MODULE 3

LEARNING OBJECTIVES

PLANT SURVEY
In this module you will learn about:

General Objectives:
L The Reason for Preliminary Plant Survey.

Specific Objectives:
L How to Organize a Plant Survey,
L How to Conduct a Plant Survey,
L How to Record Your Findings
L What Equipment is Needed to Complete the Survey.

Performance Objectives:
After successfully completing this module you will be able to:
L Organize a Preliminary Plant Survey,
L Identify the Inter-relationships between energized, Non-
energized and Human Systems,
L Conduct a Plant Energy Survey,
L Prepare a Summary Action Report on Your Findings.

SADC Industrial Energy Management Project

Implemented by AGRA Monenco Atlantic Limited for the Canadian International Development Agency
 Module 3
Plant Survey

TABLE OF CONTENTS

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.0 ORGANIZING PLANT ENERGY SURVEY . . . . . . . . . . . . . . . . . . . . . 2

2.1 Useful Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.2 Survey Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Summary Action Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.4 Energy Management Opportunities Form . . . . . . . . . . . . . . . 3

3.0 CONDUCTING THE ENERGY SURVEY . . . . . . . . . . . . . . . . . . . . . . 3

4.0 ASSIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5.0 SUMMARY - Module 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

 MODULE 3
PLANT SURVEY
1.0 INTRODUCTION

The Energy Plant Survey follows the yearly assessment of energy use (Historical
Audit) and the implementation of daily recording of all energy, water and chemical
inputs. The Historical Audit data and daily records will provide the baseline
consumption data against which to gauge the success of energy conservation
efforts in the plant or buildings.

The objective of the survey is to take a fresh unbiased look at the facility's physical
and operational conditions with an eye for wasted energy. Quick assessment of
the situation, followed by corrective action often brings considerable savings with
minimal capital outlay. The survey may also point out operational procedures and
energy systems that may require more thorough analysis to properly identify the
money saving opportunities.

All buildings, plants or institutions are composed of three basic systems:

! Energized systems are those which consume energy directly. Typical

energized systems include heating, refrigeration, lighting, production equipment
and ventilation.

! Non-Energized systems do not consume energy, but affect how much energy
an energized system must use to get its job done. Typical non-energized
systems include the building envelope, glazing on the windows and skylights,
surface finishes on interior walls and ceilings, insulation, doors and orientation
of the building.

! Human systems consist of all the people who affect energy consumption in the
buildings, manufacturing plants or institutions. The number of people in a
building at any given time determines how much ventilation is required . The
way people use a piece of machinery in the plant determines how much energy
it consumes and how efficiently it consumes it. The quality of maintenance
performed also helps determines equipment efficiency.

The efficiency of each system, independent of any other has much to do with
energy consumption. The manner in which different systems interrelate with one
another is of at least equal importance. For example even when operating and
maintenance personnel do their utmost to make equipment and its operating
characteristics as efficient as possible, energy still will be wasted if people use the
equipment improperly. Generally speaking, only a fraction of the potential savings
will be realized unless the different interrelationships are all taken into account.

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Module 3 - Plant Survey ....

2.0 ORGANIZING THE PLANT ENERGY SURVEY

Before embarking on the plant energy survey some preliminary preparation is

necessary. Most of the participants of this training course will be familiar with their
own facility's architectural features, electrical and mechanical systems and
production flow. For those who are not, it is recommended that they review the
drawings of the facility if available and familiarize themselves with the processes
in the facility. It is also recommended that they talk to the personnel directly
connected with the operation and maintenance of energy systems, and look at the
maintenance schedules and equipment manuals.

2.1 Useful Instruments

Some basic measuring instruments should be available to the auditor to improve

the quality of the survey. Such instrumentation would include:

< portable digital thermometer to measure the temperatures of exposed

surfaces of steam pipes, boilers and furnaces or refrigerating systems;
< light meter to assess the level of illumination;
< tachometer to check the RPM of rotating equipment;
< psychrometer to establish the properties of air.

2.2 Survey Forms

To facilitate the energy audit process, a set of survey forms is attached in Figure
3.1 of this module. The basic Survey Form incorporates "System" description,
"Location" and "Date". The columns marked "Items", "Conditions" and "Action
Required" are used to describe specific energy related problems

Some of the forms contain leading questions related to specific systems. The rest
are blank for additional information.

