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[null,"ENERGY EFFICIENCY TOOLS FOR COMPRESSED AIR SYSTEMS"]
[null,"VER_01/150826"]
[null,"INTRODUCTION: This workbook consists of multiple tools that conduct Assessment of Compressed Air System, calculate Energy Performance of Compressors, and calculate Energy Saving Potentials in Compressed Air System"]
[null,"ISSUE:  Companies find it difficult to draw a baseline of performance of Energy Use. \n\nWHAT WE DO HERE:  Conduct Self-assessment of systems and facilities by rating the performance against each energy saving option in \"RATING\" column."]
[]
[]
[null,"HOW TO USE:"]
[null,"1. Insert data from your company in cells that are highlighted in white.\n2. Results of calculations will be displayed in Orange Cells.\n3. Examples of Data and Calculation are shown in each tool."]
[null,"SOURCES:"]
[null,"1. Compressed Air Best Practice Tool; Sustainable Energy Authority of Ireland (seai)\n2. Recuperable heat from compressors, Energy Agency NRW\n3. Compressed Air Systems in the European Union, EU 2001\n4. International Energy Agency (IEA)\n5. Energy Markets International Limited\n6. ISO 11011 Compressed air – Energy Efficiency – Assessment\n7. Energy Efficiency Guide for Industry in Asia – www.energyefficiencyasia.org\n8. US Department of Energy  – www.eere.energy.gov/industry\n9. Bureau of energy efficiency India \n11. Enorcon Pakistan \n12.  APO Japan\n13. Spirax Sarco International \n14. www.motorsmatters.org\n15. www.rapidtables.com\n16. Consortium for energy efficiency\n17. www.energy.gov\n18. Grundfos Academy\n\n"]
[null,"WHO WE ARE:"]
[null,"ESPIRE is a partnership project between the Training and Development Centers of the Bavarian Employers‘ Association (bfz) gGmbH and business associations in Lahore and Karachi in Pakistan. \n\nThe objective of ESPIRE project is to support industries in Pakistan to work economically more efficiently and ecologically more sustainable and start making energy conservation and cleaner production part of their work routine. \n\nMain project partners are; Pakistan Association of Automotive Parts and Accessories Manufacturers (PAAPAM), Pakistan Hosiery Manufacturers Association (PHMA), Pakistan Readymade Garments Manufacturers and Exporters Association (PRGMEA), Small and Medium Enterprises Development Authority (SMEDA), Towel Manufacturers Association of Pakistan (TMA).\n\nThe Project is funded by the German Federal Ministry for Economic Cooperation and Development (BMZ) via Sequa gGmbH."]
[null,"DISCLAIMER:"]
[null,"The information, calculations and conclusions in this tool are based on the projects executed by the experts and consultant under Project ESPIRE by bfz gGmbH – International Division. Some sources (as mentioned above) were also consulted to validate the contents. The efficiency improvement measures proposed in this tool are tested and tried in many companies in Pakistan. However, implementation of these measures in any particular case should be based on real time data analysis by qualified engineers after judging financial viability. Bfz gGmbH – International Division and it's Project Partners in Pakistan accepts no liability whatsoever to any person, company or entity for any injury, loss or damage that may arise in connection with any misuse or reliance on the information.\n\nThe tool is provided as a freeware. Users may make copies and distribute the tool without making any changes."]
