. Permits;
i. Monitoring data;
j. Details of nonconformities, incidents, complaints and follow-up actions;k. Contractors and suppliers records; and
l. Process and product information.
Yes No In Progress (Scale 1 to 5):
Management ReviewC.18.1. Do periodic management reviews take place to ensure the continuing suitability, adequacy and
effectiveness of the EnMS?
Yes No In Progress (Scale 1 to 5):
C.18.2. Are management review records retained?
Yes No In Progress (Scale 1 to 5):
C.18.3. Are the management reviews carried out based on the following documents or information?
a. EnMS audit reports;
b. Evaluation of compliance with legal requirements and other requirements to which the
organisation subscribes;
c. Achievement of EnMS objectives and targets;
d. Communications and complaints on EnMS internally;
e. Energy policy;
f. Energy performance and related Energy performance indicators (EnPIs) of the organization;
g. Status of corrective and preventive actions;
h. Follow-up actions from previous management reviews;
i. Projected energy performance of the following period;
j. Changing circumstances, including developments in legal and other requirements related to
its energy use; and
k. Recommendations for improvement.
Yes No In Progress (Scale 1 to 5):
C.18.4. Are the management reviews included in the decisions or actions related to:
a. Energy performance of the organization;
b. Energy policy;
c. Energy performance indicators (EnPIs);
d. Objectives and targets of the EnMS; and
e. Allocation of resources.
Yes No In Progress (Scale 1 to 5):
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Performance MonitoringD.1.1. When was the last time your refrigeration system was audited?
1 year or less
> 2 years ago
> 5 years ago
D.1.2. How often do you monitor refrigeration costs?
Continuously
Quarterly
Yearly
Never / don't know
D.1.3. Do you monitor compressor efficiencies?
Yes No
Maintenance PracticesD.2.1. Do you have a regular maintenance program?
Yes No
D.2.2. Do you regularly inspect (at least quarterly) the refrigerant charge level?
Yes No
D.2.3. Do you regularly inspect (at least quarterly) the compressors?
Yes No
D.2.4. Do you regularly inspect (at least quarterly) the condensers and evaporators for fouling?
Yes No
Load Profile CharacteristicsD.3.1. What is the average refrigeration compressor load factor versus design (typical / estimated)?
>= 100%
> 50%
Don't know
D.3.2. What % of operating time do you spend at less than 50% load?
30% or less
60% or more
Don't know
D.3.3. What mechanism do you use to unload your compressors?
Variable speed drives
Cylinder unloading (reciprocating) / slide valves (screw) / variable inlet guide vanes(centrifugal)
Automated Compressor on / off control
Manual Compressor on / off control
Suction throttling
Hot gas by-pass
D. Process Cooling and Refrigeration
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Operating PracticesD.4.1. Is your refrigeration compressor suction pressure typically:
At or near design pressure
< design pressure by more than 15%
Don't know
D.4.2. What is the typical temperature difference between evaporator refrigerant and process
stream outlet?Within 5 F of design
> 5 F of design
Don't know
D.4.3. Is your refrigeration compressor discharge pressure typically:
At or near design pressure
> design pressure by more than 10%
Don't know
D.4.4. Do you have condenser performance problems?
Not at all
Only periodically during hot / rainy seasons
Throughout hot / rainy seasons
Continuously
Design ConsiderationsD.5.1. How old is your refrigeration equipment (average)?
< 10 years
10-20 years
> 20 years
D.5.2. Have you ever performed a Pinch Analysis study to check if refrigeration loads have been
minimized?
Yes No
DriversD.6.1. What % of your refrigeration compressor HP is delivered via the following drive types?
(Total must be less than or equal to 100%)
% Backpressure (extraction) steam turbines
% Variable speed electric motors
% Electric motors without variable speed drives
% Condensing steam turbines
ControlD.7.1. How are cooling tower fans controlled?
Always on
Manual on / off control
Fan pitch control
Automated on / off control
Combination of above
D.7.2. How is blowdown controlled?
Automatically
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Manually
Combination of above
Performance MonitoringD.8.1. Which parameters do you monitor regularly?
Ambient air temperature profiles for year
Ambient air wet bulb temperature profile for year
Cooling tower blowdown cycles
Cooling water flow demand
"Delta T" across towers
Cycles of concentration
Operation and Performance CharacteristicsD.9.1. Are overall cooling water flowrates above or below design?
Above Below
D.9.2. Do you have uneven water distribution problems in cooling towers?