2.3 Summary Action Form

When the survey is completed, the findings (deficiencies) are reviewed and
recommendations for action are entered in priority sequence in the Summary
Action Form (Figure 3.2). In order to get the deficiencies corrected, an individual
is assigned the specific responsibility with a reasonable time limit for completion.
This is usually done during the regular Energy Management Committee meeting,
where the plant manager or another person with authority to delegate, assigns the
task with agreed upon completion time. The dates of completion are then reviewed
at regular intervals.

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Module 3 - Plant Survey ....

2.4 Energy Management Opportunities Form

This one page general form (Figure 3.3) is designed to capture and evaluate the
energy saving potential resulting from plant energy survey. The same form will be
used later for detailed energy system evaluation . It records:

< System existing conditions;

< Recommended improvements;
< Calculated benefits;
< Implementation cost; and
< Simple payback or return on investment.

3.0 CONDUCTING THE ENERGY SURVEY

By now the auditor should have some understanding of the facility's function and
have adequate equipment, including the survey forms, to conduct the survey. As
mentioned earlier, the auditor should take a fresh and unbiased look at the physical
and operational conditions of the facility. The participants of this training course
who are going to survey their own plant should regard it as their competitor's
operation to bring the observations into sharper focus.

The first impressions of the facility give the first clue of what to expect during the
survey. It is difficult to put a price on plant housekeeping, but it certainly plays a big
part in the energy management programme. Unused equipment, tools, parts and
just plain junk have a way of accumulating around work benches, offices and
machinery. Dust, dirt, and grime settle on equipment, lighting fixtures and heat
exchanger surfaces, reducing their efficiencies. This is all due to poor
housekeeping and maintenance practices.

To start the survey, it is recommended that the participant take a brisk walk through
and around the facility while it is in full operation to get the first impression of the
place. If possible, repeat the same tour during a non-operating period, either in the
evening or on a weekend to spot things that would otherwise be masked by the
noise of the operating equipment. These may include compressed air and steam
leaks, lights and ventilating fans left on, wasting energy.

After the initial walk concentrate on individual systems, using the survey form check
list, survey forms and energy management opportunities form.

At the end of survey summarize the findings in the Summary Action Form and list
the potential improvements in the Energy Management Opportunities Form.
Then discuss the recommendations with the plant manager or other designated
person.

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Module 3 - Plant Survey ....

4.0 ASSIGNMENT

! Upon return to your plant after the first workshop session:

< Arrange a meeting with senior management and other personnel that
may be involved in the survey to explain the procedures. Solicit their
active participation in the survey.

< Organize and conduct the plant energy survey according to the
instructions in this module. Use the Figure 3.1 Survey Forms as a
guideline for the survey.

< With management's permission, provide a copy of the survey results to

the SADC training staff before the second workshop session.

! While completing the assignments on specific plant systems after the second
workshop session:

< Review your initial survey findings and add new items that result from your
work on the individual plant system assignments.

< Meet with senior management to discuss the findings of the survey and
to present the potential energy management opportunities resulting from the
survey. Use these results as a tool to promote the formation of an energy
management committee. Assign responsibilities for corrective action
where applicable.

5.0 SUMMARY - Module 3

In this module you learned about:

L Preliminary Energy Surveys,
L Useful Measuring Instruments,
L The Summary Action Form,
L How to Conduct an Energy Survey.

You should now be able to perform the following tasks:

L Organize a Preliminary Plant Survey,
L Conduct a Preliminary Plant Survey,
L Prepare a Summary Action Report.

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Module 3 - Plant Survey SURVEY FORM Figure 3.1

System: BUILDING - SPACE CONDITIONING Location: Date:

Items Conditions Action Required

1. What is the main source of heating and
cooling in the facility?

2. What kind of HVAC system is operating in

the facility?

< Terminal reheat

< Multizone
< Oval duct
< Variable volume
< Hot-cold deck
< Unit heaters
< Others

3. Check the thermostat setting and measure

the room temperature by calibrated
thermometer. Is the temperature in the
building maintained above 20EC during the
heating season and below 23EC during
cooling season?