[null,"CONTACT:"]
[null,"Users may contact following for any clarification, suggestion and/or improvement in this tool;"]
[null,null,"Muhammad Salman Butt\nProject Manager, Project ESPIRE\nbfz gGmbH International Division\n0092 300 4322343\nmsalmanbutt@hotmail.com","Sajid Mahmood Lakhan\nManaging Director\nGreen Energy Associates, Karachi\n0092 321 2117115\nsajid@gea.com.pk","Muhammad Farooq\nCEO\nEnergy Saving Solutions, Lahore\n0092 321 2117115\nfarooq.ess@gmail.com"]

{"sheet":"Tabelle3","index":1,"n_rows":7,"n_cols":1,"rows_kept":7,"cut":false,"hidden":true,"merged":[]}
[]
["Level"]
[1]
[2]
[3]
[4]
[5]

{"sheet":"Calor Val","index":2,"n_rows":14,"n_cols":3,"rows_kept":14,"cut":false,"hidden":true,"merged":[[2,1,2,3]]}
[]
[]
[null,"Net Calorific Values - Coal"]
[null,null,"toe/tonne"]
[null,"USA",0.64600000000000002]
[null,"India",0.47699999999999998]
[null,"South Africa",0.53500000000000003]
[null,"Australia",0.59199999999999997]
[null,"Russia",0.44400000000000001]
[null,"Poland",0.56999999999999995]
[null,"Kazakhstan",0.44400000000000001]
[null,"Ukraine",0.51600000000000001]
[null,"Germany",0.58799999999999997]
[null,"Others"]

{"sheet":"1| Checklist Boiler System","index":3,"n_rows":56,"n_cols":4,"rows_kept":56,"cut":false,"hidden":false,"merged":[[1,1,1,3],[47,2,47,3],[49,1,49,3],[44,1,44,3],[45,2,45,3],[46,2,46,3]]}
[]
[null,"CHECKLIST FOR HOT WATER & BOILER SYSTEM"]
[null,null,"ENERGY SAVING OPTIONS"]
[null,"LEVEL","PRODUCTION","RATING"]
[null,"-","Optimize boiler excess air, excess oxygen, and CO levels according to fuel type through boiler tuning based on Flue Gas Analysis [1% excess air reduction will increase 0.6% efficiency of combustion].","»"]
[null,"-","Insulate the Boiler surface completely and regularly monitor the surface temperatures to keep it close to Ambient Temperature.","»"]
[null,"-","Test Water Quality (feed water and Blow-down waste water) regularly to assess and maintain the efficiency of water treatment systems [Feed water and Blow-down TDS should be lesser than 100 ppm and 3500 ppm respectively].","»"]
[null,"-","Devise Blow-down cycle amounts and times based on water quality test to avoid the Blow-down loss.","»"]
[null,"-","Analyse the gap between the Generated and Demanded steam pressure and try to minimize it.","»"]
[null,"- -","Install automatic boiler Blow-down system.","»"]
[null,"- -","Separate fresh water from condensate water to avoid heat loss. Preheat fresh water before mixing with condensate water.","»"]
[null,"- -","Install stand-by feed water pump for contingency and to avoid any accidents.","»"]
[null,"- -","Keep stack temperature of Boiler as low as possible. Install a waste heat recovery system if the temperature of stack is more than 200°C.","»"]
[null,"- -","Install variable speed drives on Boiler Fans & Blowers.","»"]
[null,"- - -","Install waste heat recovery systems (exhaust air, blow-down) to preheat feed water or inlet air [20 degree Celsius rise in inlet air increases thermal efficiency by 1%].","»"]
[null,"- - -","Install micro modulation system with automatic excess air control and oxygen trimming.","»"]
[null,"- - -","Replace boiler if it is inefficient, over or under sized, and/or not fulfilling loading conditions. ","»"]
[null,null,"NETWORK","RATING"]
[null,"-","Regularly check steam distribution system for leakages and eliminate all steam leaks immediately.","»"]
[null,"-","Seal and insulate the Condensate tank completely to avoid heat loss.","»"]
[null,"-","Insulate all steam supply, condensate & feed water lines and fittings to avoid convection loss and keep the system pressure at optimum level.","»"]
[null,"-","Regularly monitor and maintain steam velocity and pressure drops within maximum allowable limits.","»"]
[null,"-","Avoid unnecessary Bends and Valves in the network.","»"]
[null,"-","Install all branch pipes upwards to avoid accumulation of condensate.","»"]
[null,"- -","Divide network in areas/sections to facilitate measurement and maintenance; shut off when not in use.","»"]
[null,"- -","Install all steam pipes with a fall of 1% [1:100] in direction of steam flow towards steam traps. ","»"]
[null,"- -","Reduce the length of the network to avoid pressure drops at far points.","»"]