Yes No
D.9.3. How close are basin temperature approaches to wet bulb temp?
Around 3 C
> 3 C
D.9.4. Do you have high cooling water pump discharge pressure problems due to:
D.9.4.1. Distribution piping fouling?
Yes No
D.9.4.2. Cooling water exchanger fouling problems?
Yes No
D.9.4.3. Higher than design cooling loads?
Yes No
D.9.5. Do you monitor cooling water exchanger fouling rates and / or pressure drops?
Yes No
D.9.6. Do you have the following cooling water distribution problems in the process units?
Capacity problems
Starving some users
D.9.7. Do you have sludge or sediment problems in cooling tower basins?
Yes No
D.9.8. Have you optimized water vs air cooling loads?
Yes No
Current Process Cooling ConfigurationD.10.1. Estimate the percentage of your site cooling load supplied by the following:
(Total must be less than or equal to 100%)
% Mechanical draft towers
% Natural draft towers
% Cooling ponds
% Spray ponds
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D.10.2. Estimate the percentage of cooling water distribution pump HP delivered by the following
types drives: (Total must be less than or equal to 100%)
% Backpressure turbine drives
% Variable speed drives
% Motor drives
% Condensing turbine drives
D.10.3. Are you running the minimum number of pumps?Yes No
D.10.4. If not, what is the primary reason:
Emergency on-line backup supply criteria
System capacity (high discharge pressures)
Ease of operation
N/A
D.10.5. What type of cooling tower fill is used?
Splash film
Film fill
D.10.6. Do cooling tower fans have adjustable pitch blades?All
Some
None
D.10.7. Do the cooling tower fans have adjustable speed drives?
All
Some
None
MaintenanceD.11.1. What is the general condition of cooling tower fill?
Excellent
Adequate
In need of replacement
Steam CostE.1.1. Do you monitor your fuel cost to generate steam ($ / lbs. of steam produced)?
Yes No
E.1.2. How often do you calculate and trend your fuel cost to generate steam?At least quarterly
At least annually
Less than annually
Steam / Product BenchmarksE.2.1. Do you measure your steam / product benchmark (lbs. of steam needed / unit of product
produced)?
E. Steam Generation Equipment
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Yes No
E.2.2. How often do you measure and trend your steam / product benchmark (lbs. of steam needed
/ unit of product produced)?
At least quarterly
At least annually
Less than annually
Steam System MeasurementsE.3.1. Do you measure and record critical energy parameters for your steam system?
Steam Production Rate (to obtain total steam production)
Fuel Flow Rate (to obtain total fuel consumption)
Feedwater Flow Rate
Makeup Water Flow Rate
Blowdown Flow Rate
Chemical Input Flow Rate
E.3.2. How intensely do you meter your steam flows?
By major user / equipment
By process unitBy area or building
By plant as a whole (i.e., total boiler output)
Not at all
Steam Trap MaintenanceE.4.1. Does your system steam trap maintenance program include the following activities?
Proper trap selection for application
At least annual testing of all traps
Maintaining a steam trap database
Repairing / replacing defective traps
Water Treatment ProgramE.5.1. How often do you ensure that your water chemical treatment system is functioning properly?
At least daily
At least weekly
Less than weekly
E.5.2. How often do you need to clean fireside or waterside deposits in your boiler?
Every 5-10 years
Every 1-5 years
Once / year or more
E.5.3. How often do you measure conductivity (or TDS, total dissolved solids) in your boiler and
determine what your steam and mud drum blowdown rate (or top and bottom boilerblowdown rate) should be?
Continuous, or at least once / shift
Once / day
Once / week or less
System InsulationE.6.1. Is your boiler plant equipment and piping system insulation (refractory, piping, valves, flanges,
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vessels, etc.) maintained and in good condition?
Insulation excellent
Insulation good, but can be improved
Insulation inadequate
E.6.2. Is your steam distribution, end use, and condensate recovery equipment insulation (piping,
valves, flanges, heat exchangers, etc.) maintained and in good condition?
Insulation excellent
Insulation good, but can be improved
Insulation inadequate
Steam LeaksE.7.1. How would you characterize steam leaks in your steam system?
None
Minor
Moderate
Numerous
Water HammerE.8.1. How often do you detect noticeable water hammer in your steam and condensate recovery
system?
Less than once a month
Monthly or weekly
Daily or hourly
Maintaining Effective Steam System OperationsE.9.1. Do you periodically, at least once a year, inspect the following important steam plant
operational equipment?
