Have boilers turned up to save energy and money. Replace old combustion systems with new burners and combustion controls. This can reduce fuel consumption. Remember to check on permit requirements when making changes. Small increases in combustion efficiency can translate into significant savings on your gas bill … and you may qualify for DTE rebates.
Bleed trapped air from hot-water radiators once or twice a season; if in doubt about how to perform this task, call a professional.
Compressors
Proper type and sizing of compressors can reduce system operational cost. The most common source of energy loss is the easily repaired air leak and misuse of compressed air. Some examples are continuous blow offs, or the lack of blower use to replace continuous blow offs. Also, keep in mind that 80% of the compressor energy ends up as heat in your plant. By capturing and using the compressor heat, you should be able to lower your heating costs. You should save 1% energy cost for each 2psi when the system pressure is lowered. By using blow off nozzles, you may be able to qualify for a DTE rebate. Centrifugal compressors are very expensive to run when blowing off.
Chillers
Replace older chillers with the newer high efficiency models. You may then qualify for an EPACT 2005 federal tax deduction and DTE rebate, plus this is a chance to replace older CFC units. Now is a good time to consider replacing HCFC units as part of a phase out process.
Water Treatment
Require your service provider to use products that are environmentally- friendly, like ozone gas, and ultraviolet light, and use the products in the proper amounts to reduce water consumption.
Cooling Towers
Look for towers with VFD tower fans and VFD circulating pumps. Proper placement of the towers is important for efficient operation. Try to keep a minimum head for the tower pump’s discharge. VFD controls can replace older electrical fan controls ( high speed starter, low speed starter, reverse starter, timers for change of speed and directions, relays) with logical control, saving enough to nearly cover the cost of a VFD control. VFD controls take the starting shock out of the mechanical system, helping to lower maintenance.
Energy Efficient Motors
Motors that are at minimum 30 hp and run 24 hours a day, at least five days per week are good targets for replacement. The new energy efficient motors can pay for themselves in several years – the premium can be paid for in little over one year. A typical 2% increase in efficiency at $.10 kwh for one of these new models translates into a $313 per year cost savings. There are DTE rebates for energy efficient motors, and an EPACT 2005 federal tax deduction may be used.
Variable Frequency Drive Motors
Spec out an inverter grade duty motor for VFD to avoid electrical problems. It is not uncommon for older motors to fail within a year or two after being hooked up to a VFD, due to carrier voltage and frequencies.
Energy Efficient Valves
Control valves should normally operate in a 20%, give or take 5%, range; otherwise they may be improperly sized or set up incorrectly. This may be an ideal time to consider a VFD pump. It is not uncommon for a full ported ball valve to cost less than a gate valve. Full ported ball valves put less resistance in the piping system, thereby reducing pumping cost.
Piping
Size your piping for future needs, so that you don’t have an excessive pressure drop resulting in added pumping expense and operational problems. You want minimum fitting flow resistance and dead headed tees. Life cycle cost may justify larger piping or even stainless steel piping.
Automated Controls
In too many cases control loops are turned off. Make sure your control loops are operating properly and keeping energy costs in check.