[null,"- -","Regularly monitor and maintain steam traps.","»"]
[null,"- -","Install pipe sizes appropriate to the flow and pressure requirements.","»"]
[null,"- - -","Design a proper condensate return system to maintain the condensate temperature and reduce evaporation loss. Also consider pressurizing the condensate return system.","»"]
[null,null,"USE","RATING"]
[null,"- -","Regularly check steam distribution system for leakages and eliminate all steam leaks immediately.","»"]
[null,"- - -","Seal and insulate the Condensate tank completely to avoid heat loss.","»"]
[null,"- - -","Insulate all steam supply, condensate & feed water lines and fittings to avoid convection loss and keep the system pressure at optimum level.","»"]
[null,"- - -","Regularly monitor and maintain steam velocity and pressure drops within maximum allowable limits.","»"]
[null,null,"MAINTENANCE","RATING"]
[null,"-","Monitor condensate temperatures regularly and keep it below saturated steam temperature (there should be no steam in the returned condensate).","»"]
[null,"-","Regularly check the steam traps and repair or replace the failed steam traps.","»"]
[null,"-","Regularly monitor pressure drops in the steam distribution system (Pressure drop of steam should be below 0.1 bar per 50m of transmission).","»"]
[null,"-","Inspect boiler for scaling [indicators of scaling could be rise in flue gas temperature, imbalance between water intake and steam production, reduction in steam production. Every 22°C increase in temperature reduces thermal efficiency by 1%].","»"]
[null,"- -","Maintain cleanliness of boiler through feed water treatment (Reverse Osmosis, Chemical Treatment) to avoid fouling and/or scaling.","»"]
[null,"- -","Physically inspect boiler for scaling at least once a year and remove any scaling.","»"]
[null,"- -","Remove soot as it increases the stack temperature and reduces efficiency [every 3mm soot increases fuel consumption by 2.5%].","»"]
[]
[null,"LEVEL OF DIFFICULTY:"]
[null,"-","No/Low Cost or Short Term Investment [Pay-back period < 6 months]"]
[null,"- -","Medium Term Investment  [Pay-back period < 18 months]"]
[null,"- - -","Long Term Investment or Needs Feasibility Study  [Pay-back period > 18 months]"]
[]
[null,"RATING OF IMPLEMENTATION STATUS:"]
[null,null,"Energy Saving Option has not been considered yet.",1]
[null,null,"Energy Saving Option is in the planning stage but not yet realized.",2]
[null,null,"Energy Saving Option is partially (not in all areas/ machines or not all the time) implemented/ realized. ",3]
[null,null,"Energy Saving Option has been mostly implemented/ realized.",4]
[null,null,"Energy Saving Option is fully realized. ",5]
[null,null,null,"»"]

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[]
[null,"CHECKLIST FOR COMPRESSED AIR SYSTEM"]
[null,null,"ENERGY SAVING OPTIONS"]
[null,"LEVEL","PRODUCTION","RATING"]
[null,"-","Ensure compressors are only switched on if there is a demand for compressed air.","»"]
[null,"-","Match system’s air pressures with the lowest pressure practical for the application.","»"]
[null,"-","Provide cool inlet air (ventilation and compressed) to the compressors [4 degree Celsius rise in inlet air temperature increases the energy consumption by 1%].","»"]
[null,"-","Optimize the pressure stages of compressors considering the base load and peak load requirements.","»"]
[null,"-","Ensure proper operation of dryers and filters.","»"]
[null,"-","Ensure proper operation of low-flow blow down nozzles on compressed air systems.","»"]
[null,"- -","Investigate the use of a VSD/VFD based compressor.","»"]
[null,"- -","Design the header size to maintain air velocity below 6 m/sec and a maximum pressure drop of 2 psi in the compressor room.","»"]
[null,"- -","Check potential sequencing of compressors to operate most efficient compressors for total system air requirement.","»"]
[null,"- - -","Install a High Efficiency Motor on the compressor.","»"]
[null,"- - -","Recover waste heat from compressors to use for other heating operations.","»"]
[null,"- - -","Replace reciprocating compressors with high efficiency centrifugal compressors.","»"]
[null,null,"NETWORK","RATING"]
[null,"-","Avoid unnecessary bends and valves.","»"]