E.9.1.1. Boiler plant equipment; boiler, deaerator, feedwater tank, chemical treatment equipment,
blowdown equipment, economizer, combustion air preheater, insulation, etc.?
Yes No
E.9.1.2. Distribution system equipment; piping (including design), steam traps (types, sizes, locations),
air vents, valves, pressure reducing stations, insulation, etc.?
Yes No
E.9.1.3. End use system equipment; turbines, piping (including design), heat exchangers, coils, jacketed
kettles, steam traps (types, sizes, locations), air vents, vacuum breakers, pressure reducing
valves, insulation, etc.?
Yes No
E.9.1.4. Recovery system equipment; piping (including design), valves, fittings, flash tanks, condensate
pumps, condensate meters, insulation, etc.?
Yes No
Boiler EfficiencyE.10.1. How often do you measure your overall boiler efficiency: heat absorbed to create steam /
energy input from fuel?
At least quarterly
At least annually
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Less than annually
E.10.2. Do you measure the following parameters as a function of boiler load and ambient
temperature?
E.10.2.1. Flue gas temperature?
Yes No
E.10.2.2. Flue gas oxygen content?
Yes No
E.10.2.3. Flue gas CO content?
Yes No
E.10.3. How do you control excess air in your boiler to maximize boiler efficiency?
Automatically
Manually
Not at all
Heat Recovery EquipmentE.11.1. Do you have any of the following heat recovery equipment installed on your boilers?
E.11.1.1. Feedwater economizer and / or combustion air preheater
Yes No
E.11.1.2. Blowdown heat recovery
Yes No
Generating Dry SteamE.12.1. How often do you check the quality of steam that is output from your boiler to the distribution
system, and ensure that you are generating dry steam?
At least quarterly
At least annually
Less than annually
General Boiler OperationE.13.1. Do you have an operational automatic blowdown controller on your boiler?
Yes No
E.13.2. What is the frequency of high level alarms (possibly indicating boiler undersized) or low level
alarms (possibly indicating boiler oversized) for your boiler?
Less than 1 / month
1-5 per month
More than 5 / month
E.13.3. How often do you experience steam pressure fluctuations of greater than 10% of your boiler
operating pressure?
Less than 1 / month
1-5 per month
More than 5 / month
Options for Reducing Steam Pressure, Minimize Steam Flow Through PRVsE.14.1. How do you reduce steam pressure in your steam system?
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Steam generated at required pressure or PRVs appropriately applied
Backpressure turbines used in parallel with PRVs
Boiler control used to reduce pressure
Excess steam vented and / or used inefficiently
Recover and Utilize Available CondensateE.15.1. How much of your available condensate do you recover and utilize?
Greater than 80%
40% to 80%
20% to 40%
Less than 20%
Use High-Pressure Condensate to Make Low-Pressure SteamE.16.1. How much of your available flash steam do you recover and utilize?
Greater than 80%, or flash steam unavailable
40% to 80%
20% to 40%
Less than 20%
F.1. Have you conducted a detail energy assessment for your heating equipment to identify energy
saving opportunities?
Yes No
F.2. Do you measure oxygen (O2) and Carbon Monoxide CO or combustible in flue gases and "tune"
the burners periodically to maintain low values for O2 and combustibles in the furnace flue
gases?
Yes No
F.3. Have you sealed openings in furnaces and repaired cracks, and damaged insulation in furnace
walls, doors etc.?
Yes No
F.4. Do you regularly clean heat transfer surfaces to avoid build up of soot, scale or other material?
Yes No
F.5. Do you have a program for calibration/adjustment of sensors (i.e. thermocouples), controllers,
valve operators, etc.?
Yes No
F.6. Do you operate the furnace at or close to design load by proper furnace scheduling and loading,
and avoid delays, waits between production?Yes No
F.7. Do you maintain proper (balanced or slightly positive) pressure in furnaces to avoid air leakage
in the furnace?
Yes No
F.8. Check all the flue gas recovery systems that are in the plant:
A heat recovery system (i.e. recuperator, regenerator, water or heating etc.) is used to
F. Process Heating
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recover heat from the furnace flue gases.
Heat of flue gases from the furnace or air preheater is used to heat charge material,
fixtures etc.
Heat of flue gases from the furnace or air preheater is used for lower temperature
processes such as steam generation, water heating or air heating for the plant or other
application.
F.9. Do you use design of fixtures, trays and other material handling system components with
minimum weight and proper material?
