Energy management

Primary Action plan

1. Furnace
Use of improved controls such as pulse firing which can help in continues operations Heating system: proper spacing of electrilcal elements, cleaniing of heating elements, shield elements to avoid possible shorting due to mismanaged load, Airfuel ratio control, Use of O2 enrichment, Air preheating, Flame size and shape Heat transfer: frequent cleaning of heat transfer surfaces ( rediant tubes, electrical tubes), Enhanced heat transfer, Temperature profile control, Optimal process atmosphere Heat containment: properly installed-better-higher value-Optimum insulation, use Rediation shields-insulations and seals to avoid radiation losses and air leaks, Pressure control, Cracks or openings, etc Waste heat recovery: combustion air preheating using flue gases, charge or load prehating using furnace flue gases or separate heating system, use of waste heat boiler for large continues reheat furnaces, steam generation, heat cascading(heat from furnace exhaust gases is transferred to the low temperature processes), etc Control system: draft pressure control, controlled head heating, burner firing control (pulse), use of process models, etc Emmissions: use of low Nox burners, control to eliminate rich firing (no soot or CO etc.) Use of proportional controls Vs on-off controls Use of more natural light in shop-floor Awareness campaign in office and shop floor and display boards to save energy Installation of movement sensors in office and out door Replacing incandescent or halogen lights with CFLs and LEDs when required to change (http://catalogs.indiamart.com/products/motion-sensor-light.html ) Installation of reflectors Electric motor systems: use adjustable speed drives (ASDs) or two speed motors where aprppriate, Use of controls to turn of idling motors, Consider replaceing V belts with cogged belts, choose energy efficient motors for new applications Compressed air systems: check identify and repair leaks, review air pressure requirements and use lower pressure blowers whereever possible, proper control of moisture control system to eliminate exssessive moisture and contaminants in compressed air, etc Pumping systems: use adjustable speed drives or parallel ppumps to meet variable flow requirements, use automatic start or manually turn off a pump that is used intermittently or occasionally, clean pipe sustemto reduce frictional losses, etc Instructions on every machine on shop floor about time more than which it should not run idle and should be turned off in such cases.

2. Lightings

3. Industrial equipments

4. Business equipments
Activation of standby mode on all office computers with the help of SIG Activation of timers to turn off large printers and copiers with the help of SIG Procuring laptops instead of desktops when it needs to be replaced Procuring inkjet printers instead of LASER printers when it needs to be replaced Ensure that heating and cooling are adjusted each summer and winter. Ensure that all door closers are working properly Check location of thermostats and change it in case requires Check insulation of furnaces and ceiling In winter keep doors and windows open for fresh air

5. Heating and cooling

References:
http://www.powerdirect.com.au/energy-saving-tips-for-businesses/w1/i1012514/ http://www.business.qld.gov.au/business/running/environment/energy-saving-ideas/saving-energy-tips http://www2.warwick.ac.uk/about/environment/energy/whattodo/switch_it_off_-_office.pdf http://www1.eere.energy.gov/manufacturing/