[null,"-","Keep the piping network rust-free by regularly maintaining moisture filters and condensate traps.","»"]
[null,"-","Install all branch pipes up-wards to avoid Moisture Accumulation.","»"]
[null,"-","Use leak-loss free condensate traps.","»"]
[null,"- -","Use closed loop piping network [reduces pressure Drop by 75%].","»"]
[null,"- -","Install pipe sizes appropriate to the flow and pressure requirements [Increasing pipe diameter from 1 ½” to 2” reduces Pressure Drop by 75%].","»"]
[null,"- -","Divide network in areas/sections to facilitate measurement, maintenance and shut off when not in use.","»"]
[null,"- -","Optimize air storage (location near equipment with high variation, size big enough to avoid regular frequent on/off).","»"]
[null,"- -","Design the piping to maintain air velocity below 9 m/sec and a maximum pressure drop of 3 psi to the farthest point of use.","»"]
[null,"- -","Install local compressor for High Pressure Demand equipment as a pressure booster [System pressure can thus be reduced to match base pressure requirements].","»"]
[null,"- - -","Reduce the length of the network to avoid pressure drops at far points.","»"]
[null,"- - -","Install all compressed air pipes with a fall of 1% [1:100] in direction of air flow.","»"]
[null,null,"USE","RATING"]
[null,"-","Eliminate wasteful practices, leaks, artificial demand and inappropriate use [e.g. for cleaning the floor].","»"]
[null,"-","Install pressure regulators at low-pressure requirement points.","»"]
[null,"-","Verify pressure requirements of end-use applications from their operations manuals.","»"]
[null,"- -","Segregate low & high pressure air requirements.","»"]
[null,"- -","Use blower air instead of compressed air (aeration in effluent treatment plants, drying applications, etc) [Saving potential is about 30%; blowers are available for pressures up to 1 bar in single stage and up to 2.2 bar in two stage design].","»"]
[null,"- -","Replace Pneumatic tools with hydraulic tools [Energy saving potential is about 30%].","»"]
[null,"- -","Replace pneumatic tools with electrical tools [Energy saving potential is about 50%].","»"]
[null,"- -","Replace pneumatic conveying by mechanical conveying [Energy Saving potential is about 30%]","»"]
[null,null,"CONTROL","RATING"]
[null,"- -","Install measurement equipment (flow meters, air meters, current meters, pressure gauges). ","»"]
[null,"- -","Assess performance of critical air demands and existing poor-performing end-use applications.","»"]
[null,"- -","Create and maintain an energy balance between supply and demand.","»"]
[null,"- -","Evaluate the system pressure profile and identify opportunities to eliminate pressure loss.","»"]
[null,"- -","Monitor and Calculate specific energy consumption (e.g. 7 kWh/m³/min by a loading factor of 80%).","»"]
[null,null,"MAINTENANCE","RATING"]
[null,"-","Regularly inspect and clean air inlet filters.","»"]
[null,"-","Regularly check the joints, valves, filters and connectors for leakages and eliminate all leakages immediately.","»"]
[]
[]
[null,"LEVEL OF DIFFICULTY:"]
[null,"-","No/Low Cost or Short Term Investment [Pay-back period < 6 months]"]
[null,"- -","Medium Term Investment  [Pay-back period < 18 months]"]
[null,"- - -","Long Term Investment or Needs Feasibility Study  [Pay-back period > 18 months]"]
[]
[null,"RATING OF IMPLEMENTATION STATUS:"]
[null,null,"Energy Saving Option has not been considered yet.",1]
[null,null,"Energy Saving Option is in the planning stage but not yet realized.",2]
[null,null,"Energy Saving Option is partially (not in all areas/ machines or not all the time) implemented/ realized. ",3]
[null,null,"Energy Saving Option has been mostly implemented/ realized.",4]
[null,null,"Energy Saving Option is fully realized. ",5]
[null,null,null,"»"]

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[]
[null,"CHECKLIST FOR LIGHTING SYSTEM"]
[null,null,"ENERGY SAVING OPTIONS"]
[null,"LEVEL","DESIGN / PURCHASE","RATING"]
[null,"- -","Design lighting layout to fulfill standard light level requirements of the process.","»"]
[null,"-","Select height of lighting according to location and luminance requirement.","»"]
[null,"-","Identify lights with low energy efficiency and replace with energy efficient lights [e.g. Electronic Ballast, LEDs, T5 Tube Lights, etc.]","»"]