4. Is there severe negative pressure in the

building? Use smoke pencil or measure
the airflow velocity at partially opened
door.

5. Are exhaust fans on continually and why?

6. In mechanical room or penthouse:

< When was the HVAC equipment

serviced last?
< Are the filters clean?
< Are intake air dampers operating
freely and closing tight?
< Are blowers rotating in right direction
as indicated on the blower housing?
< Are the belts on HVAC equipment
tight and in good shape?

Comments:

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Module 3 - Plant Survey SURVEY FORM Figure 3.1

System: BUILDING - SPACE CONDITIONING Location: Date:

Items Conditions Action Required

6. Continued .......

< Is there enough warm air being

exhausted to warrant heat recovery
investigation? Record exhaust
temperature and rated volume of the
exhaust blower?
< Is there an air make-up system used
in the facility?

7. Is there a proper instrumentation to

determine if equipment is operating
properly, including thermometers gauges
and meters for:

< Chilled and condenser water

temperature
< Boiler pressures and feed water
temperatures
< Pump pressures and pressure drops
across strainers
< Major flow rates, such as chilled water
steam flow etc
< Air discharge temperature at coils and
fans.

8. Temperature controls:

< Is there a programm to check and

calibrate temperature controls
periodically?
< Are the room thermostats located properly
to maintain correct temperature in the
room?
< Are there any complaints about the
operation of HVAC system?

Comments:

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Module 3 - Plant Survey SURVEY FORM Figure 3.1

System: ELECTRICAL POWER Location: Date:

Items Conditions Action Required

1. Has accuracy of main facility metering
system ever been checked?

2. What is the power factor in the facility? Is

there a power factor meter or is there a
kW and kVA meter available to measure
power factor PF ' kW
kVA
If PF is below 0.9, investigate.

3. Are the capacitors installed to correct

Power Factor in good operating order? (If
the box holding the capacitors is cold to
touch, the capacitors are probably not
working.)

4. Are there large numbers of electric motors

in the plants? If so, are they left idling
during breaks?

5. Is the wiring adequate for present load?

< Are some of the larger electrical

devices overheating?
< Check the temperature of the feeders
and boxes with infrared scanner
thermometer.

Comments:

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Module 3 - Plant Survey SURVEY FORM Figure 3.1

System: LIGHTING SYSTEM Location: Date:

Items Conditions Action Required

1. Is the illumination too high or too low for
the task? (Use illumination tables and
light meter.)

2. Is the illumination unnecessarily high in

seldom used areas of the facility?
(Warehouses, storage places, etc)

3. Are the reflectors of luminaires rusty and

dirty? Are the plastic lenses dirty and
turning green?

4. How many fluorescent lamps are flickering

or burned out?

5. Are the walls and equipment in the area

painted dark or covered with dirt?

6. Are the lights on even after working

hours?

7. Could the lighting fixtures be lowered to

increase the illumination or replaced by
task lighting?

8. Could more efficient lighting be used?

9. Is there a program to turn the lights off

when not needed?

10. Is parking lot and outside security lighting

controlled so it is shut off when not
needed?

Comments:

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Module 3 - Plant Survey SURVEY FORM Figure 3.1

System: COMPRESSED AIR Location: Date:

Items Conditions Action Required

COMPRESSORS - General data

How many compressors?

What type - stage?
Total horsepower?
Air cooled?
Pressure
Operating hours/day

Is air intake inside or outside the building?

Is the air filter clean?

What is the air temperature around the air

intake?

Is the compressor equipped with intercooler

and aftercooler?

Are the drive belts at the correct tension?

What is the temperature of cooling water in

and cooling water out?

What is the temperature of exhaust cooling

air?

Where does the cooling water go - is it

discharged or used in process?

What is the maintenance schedule for the

compressors?

Are the compressor accessories in good

working order, the traps, oil separators,
moisture separators, etc?

What is the pressure range (on-off) observed

on pressure gauge at receiver?

Comments:

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Module 3 - Plant Survey SURVEY FORM Figure 3.1

System: COMPRESSED AIR (cont'd) Location: Date:

Items Conditions Action Required

What type of air dryer is used?

