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How it Works
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
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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
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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
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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.
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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.
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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.
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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
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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
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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
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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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