[null,"-","Compare life-cycle cost of available alternate lights while purchasing and do not make your decision based on purchase price only [Consider Demand Power, Life Time, Luminance Levels, Color Rendering Index, Replacement Cost, Warrant, etc.].","»"]
[null,"- -","Install proper fixtures aided with reflectors for all lights.","»"]
[null,"- -","Install lights close to the workplace to meet the required light level and to reduce the quantity of required lights.","»"]
[null,null,"USE","RATING"]
[null,"-","Switch off all lights in unoccupied/unattended areas.","»"]
[null,"-","Balance the lighting load on three phases to avoid phase imbalance and reduce voltage fluctuations.","»"]
[null,"-","Regularly clean the lights and reflectors to maintain luminance levels and improve life of lights.","»"]
[null,"- -","Maximise sunlight utilization to reduce light consumption while keeping in mind the air conditioning requirements.","»"]
[null,"- -","Use day light linked control, which will decrease use of lightings with increases in sun light. ","»"]
[null,"- -","Adopt Control Systems, such as voltage reduction, motion detectors, light sensors, time switches, de-centralized switching, etc. to improve energy performance.","»"]
[]
[null,"LEVEL OF DIFFICULTY:"]
[null,"-","No/Low Cost or Short Term Investment [Pay-back period < 6 months]"]
[null,"- -","Medium Term Investment  [Pay-back period < 18 months]"]
[null,"- - -","Long Term Investment or Needs Feasibility Study  [Pay-back period > 18 months]"]
[]
[null,"RATING OF IMPLEMENTATION STATUS:"]
[null,null,"Energy Saving Option has not been considered yet.",1]
[null,null,"Energy Saving Option is in the planning stage but not yet realized.",2]
[null,null,"Energy Saving Option is partially (not in all areas/ machines or not all the time) implemented/ realized. ",3]
[null,null,"Energy Saving Option has been mostly implemented/ realized.",4]
[null,null,"Energy Saving Option is fully realized. ",5]
[null,null,null,"»"]

{"sheet":"4| Checklist Motor System","index":6,"n_rows":50,"n_cols":4,"rows_kept":50,"cut":false,"hidden":false,"merged":[[43,1,43,3],[1,1,1,3],[38,1,38,3],[39,2,39,3],[40,2,40,3],[41,2,41,3]]}
[]
[null,"CHECKLIST FOR ENERGY SAVING OPTIONS IN THE MOTORS"]
[null,null,"ENERGY SAVING OPTIONS"]
[null,"LEVEL","DESIGN / PURCHASE","RATING"]
[null,"-","Develop purchasing specification of all motors including criterion to judge energy performance.","»"]
[null,"-","Compare life-cycle cost of available alternate motors while purchasing and do not make your decision based on purchase price only [A motor consumes energy equal to its purchase price in less than 2 months].","»"]
[null,"-","When purchasing a large number of small motors or a large motor, ask for a detailed test certificate.","»"]
[null,"-","For optimum efficiency, select motor size appropriate to the load.","»"]
[null,"- -","Investigate use of multi speed motor for variable load conditions.","»"]
[null,"- - -","Check technical and financial feasibility of using energy-efficient motors","»"]
[null,"- - -","Where possible, investigate installing a Direct Current (DC) motor instead of Alternating Current (AC) motor.","»"]
[null,null,"USE","RATING"]
[null,"-","Prepare and regularly update Inventory of installed motors in the facilities, including their design parameters, locations of installation and maintenance record.","»"]
[null,"-","Ensure a balanced power supply to motors with balanced voltage across phases [An imbalanced voltage can de-rate motor by 3 – 5%].","»"]
[null,"-","Ensure power supply to motors is within recommended voltage limits [5% or more voltage drop observed at motor input, while motor shifts to high load, indicates undersized cables].","»"]
[null,"-","Check load conditions of motors and identify overloaded and underloaded motors [A change in motor load indicates a possible change in the driven load].","»"]
[null,"- -","Convert lightly loaded motors [below 30% of rated power] from Delta to Star connection [Star connection reduces the voltage across the motor windings to 58% of the Delta connection].","»"]
[null,"- -","Install Variable Speed Drive (VSD) for variable load or lightly loaded motors. ","»"]
[null,"- -","Use synchronous motors to improve power factor.","»"]