Is the vibration of the compressor and piping

noticeable under load conditions.?

DISTRIBUTION

Have all the fittings, joints, flanges and flexible

connections been checked for air leaks with
soap solution?

< Are there any obvious large leaks in the

system?
< Is the condensate in the down leg of the
supply pipe blown off regularly?
< What is the pressure at the end use
equipment furthest from the compressor?

END USE

What is the main use for compressed air the

facility?

What is the rated pressure for the tool?

Is there oil in the air lubricators?

Is compressed air used for cooling or agitation

in the process?

Is the compressed air used for sweeping the

floors or cleaning of equipment?

Comments:

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Module 3 - Plant Survey SURVEY FORM Figure 3.1

System: STEAM DISTRIBUTION Location: Date:

Items Conditions Action Required

1. Are there any leaks in the steam

distribution or condensate return system?

< Record location

Are steam pipes and condensate return

pipe insulated?

< Record location of any deteriorating

insulation

2. Is there a regular steam trap checking

program?

Survey the system for obvious faulty traps

(Start with condensate collecting tanks.)

Check amount of steam being released by

vents. Steady heavy exhaust of steam out
of a vent may indicate leaky traps in the
system.

3. Is the maximum pressure of the end use

equipment well below the generated steam
pressure. If so, ask why?

< Could steam turbine be used to reduce

the pressure and generate power for
plant equipment?

4. If the steam is purchased, is there a heat

reclaim exchanger to heat the domestic or
process water. If not, should this be
investigated?

Comments:

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Module 3 - Plant Survey SURVEY FORM Figure 3.1

System: WATER DISTRIBUTION Location: Date:

Items Conditions Action Required

1. Is the water supplied by municipality or

own pumping system?

2. Is water used primarily for process or

sanitary purposes?

3. The process water:

< Could the process temperature be

lowered?
< Are there many leaks in supply
system?
< Can any of the water be recycled?
< Is too much hot water being sewered?
< Are any shut-off valves leaking?

Check the water meter when the entire

plant is shut off.

< Can cold water detergent be used in

some cleaning processes?

4. The domestic (sanitary) water:

< How is the water heated for domestic

applications - electric, gas, steam
heaters?
< Can the water be heated or preheated
by some other source such as air
compressors, refrigeration
compressors, or continuous
blowdown?
< Are there showers or faucets where
the addition of flow control devices
could save substantial amount of hot
water?

Comments:

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Module 3 - Plant Survey SURVEY FORM Figure 3.1

System: FUEL CONVERSION SYSTEMS Location: Date:

Items Conditions Action Required

THE HEATING PLANT

1. Record type of heating system and fuel

used.

2. Is there a proper record maintained on

operation of the boilers? If so, ask the
operator to explain various entries
particularly the overall efficiency, stack
temperature, boiler operating pressure and
feed water treatment and average oxygen
or carbon dioxide readings. High oxygen
readings (above 3%) indicates excess
combustion air.

3. What is boiler operating pressure, stack

temperature? The stack temperature
should be about 50EC above the operating
temperature of the boiler.

4. Are there any cracks around the boiler

door or any part of the boiler structure?

5. What is the % of continuous blowdown?

Is any of the heat in blowdown recovered?

6. If steam boiler used:

< What is the daily production of steam

in kg?
< How much make-up water is being
used?
< How much make-up water is being
treated?
< What is the primary use of steam?

Comments:

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Module 3 - Plant Survey SURVEY FORM Figure 3.1

System: DIRECT/INDIRECT FIRED SYSTEM Location: Date:

Items Conditions Action Required

1. Record type of equipment

< Process furnaces

< Kilns
< Dryers
< Heat treating
< Baking ovens
< Others

2. Operating temperatures

3. Flue gas temperature

4. Are the surfaces of the equipment too hot

to touch? (If they are, there is not enough
insulation on the equipment.)

5. Are there cracks or openings around the

furnace, doors and openings?

6. Any possibility of heat recovery - Is there a

place to use the recovered heat?

7. Is the equipment fully instrumented and all

the controls in operating order?

