Step 1 − Lighting

Definitions

explanation of words

  • Incandescent lamp
  • T8 fluorescent lamp
  • Metal halide lamp

What do we get?

What are we doing?

Example

Part I: Instructions

Please read the instruction below carefully before filling the data
  • 1 Please answer yes/no question related to Lighting.
  • 2 Read carefully the options we provide

Part II: Data-filling steps

Is there lighting at non-working areas?
Yes No
  • Manual switch-off
  • Installation of photoelectric sensor set (suitable for lobby area, storage, pumping stations, meeting rooms, etc.)
Still use incandescent lamps for lighting?
Yes No
  • Replace incandescent lamps with T8 fluorescent lamps (integrated electronic ballast) - power consumption may decrease by 50%
  • Installation of photoelectric sensor set (suitable for lobby area, storage, pumping stations, meeting rooms, etc.)
Still use fluorescent lamps with magnetic ballast?
Yes No
  • Replace with T8 fluorescent lamps using electronic ballast (efficiency may increase by 35-45%)
  • Replace the magnetic ballast with an electronic one (efficiency may increase by 10-25%)
Still use mercury lamps?
Yes No
  • Replace with high-efficiency metal halide lamps (efficiency may increase by 80%) for those areas that need colour light (e.g. product control area)
  • Replace with T8 fluorescent lamps using electronic ballast

Direct result

Next to here all aspects of swot analysis are shown. Examine this list, since it can improve your business a lot.
100%

Solution

Step 2 − Power

Definitions

explanation of words

  • Power factor cos F
  • The power load
  • Day-night power load chart
  • Peak power load

What do we get?

What are we doing?

Example

Part I: Instructions

Please read the instruction below carefully before filling the data
  • 1 Please answer yes/no question related to Power.
  • 2 Read carefully the options we provide

Part II: Data-filling steps

Are there peak power loads?
Yes No
  • Develop a plan to effectively control power loads: Move non-essential loadsand interrupted processes to off-peak hours, disconnect non-essential loads during peak hours
Has your company ever been fined (or had to purchase reactive power) because your power factor (cos Φ) was low (= 0,85)?
Yes No
  • Install capacitors to increase the power factor cos Φ (best cos Φ = 0,85-0,95)
Do your electric motors operate at reduced load?
Yes No
  • Reduced load below 40% of the installed capacity: may apply an effective and inexpensive method of changing from standard triangular wiring to star wiring (only re-wiring at the connection box).
  • Should replace with motors of suitable capacity if frequent operating at reduced load
  • Re-arrange production plan to ensure motor load higher than 60%
Any engines running when device or process is operating at no-load?
Yes No
  • Minimize no-load operating time such as shutdown during lunchtime or breaks
  • Install automatic sensor to automatically disconnect when machines operate at no-load
Does your company use rewinded motor?
Yes No
  • Have engine wires re-wrapped by good technical services to maintain engine performance
  • If the cost for re-wrapping exceeds 50% - 65% of the price for a new high-capacity engine, you should buy the new one. Higher reliability and performance will quickly offset the price difference
  • Replace with higher-capacity engines
Does your company still use common motors?
Yes No
  • Replace the common motors with high-efficiency ones. The range of installed capacity and full load level of high-efficiency motors are large. Their efficiency is 3-7% higher than that of common motors. The cost of high-efficiency motors is certainly higher than that of the common ones, but this higher cost will be quickly paid back through reduced operating cost, especially with the demand for new purchase or replacement of expired motors.
Are the motors placed in areas of poor ventilation, bad environment (under direct sunlight, thickly covered with dust and grease...)?
Yes No
  • Perform proper maintenance to maintain engine performance (regularly do the tear/wear check on the motor drive shaft and case to reduce losses due to friction; check dust and dirt in the motor's wind tunnel to ensure heat release; ensure that the motor is sun-shielded and periodically lubricated according to the manufacturer's instructions...
Are the belts loose?
Yes No
  • Retighten the belts or replace with new ones

Direct result

100%

Solution

Step 3 − Thermal energy

Definitions

explanation of words

  • Industrial boiler
  • Steam distribution system
  • Condensed water

What do we get?

What are we doing?

Example

Part I: Instructions

Please read the instruction below carefully before filling the data
  • 1 Please answer yes/no question related to Thermal energy.
  • 2 Read carefully the options we provide

Part II: Data-filling steps

Is the temperature of boiler's body higher than 500C (touch sense)?
Yes No
  • Heat loss by radiation and convection is large due to poor insulation of the boiler or it is broken, hence it is necessary to ensure better insulation of the boiler
Is the steam distribution system (along the pipes, on the pipe joints, or valves ...) deflated?
Yes No
  • Check and seal the leak(s)
Are many parts of the steam pipe not insulated?
Yes No
  • Perform proper insulation for non-insulated parts or repair insulation layers that are broken
Are there compressed air leaks in the air compressor systems?
Yes No
  • Check and seal the leak(s)
Do worker use the compressed air for improper purposes (such as clothes cleaning or cooling)?
Yes No
  • Provide training and regulations on using compressed air
Is the temperature of boiler flue gas higher than 2500C?
Yes No
  • Clean the heat transfer surfaces (possibly covered with soot or residual water)
  • Make use of the waste heat of the boiler flue gas to heat water supplied to the boiler or heat air supplied to the boiler to reduce fuel consumption and increase its efficiency
Is the boiler's flue gas in dark color?
Yes No
  • The combustion is not entirely done due to insufficient supply of air for combustion (or excess air ratio is lower than requested). It is necessary to check the fan to adjust proper flow for blower and exhaust fans, by which ensuring excess air ratio.
  • If the fuel type is coal, it is necessary to check and improve the boiler grate in order to make good contact between the fuel and the air
Is condensed water from devices that indirectly use the steam wasted direcly into the company's drainage system?
Yes No
  • It is necessary to install a system that recollects condensed water and supplies it back to the boiler as condensed water of high temperature will help reduce the amount of fuel and water needed to supply to the boiler

Direct result

100%

Solution

What's next?

1-on-1 Consultancy

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E-library

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Implementation form

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Stakeholders

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Added Value

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