[null,"- -","Investigate machine-side inefficiencies, such as idle operations, throttling of pumps, damper operations in fans, leakages, etc.","»"]
[null,null,"SAFETY and MAINTENANCE","RATING"]
[null,"-","Ensure good housekeeping conditions and proper ventilation for motors [For every 10°C increase in motor operating temperature over recommended peak, the motor life is estimated to be reduced by 50%].","»"]
[null,"-","Ensure appropriate lubrication as per manufacturers' recommendations.","»"]
[null,"-","Ensure that supply wiring and terminal boxes are properly sized and installed.","»"]
[null,"-","Inspect regularly the connections at the motor and starter to be sure that they are clean and tight.","»"]
[null,"-","Identify motors with low voltage, low power factor and voltage imbalance and immediately take improvement measures.","»"]
[null,"-","Develop a motor assessment programme and identify motors with rising temperature, high noise, high vibration and increased power consumption.","»"]
[null,"-","Develop and implement a predictive and preventive maintenance programme.","»"]
[null,"-","Inspect motors regularly for wear in bearings and housings and for dirt/dust in motor ventilating ducts to ensure proper heat dissipation.","»"]
[null,"-","Develop guidelines for proactive repair/replace decisions, based on operating and maintenance cost and energy performance.","»"]
[null,"- -","Periodically check alignment of the motor and the driven equipment [Improper alignment can cause shafts and bearings to wear quickly, resulting in damage to both the motor and the driven equipment].","»"]
[null,"- -","Periodically check motor load at Zero-load condition [Motors consuming 5% or more power at Zero-load conditions indicate increased losses and should be replaced].","»"]
[null,"- -","Check and maintain motor efficiency after repair or maintenance [e.g. If rewinding is not done properly, the efficiency can be reduced by 5 – 8%].","»"]
[null,"- -","Avoid frequent rewinding of motors. The greater the number of rewinds, the lesser the efficiency.","»"]
[null,"- -","Identify and investigate cases of repeated motor failure and take immediate improvement measures.","»"]
[null,"- -","Provide interlock for electric motors to avoid idle running.","»"]
[null,"- - -","Replace eddy current controls with variable frequency drives for varying speed driven equipment.","»"]
[]
[null,"LEVEL OF DIFFICULTY:"]
[null,"-","No/Low Cost or Short Term Investment [Pay-back period < 6 months]"]
[null,"- -","Medium Term Investment  [Pay-back period < 18 months]"]
[null,"- - -","Long Term Investment or Needs Feasibility Study  [Pay-back period > 18 months]"]
[]
[null,"RATING OF IMPLEMENTATION STATUS:"]
[null,null,"Energy Saving Option has not been considered yet.",1]
[null,null,"Energy Saving Option is in the planning stage but not yet realized.",2]
[null,null,"Energy Saving Option is partially (not in all areas/ machines or not all the time) implemented/ realized. ",3]
[null,null,"Energy Saving Option has been mostly implemented/ realized.",4]
[null,null,"Energy Saving Option is fully realized. ",5]
[null,null,null,"»"]

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[]
[null,"CHECKLIST FOR POWER GENERATION & DISTRIBUTION"]
[null,null,"ENERGY SAVING OPTIONS"]
[null,"LEVEL","POWER GENERATION","RATING"]
[null,"-","Install power factor correction equipment to avoid penalties from utility supplier, reduce distribution losses and demand load on captive generation.","»"]
[null,"-","Periodically monitor combustion efficiency of power plant and optimize Air:Fuel ratio.","»"]
[null,"- -","Consider alternative fuel options [Price, stability of supply, storage requirements, market access] before selecting the type of power plant.","»"]
[null,"- -","Select power plant appropriate to load requirement [Efficiency drops considerably when engines run below 80% load].","»"]
[null,"- -","Consider fuel oil additives in case they benefit fuel oil properties for diesel generator usage.","»"]
[null,"- -","Use engine/turbine Jacket Cooling Water for heat recovery, vapour absorption system adoption.","»"]
[null,"- -","Synchronize the engine operation for improved loading and fuel economy.","»"]
