Energy Audit Data Templates (DOE-EERE, 2014-02-25) - Test

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?


C.1.3. Have the roles, responsibilities, and authorities for the Management Representative and Energy

Management Team been defined?


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?


C.1.5. Does the personnel appointed in energy management have the competence required?


Energy PolicyC.2.1. Has the organization defined and documented its energy policy?


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?


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?


C.2.4. Does the energy policy provide a framework for setting energy objectives and targets?


C.2.5. Has the energy policy been documented, implemented, maintained and communicated to all

persons working for or on behalf of the organization?


C.2.6. Has the energy policy been regularly reviewed and updated?


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?


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?


C.3.4. Are current copies of all applicable regulatory and other requirements accessible to personnel

as necessary?


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?


C.4.2. Has energy baseline related to potential significant energy use been considered in establishing

and implementing the EnMS?


C.4.3. Has the organization identified the areas of significant energy use?


C.4.4. Has the organization determined the current energy performance related to identified

significant energy uses?


C.4.5. Are all significant energy uses controlled by objectives, targets, and programmes, procedures

or monitoring?


C.4.6. Has the organization identified other relevant variables affecting significant energy uses?


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?


C.5.2. Are the energy objectives and energy targets specific, measurable, concrete and

understandable?


C.5.3. Are the objectives and targets consistent with the energy policy?


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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?


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.


C.5.6. Have the action plans been documented and updated at defined intervals?


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?


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?


C.6.4. Are training records, certificates and licenses maintained to demonstrate the competence?


CommunicationC.7.1. Does the organization communicate internally with regard to its energy performance and the

EnMS?


C.7.2. Are procedures maintained for communication of energy issues between various levels of the

organization?


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?


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Internal AuditC.15.1. Have internal audit procedures been developed and implemented?


C.15.2. Has the internal audit schedule been developed?


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?


C.15.4. Are audit reports and records documented?


C.15.5. Are the auditors conducting the audits competent and in a position to conduct the audits

objectively and impartially?


Nonconformity, Corrective Action and Preventive ActionC.16.1. Have procedures been established to define the responsibility for handling, investigating and

controlling, and mitigating nonconformity?


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.


C.16.3. Are procedures changed and / or updated as a result of corrective action and preventive

action?


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?


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.


Management ReviewC.18.1. Do periodic management reviews take place to ensure the continuing suitability, adequacy and

effectiveness of the EnMS?


C.18.2. Are management review records retained?


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.


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.


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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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Date post:	03-Jun-2018
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