Comments:

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Module 3 - Plant Survey SURVEY FORM Figure 3.1

System/Use: REFRIGERATION Location: Date:

Items Type/Condition Action Required

1. Refrigeration system components:

< Evaporator
< Condenser
< Compressor
< Cooling Tower
< Other

2. Record pressures and temperatures:

< Compressor suction
< Condenser
< Water leaving condenser
< Ambient air (DB/WB)

3. Check the evaporator surfaces - Are they

free of ice and dirt?

4. What is the temperature in cold space?

Does it match the recommended product
temperatures? (The lower the
temperature the more expensive the
process.)

5. Is the cold space properly sealed? How

are the openings protected against warm
air infiltration?

6. Is the insulation in cold space kept in good

shape? No ice build-up on the walls.

7. Does the cold space have appropriate

lighting?

8. Are the condenser clean and cooling fans

unobstructed?

9. Is heat recovery from condenser feasible?

10. Is the refrigeration system checked

regularly for leaks and air infiltration?

11. Does the refrigerating system have

manual or automatic purge system?

12. Record any complaints about operation of

the refrigerating plant.

Comments:

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Module 3 - Plant Survey SURVEY FORM Figure 3.1

System: WASTE - SCRAP Location: Date:

Items Conditions Action Required

1. What kind of waste is generated at the

facility now?

< Wood for packaging

< Paper
< Plastics
< By-products of process

2. How is it being disposed of at present?

3. Does the company pay for the disposal of

waste?

4. Can some of the by-product of the

operation be sold?

5. Can generation of waste be reduced in the

plant?

6. If paper is the major waste product could it

be compressed and sold rather than
delivered at cost to the disposal site?

7. Is there enough waste generated to

warrant purchase of a incinerator with heat
recovery option?

Comments:

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Module 3 - Plant Survey Figure 3.2

SUMMARY ACTION FORM

Presented by: Henry Date: 1/2/96
Responsible Date
Priority System Action Required
for Action Start Finish

4 Ventilation Clean supply fan & Mike 22/2/96 2/3/96

check cause of vibration

1 Compressed Air Repair air leak located John 2/2/96 3/2/96

near Processor unit.

3 Insulation Repair damaged John 12/2/96 15/3/96

insulation on process hot
water pipe near Scalding

Replace/repair steam
2 Steam Distribution trap at HE#4 Mike 3/2/96 6/2/96

Comments:

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Module 3 - Plant Survey Figure 3.3

ENERGY MANAGEMENT OPPORTUNITIES

Presented by: J.D. Date: 1/2/96

SYSTEM EXISTING CONDITIONS:

The hotwell tank in the boiler house contains 85EC feedwater for the boiler. The tank is
not insulated. The surface area of the tank is 15 m2 and the system operates
approximately 6,000 hours per year.

Excessive heat energy is lost from the tank due to the lack of insulation.

RECOMMENDED IMPROVEMENTS:
It is recommended that the feedwater tank be lagged with mineral fiber insulation,
38 mm thickness, complete with protective canvass cover.

CALCULATED BENEFITS:
This measure will provide an annual energy reduction of 222 GJ, valued at
$17.80 per GJ. The total cost saving will be $3,950 per year.

IMPLEMENTATION COST:
The total cost to implement this measure is estimated at $4,750.

This cost is based on quotations for material and estimated labour costs for an outside
contractor.

SIMPLE PAYBACK or RETURN ON INVESTMENT:

The simple payback period is 1.2 years.

Cost $4,750
SPB ' ' ' 1.2 years
Annual Saving $3,950/yr

Comments:
Calculations for cost savings are attached.

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 SURVEY FORM
System: Location:
Date:

Items Conditions Action Required

Comments:

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 SUMMARY ACTION FORM

Presented by: Date:

Action Responsible Date

Priority System
Required for Action Start Finish

Comments:

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 ENERGY MANAGEMENT OPPORTUNITIES
Presented by: Date:

SYSTEM EXISTING CONDITIONS:

RECOMMENDED IMPROVEMENTS:

CALCULATED BENEFITS:

IMPLEMENTATION COST:

SIMPLE PAYBACK or RETURN ON INVESTMENT:

Comments:

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