[null,"- -","Install waste heat recovery system on power plants for steam generation or any other appropriate use in case of a base load operation.","»"]
[null,"- -","Investigate options for exporting power to national grid if you have any surplus in your captive generation.","»"]
[null,null,"DISTRIBUTION NETWORK","RATING"]
[null,"-","Check system for undersized cables according to current flow requirements [Indicator: Significant voltage drop when drive goes on-load].","»"]
[null,"-","Shift non-critical / non-continuous process loads to off-peak time.","»"]
[null,"-","Operate AC units during off-peak times and utilize cool thermal storage.","»"]
[null,"- -","Maintain MDI Load Factor [Ratio between MDI (kW) and Average Running Load (kW)] near to unity by proper load management.","»"]
[null,"- -","Minimise Minimum Demand Indicator (MDI) by tripping loads through a demand controller","»"]
[null,"- -","Keep Incoming Voltage fluctuations from captive power plants within 5% for proper operation of facilities.","»"]
[null,"- -","Stagger start-up times for equipment with large starting currents to minimize load peaking.","»"]
[null,"- - -","Check feasibility of relocating transformers close to main loads to reduce transmission losses.","»"]
[null,null,"SAFETY & CONTROL","RATING"]
[null,"-","Provide cold, dust free air at intake (use of air washers for large sets, in case of dry, hot weather, can be considered)","»"]
[null,"-","Ensure that fuel oil storage, handling and preparation are as per manufacturers' guidelines and Safety Data Sheets.","»"]
[null,"-","Ensure steady load conditions, avoiding fluctuations, imbalance in phases and/or harmonic loads.","»"]
[null,"-","Maintain the frequency of electricity close to the recommended frequency of electric drives [1% higher frequency for Centrifugal Load means approx. 3% more Energy Consumption at Demand Side].","»"]
[null,"-","Implement Good Housekeeping on electric installations (especially cables and distribution boards) to avoid any transmission losses and fire hazards.","»"]
[null,"-","Check and verify phase-to-phase voltage difference and maintain within 1%.","»"]
[null,"-","Current imbalance among 3 phases should be maintained within 5% [This can be done by balancing the single phase load installed on each phase; current imbalance also causes voltage imbalance].","»"]
[null,"-","Check and verify that the voltage drops from supply till demand are maintained within 2.5% [5% voltage drop may result in 2 to 4 point loss in efficiency and 10 to 11 ºC increase in temperature; 1 ºC increase in temperature means 0.5 % efficiency loss].","»"]
[null,"-","Ensure that high voltage transformer stations are secure, keep locked and are only accessible to the authorised persons. ","»"]
[null,"-","Use trays for cables distribution.","»"]
[null,"-","Regularly check for the air & flue gas leakages [leakages in air & flue gas path increases fan loading]. ","»"]
[null,"- -","Inspect and replace oversized FD and PA fan [Many thermal power plants have oversized fans causing a huge difference between design and operating point, which leads to lower efficiency].","»"]
[]
[null,"LEVEL OF DIFFICULTY:"]
[null,"-","No/Low Cost or Short Term Investment [Pay-back period < 6 months]"]
[null,"- -","Medium Term Investment  [Pay-back period < 18 months]"]
[null,"- - -","Long Term Investment or Needs Feasibility Study  [Pay-back period > 18 months]"]
[]
[null,"RATING OF IMPLEMENTATION STATUS:"]
[null,null,"Energy Saving Option has not been considered yet.",1]
[null,null,"Energy Saving Option is in the planning stage but not yet realized.",2]
[null,null,"Energy Saving Option is partially (not in all areas/ machines or not all the time) implemented/ realized. ",3]
[null,null,"Energy Saving Option has been mostly implemented/ realized.",4]
[null,null,"Energy Saving Option is fully realized. ",5]
[null,null,null,"»"]

{"sheet":"6| Checklist Pumping System","index":8,"n_rows":49,"n_cols":4,"rows_kept":49,"cut":false,"hidden":false,"merged":[[42,1,42,3],[1,1,1,3],[37,1,37,3],[38,2,38,3],[39,2,39,3],[40,2,40,3]]}
[]
[null,"CHECKLIST FOR PUMP & PUMPING SYSTEM"]
[null,null,"ENERGY SAVING OPTIONS"]
[null,"LEVEL","DESIGN / PURCHASE","RATING"]
