Industrial Assessment
Procedure
Once a manufacturing facility
has been selected for an assessment visit,
this procedure is followed:
Previsit
Site Visit
Introductory
Discussion
Plant
Tour
Information/Data
Gathering
Assessment
Review and Recommendation Development
Wrap-up
Meeting
After the Visit
Final Report
Previsit
Prior to a site visit,
the IAC staff confirms that the facility
is eligible for IAC Services by obtaining
and reviewing the plant's four-digit SIC
code, the number of employees, and the
annual sales. Several pieces of information
are requested from plant personnel including
a plant layout drawing or blueprint, operating
hours, shift information, building construction
characteristics, plant environment control,
and any available lists of major energy
consuming equipment.
The plant is requested
to supply a complete set of cost and quantity
of consumption records for all forms of
energy used at that location. This data
is analyzed in advance of the plant visit.
The cost and consumption data is graphically
displayed to show various trends and peaks
in usage, allowing for the identification
of the times when energy savings is at
its greatest (or least) potential.
Site
Visit
Once a plant has been
selected for an industrial assessment,
and the preliminary information has been
obtained and analyzed at the IAC, the
next action is to conduct the actual site
visit.
Introductory
Discussion
-
First, the assessment
team headed by either the IAC
Director or the Assistant Director,
provide a brief description
of the assessment process, and
information about the IAC program.
The preliminary information
obtained on the plant (SIC codes,
employees, sales, and energy
costs) is verified, and the
graphs of energy cost and consumption
are shown. The plant representatives
are then asked to discuss plant
operations, process equipment,
and various other energy-related
matters. Also discussed are
water costs, waste disposal
costs, and other concerns that
were identified in the pre-assessment
analysis. Finally a brief description
of the audit process is explained.
Plant
Tour
- Following the initial
meeting with plant personnel, the
audit team is conducted on a plant
tour in order to better understand
the process, and to determine the
flow of materials through the plant.
Notes are made of specific operations
or equipment identified during the
tour which may have possible energy
or waste saving potential.
Information/Data
Gathering
- Following the plant
tour, the assessment team discusses
areas of potential savings which
have been identified. Each potential
area is assigned to an individual
on the team for further investigation
and data collection. Measuring equipment
is utilized to record pertinent quantitative
information about the equipment in
the plant. Further discussions with
appropriate plant personnel about
specific equipment or processes may
also take place. In some cases, the
plant personnel may be requested
to assist in the actual measurements.
-
Combustion efficiency is measured
for all major fuel-burning equipment.
At a minimum, excess oxygen and stack
temperature are measured in oil and
gas boilers. Carbon monoxide and
carbon dioxide levels are measured
if necessary.
-
Efficiency and power factors of large
motors and motor-driven equipment
may be measured when there is reasonable,
safe access to power conductors.
Single-phase or three-phase measurements
can be taken as appropriate to obtain
the efficiencies and power factors.
Similar measurements are taken when
safe and practical for all other
large, electrically powered equipment.
Examples of such equipment include
arc furnaces, electrolytic cells,
infrared heaters, or induction heaters.
-
Other factors that affect energy
consumption are measured including
process temperatures, equipment temperatures,
and working temperatures in various
plant and office areas. Light levels
are measured in most areas of the
plant and offices. Air flow and ambient
temperature are measured to determine
efficiencies of HVAC systems throughout
the plant.
Assessment
Review and Recommendation Development
- After the measurements
have been completed, the members
of the IAC audit team meet to compile
their data, perform elementary analyses,
and prepare preliminary recommendations
based on the information collected.
The focus of the Assessment Recommendations
is to improve the plant's manufacturing
processes, operations and waste management.
Equipment modifications and replacements
are considered, as well as potential
changes in the plant operating schedule,
or operational procedures.
Wrap-up
Meeting
- Following the assessment
review, the team again asks to meet
with the plant representatives for
an informal discussion of the audit
procedure and any audit results obtained
so far. At this meeting potential
recommendations are discussed.
After
the Visit
- After the IAC staff
has thoroughly analyzed and evaluated
the plant operation and process equipment,
additional suggestions for improvements
may be made. The IAC staff also conducts
research after the audit visit, to
identify technological products or
processes that could help make the
particular plant's operation more
efficient and cost-effective. The
IAC staff then prepares a formal,
Final Report to be sent to the manufacturing
company. The report contains a description
of the plant operation, equipment,
energy costs, consumption patterns,
and assessment recommendations together
with detailed economic evaluations.
Final
Report
Two
copies of the final report are sent to
the manufacturing company within two months
of the site visit. A copy of the Final
Report, without the plant identification
information, is also sent to Rutgers University
for their review, suggestions, and final
approval. Non-proprietary data from the
report is entered into a U.S.
DOE Database at Rutgers University.
Basic information on the plant and
the assessment recommendations are
contained in this database based
on SIC code.
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