Yes No
F.10. Do you use proper insulation for (or minimize use of) water or air cooled parts such as rolls, load
supports etc. used in furnaces?
Yes No
F.11. Are you using oxygen enriched air or oxy-fuel fired burners for high temperature processes?
Yes No
F.12. Are you using the most cost effective source of heat for processes where it is possible use
alternate energy sources (i.e. steam vs. electricity vs. fuel firing) where applicable?
Yes No
F.13. Do your heating equipment and other heated parts use cost effective type and thickness of
insulation?
Yes No
Compressed Air SystemG.1.1. Have you developed a basic block diagram of the system?
Yes No
G.1.2. Have you developed a pressure profile of your system to determine peak demand and
dynamics of demand?
Yes No
G.1.3. Have you estimated total compressed air flow during different shifts?
Yes No
G.1.4. Have you measured pressure at various points in the system to determine pressure drop?
Yes No
G.1.5. Have you measured compressed air temperature at various points in the supply system?
Yes No
G.1.6. Have you estimated leak load?Yes No
MaintenanceG.2.1. Do you meet or exceed compressor and dryer manufacturer's requirements for maintenance?
Yes No
G.2.2. Do you periodically check ventilation openings to the compressor room to make sure they are
G. Compressed Air
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free of obstructions?
Yes No
G.2.3. Do you inspect condensate drains daily?
Yes No
G.2.4. Do you periodically inspect and replace hoses that have become cracked or worn?
Yes No
G.2.5. Do you periodically inspect and replace end-use filters, check regulators, and lubricators to
maintain functionality?
Yes No
Compressed Air Demand Vary Significantly Over Time If No, Skip)G.3.1. Have you adjusted your compressor controls in the last year?
Yes No
G.3.2. Have you developed a control strategy that allows you to efficiently match supply with demand?
Yes No
G.3.3. Do you monitor compressor operation to avoid rapid cycling of equipment?
Yes No
Compressed Air End-Uses Require Significantly Different Pressures If No, Skip)G.4.1. Do you have a few high pressure applications that determine operating pressure for your entire
plant?
Yes No
G.4.2. Have you investigated ways to serve high pressure applications at a lower pressure?
Yes No
Compressed Air End-Uses Require Significantly Different Levels of Air Quality If No, Skip)G.5.1. Do you have a few end use applications requiring high quality air that determine the air quality
for the entire plant?
Yes No
G.5.2. Have you investigated ways to serve these high air quality applications with point-of-use
solutions?
Yes No
Compressed Air End-Uses That Are Intermittent, But Require High Volumes If No, Skip)G.6.1. Are you using any of the following to supply the intermittent, high volume applications? (Check
all that apply)
Secondary storage receiversSeparate compressor, booster or amplifier
Potentially Inappropriate End-UsesG.7.1. Have you analyzed your end uses to make sure they could not be more efficiently using
alternative energy sources?
Yes No
G.7.2. Is compressed air being sent to abandoned equipment?
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Yes No
Leak ManagementG.8.1. Have you estimated the amount of leakage in your system?
Yes No
G.8.2. Do you have the equipment to detect leaks (e.g., ultrasonic detector) or outsource leak
detection?Yes No
G.8.3. Do you have an ongoing leak management program?
Yes No
Heat RecoveryG.9.1. Does your plant have a demand for space heating or hot water?
Yes No
G.9.2. Are you using heat recovery on your compressed air system?
Yes No
Control MethodsH.1.1. For systems in which flow is controlled or regulated, estimate the percentage that are
controlled by: (Total must be less than or equal to 100%)
% Valve throttling or bypass flow regulation
% Turning pumps on and off to match needs
% Constant load-pump matched to meet need at pump best efficiency point
% Adjustable speed drives
% Combination of above, other, or unknown
Performance MonitoringH.2.1. Estimate the percentage of pumping systems for which the answer to the following questions is
"Yes".
H.2.1.1. Are pump performance curves readily available?
%
H.2.1.2. Are the system head-capacity curves well understood (static and dynamic head components)?
%
H.2.1.3. Are pumps tested at installation to compare performance with the manufacturer's curve?
%
H.2.1.4. Is motor power or current measured and pump efficiency estimated as a part of the installation
test?
%
H.2.1.5. Are pumps periodically tested or performance measures trended to check for performance
degradation?
%
H. Pumps
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H.2.1.6. Do you evaluate the potential energy cost savings (compared to optimal commercially available
equipment operating at the existing head and flow rates)?
%
H.2.1.7. What percentage of your systems have permanently installed flow meters?