[null,"-","Select pump size appropriate to the load for optimum efficiency. Avoid purchasing of oversized or undersized pumps.","»"]
[null,"-","Select the pump type appropriate to the requirement i.e. axial, centrifugal etc. with right impeller size.","»"]
[null,"-","Ensure that the selected pump is compatible with variable-speed drives.","»"]
[null,"-","Ensure basic instrumentation of pumps [e.g. pressure gauges, flow meters, energy meters, etc.]","»"]
[null,"-","Reduce system resistance by pressure drop assessment and selection of right pipe size and material.","»"]
[null,"- -","Optimise the plant design and pipe layout to minimize pumping need and pressure losses. Maximize the pipe diameter.","»"]
[null,"- -","Develop purchasing specifications of all pumps, including criterion to judge energy performance.","»"]
[null,"- -","Setup multiple sized pumping system for varying flows.","»"]
[null,null,"USE","RATING"]
[null,"-","Conduct water balance analysis to identify wastages and ensure that the system is balanced in order to minimize flows and reduce pump power requirements.","»"]
[null,"-","Ensure that the pumping demand  is reduced and system has a low required flow rate.","»"]
[null,"-","Ensure that the operating pressure of the pumping system is kept low.","»"]
[null,"-","Avoid using bypass lines and throttle valves. Instead minimise pressure losses through valves and fittings.","»"]
[null,"-","Optimise number of stages in multi-stage pump in case of head margins.","»"]
[null,"-","Increase fluid temperature differential to reduce pumping rates in case of heat exchangers.","»"]
[null,"- -","Adapt to wide load variation with variable speed drives or sequenced control of multiple pumping units.","»"]
[null,"- -","In the case of over designed pump, provide variable speed drive, or downsize / replace the impeller or replace it with the correct sized pump for efficient operation.","»"]
[null,"- - -","Use booster pumps for small loads that require higher pressures or higher heads.","»"]
[null,null,"SAFETY & MAINTENANCE","RATING"]
[null,"-","Regularly monitor pumping efficiency and energy performance of pumping system.","»"]
[null,"-","Monitor vibration of pumps periodically, identify pumps with increased vibration and take immediate corrective and preventive action.","»"]
[null,"-","Monitor differential head and temperature rise across the pump (also known as thermodynamic monitoring). ","»"]
[null,"-","Perform distribution system inspection for scaling or contaminant build-up. ","»"]
[null,"-","Check and maintain pump efficiency after repair or maintenance. ","»"]
[null,"-","Monitor leaks in pumps regularly and immediately fix identified leaks.","»"]
[null,"-","Conduct bearing inspection for increased noise and repair / replace based on conditions.","»"]
[null,"-","Ensure bearing lubrication replacement, once annually or semi-annually based on prevailing conditions or as per manufacturer's guidelines.","»"]
[null,"-","Put pressure or flow sensors in the location that will help ensure process requirements are met without excess pumping energy.","»"]
[null,"-","Replace worn impellers, especially in caustic or semi-solid applications. ","»"]
[null,"-","Inspect pumps for wear in seals, rings, impellers and bearings and take immediate corrective and preventive measures.","»"]
[null,"-","Develop and implement a predictive and preventive maintenance programme.","»"]
[null,"-","Develop guidelines for proactive repair/replace decisions based on operating and maintenance cost and energy performance.","»"]
[]
[null,"LEVEL OF DIFFICULTY:"]
[null,"-","No/Low Cost or Short Term Investment [Pay-back period < 6 months]"]
[null,"- -","Medium Term Investment  [Pay-back period < 18 months]"]
[null,"- - -","Long Term Investment or Needs Feasibility Study  [Pay-back period > 18 months]"]
[]
[null,"RATING OF IMPLEMENTATION STATUS:"]
[null,null,"Energy Saving Option has not been considered yet.",1]
[null,null,"Energy Saving Option is in the planning stage but not yet realized.",2]
[null,null,"Energy Saving Option is partially (not in all areas/ machines or not all the time) implemented/ realized. ",3]
[null,null,"Energy Saving Option has been mostly implemented/ realized.",4]
[null,null,"Energy Saving Option is fully realized. ",5]
[null,null,null,"»"]