%
Purchasing and Repair PoliciesH.3.1. Do you purchase energy efficient or premium efficiency motors as a standard practice? (Applies
to all motors, regardless of size)
Yes No
H.3.2. Do you have a motor repair / replacement decision policy in place? (This question applies to all
motors)
Yes No
H.3.3. Do you include energy-efficiency guidelines in pump purchase specifications (e.g., minimum
operating efficiency, specify precision castings, coated bowls, etc.)?
Yes No
H.3.4. Are energy factors a primary consideration when repairing or replacing an existing pump that
has failed?Yes No
PersonnelH.4.1. Percentage of operators that could explain how to read and use a pump head-capacity curve:
%
H.4.2. Percentage of system engineers that could explain all standard pump performance curves:
head, power, efficiency, and NPSHR:
%
Cogeneration ConfigurationI.1.1. Check which items are part of your CHP system:
Gas Turbine
Unfired HRSG
Supplementary Fired HRSG
Fully Fired Boiler(s)
Extraction Steam Turbogenerator(s)
Condensing Steam Turbogenerator(s)
Diesel EngineDirect Exhaust to Furnace, Kiln, Dryer
I.1.2. If this is a condensing turbine, do you have to run the turbine for extended periods at low to
minimum load to keep it on-line?
Yes No
I.1.3. Do you sell excess steam or is there a potential customer for excess steam?
Yes No
I. Combined Heat and PowerThis part can be skipped if not applicable
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I.1.4. If you have a Gas Turbine or Diesel generator, is the exhaust gas used for:
Direct heating (dryer, kiln or preheated furnace air)
Steam Generation
I.1.5. Do you use the turbo-generator for peak load shaving?
Yes No
I.1.6. Are any of the boilers outside of the co-generation unit operated:
I.1.6.1. On hot standby?Yes No
I.1.6.2. At minimum load?
Yes No
I.1.7. If you have a condensing steam turbine as a part of your cogeneration unit, what is the average
condensing pressure?
< 2 in Hg
Between 2-4 in Hg
> 4 in Hg
I.1.8. Do you export power to the grid or external customers?
Yes NoI.1.9. What is the average load factor (average/rated power production ratio) for the cogeneration
unit?
%
I.1.10. What is the average net heat rate of the cogeneration unit (net Btu's of the fuel / kWh of power
produced)?
5,000 or less
5,000 - 7,000
> 7,000
Don't know
I.1.11. What is the average co-generation unit operating stream factor (on-line time as a fraction)?
%
I.1.12. How many unplanned trips per year?
%
I.1.13. How often is the overall co-generation efficiency monitored?
Continuously
Monthly
Annually
I.1.14. Do you have on-line dynamic load optimization?
Yes No
Existing EmissionsI.2.1. How do you control exhaust NOx levels?
Water injection
Steam injection
Low NOx burners
Existing MaintenanceI.3.1. Do you have a program for preventive maintenance of the CHP system?
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Routine lubrication
Borescope inspections
Instrument calibrations
Blade cleaning, peanut/almond shells
I.3.2. Do you have a program for predictive maintenance?
Lube oil sampling
Advanced diagnostics
Instrument histograms
I.3.3. Do you periodically re-certify co-generation operators?
Yes No
I.3.4. If an HRSG is a part of the system, how many steam generation levels?
1
2 or more
I.3.5. What type of deaerator to you have?
External
Integral
I.3.6. If the HRSG has supplementary firing, does the HRSG run at maximum firing or maximum steam
generation capacity all the time?Yes No
I.3.7. Are the Boilers used as the swing steam load production or the HRSG?
Boilers (HRSG base loaded)
HRSG (Boilers base loaded)
I.3.8. Is your HRSG stack temperature:
300 F
Between 300 - 400 F
> 400 F
I.3.9. If the HRSG is supplementary fired, what is the typical HRSG fired operating temperature?
1,500 F or greater
1,400 F
1,200 F or less
I.3.10. Do you use evaporative cooling on the GT inlet air temp?
Yes No
I.3.11. Is the energy for this cooling supplied by the HRSG?
Yes No
I.3.12. Do you have large seasonal variations in gas turbine inlet air temp?
Yes No
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No. Units PeriodApproximate
% Energy
Consumption
Production Line
NameProduct Name Average Quantity
J. Production Information
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Meter
IDUnits Period
Unit
CostRemark
K. Supplied Energy
Energy TypeUsage per
PeriodCost per Period
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