ALGORITHM OF CHARACTERIZATION INDUSTRIAL SECTORS. Author: Juan Aranda Abel Ortego. date October Zaragoza

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2 ALGORITHM OF CHARACTERIZATION INDUSTRIAL SECTORS Author: Juan Aranda Abel Ortego date October 2012 Zaragoza

3 Food ector 15.1 Meat indutry 15.3 Fruit and Vegetable 15.4 Fat and oil 15.7 Animal food / Patry, bakery and confectionery alcohólic drink Mineral water and non-alcoholic drink Metal 28.2 Metal tank and container 28.4 Iron cating, metal printing and drawing Metal coating and urface treatment 28.7 Metal product manufacturing (except furniture) 29.1 Machinery and mechanical equipment manufacturing 29.2 Other Machinery and general purpoe mechanical equipment manufacturing 29.3 Farming machinery manufacturing Other pecific-purpoe machinery manufacturing Chemical ector 24.1 Baic chemitry manufacturing Manufacturing of peticide and other agro-chemical product 24.3 Manufacturing of paint, varnihe, coating, printing ink and putty Manufacturing of pharmaceutical product 24.5 Manufacturing of oap, detergent and other cleaning and polihing item. Manufacturing of beauty and hygiene product Manufacturing of other chemical product 24.7 Manufacturing of man-made ynthetic fiber n metalic mineral indutry 26.1 Manufacturing of gla and gla product 26.2 Manufacturing of ceramic product, not related to contruction 26.3 Manufacturing of ceramic tile 26.4 Manufacturing of brick, roof tile and terracota product for contruction Textile 17.1 Textile fiber manufacturing 17.2 Textile tiue manufacturing 17.3 Textile Finihing platic 25.2 Platic material product

4 ALGORITHM OF CHARACTERIZATION FOOD SECTOR

5 GENERAL INFORMATION. COMPANY NAME * VAT NUMBER* CUPS CONTACT PERSON * ADDRESS * TEL * REGION / DEPARTMENT * FAX * TOWN * POSTAL CODE * NACE CONCRETO DE LA EMPRESA * (LISTA DESPLEGABLE) HOURS/DAY OF ACTIVITY * NUMBER OF WORKING DAYS PER YEAR * NUMBER OF WORKERS * COMPANY INCOMES * LOGIN * PASSWORD * repeat PASSWORD * COMPULSORY DATA *

6 GENERAL INFORMATION. ADDITIONAL QUESTION Ak thi quetion to all companie I there an Energy Manager in the company? THIS GROUP IS DIVIDED INTO 2 CATEGORIES WITH DIFFERENT QUESTIONS group 1: NACE 153,154 and 157 group 2: NACE 151,158 and 159 Recommendati on 1

7 INITIAL INFORMATION TO COLLECT: Quantity of final product per year m 3 /year Liter /year Tone /year Kg /year Fill in one or more cell. Pleae fill in the type of product and packaging. 1 Example: a bottled water company. Liter/year -> Bottled water in 5 l, 1.5 l and 0.5 l bottle.

8 Group 1 Oil and fat Fruit and vegetable Animal feeding

9 Mark a many a applie conumption: conumption electric kwh/year conumption Natural Ga kwh/year conumption ga-oil Liter/year conumption propane kwh/year conumption Bioma kg/year conumption fuel-oil Liter/year Pleae pecify price per unit in I natural ga available? only if no conumption of natural ga pecified group 1 number of thermal equipment: boiler X ud furnace X ud one quetionnaire per equipment Recommendation 3 Saving with repect to initial thermal conumption: 1% if 1-10m 2% if m 3% If >50m How many m of defective inulation? Only in cae of thermal conumption Inulation? I any of thee point viible? Crack Change in appearance inulation at ome point Temp very high. Vegetable wate in any proce? Recommendation 2 Saving with repect to initial thermal conumption: 3% Recommendation 4

10 group 1 Cooling equipment? a many quetionnaire a cooling equipment Freezer, fridge, cooler Number of cooling equipment Temperature etpoint per equipment: 1. Temp 2. Temp 3. Temp X Engine and pump: engine X ud pump X ud Go to engine/pump quetionnaire I there an automatic proce control? Cleaning Recommendation 6 Recommendation 5 General recommendation to be included in all cae

11 LIGHTING Type of light? incandecent incandecent halogen Low conumption and Fluorecent lamp High preure mercury vapour lamp Sodium vapour lamp LED (Chooe all the option that apply) How often do you perform maintenance and cleaning for the lamp? yearly Every two year Never

12 LIGHTING Do you have electronic ballat primer for the dicharge lamp? Only in cae of fluorecent, low conumption or Na, Hg vapour lamp Recommendation 90

13 Type of conumption: electric Natural Ga fuel-oil Scroll up with the previouly mentioned fuel Power: ---- kw ---- Kcal/h ---- CV Age: Only one input allowed. The ret will be automatically calculated < 10 year > 10 year boiler When checking the boiler performance, do you apply corrective action to reach the recommended combution parameter? Boiler name Are there periodical reviion? Le than once a year More than once a year If more than once a year Full load operating time per year? ----hour/year Recommendation 8 Recommendation 8 Recommendation 7 aving with repect to the initial equipment conumption 6.5%

14 boiler The boiler i ued for: Hot Water Temp exhaut gae: I there an exce of heat around the boiler? High temp team(>130ºc) Low temp team(<130ºc) Steam Temp unknown ºC unknown Recommendation 11 If unknown Recommendation 10 If known temp I there a condenate recovery ytem? If unknown Recommendation 10 aving for the equipment2% Recommendation 9 If Temp>130º, thermal aving 4% If Temp<130º, aving 2% If unknowntemp, aving 3%

15 Concluion baed on the anwer 1 If Temp exhaut gae >230 2 If Temp exhaut gae >230 and High Proce Temp Recommendation 12 cleaning Recommendation 13 intall a heat recovery ytem aving of 1% with repect to the current conumption for every 20º of exhaut gae temp exceeding the table data. Low temp proce = hot water and/or low temp team(<130º)) aving of 15% with repect to the current conumption 3 Age >10 year + Temp exhaut gae > 230 & Low Temp Proce + boiler room temp high if acce to Natural Ga Recommendation 14 Boiler replacement by a Natural Ga boiler if NO acce to Natural Ga Recommendation 15 Boiler replacement by a new boiler with ame fuel Clarification: The Temp in red change according to the fuel ued. If: conumption Ga fuel: 175ºC conumption Liquid fuel: 230ºC conumption Solid fuel: 230ºC aving 15% with repect to the current conumption if previouly not a Natural Ga and aving of 10% if previouly Natural Ga aving of 10% with repect to the current conumption

16 Power: ---- CV ---- kw ---- kcal/hour Only one input allowed. Other are calculated automatically Age: < 5 year 5-10 year > 10 year Proce Temp? Cooling equipment Are there periodical reviion? Le than once a year More than once a year Recommendation 20 I there uually ice covering the cabinet wall and coil? equipment name Recommendation 21 I the preure witch adapted to changing condition (winter/ummer)? Recommendation 22 If more than once a year aving of 2% with repect to initial equipment conumption Recommendation 20 Conumption i obtained by multiplying power time number of operating hour 4 hour for equipment operating at Temp > 5º (fridge) 7 hour for equipment operating at Temp < 5º (freezer) conumption = Power * time

17 Cooling equipment I it fitted with an open door enor? Recommendation 22 Are joint in good condition? Recommendation 23 The target temp i below the value on the table? Show Table Recommendation 24 I the heat exchanger covered from unhine? Recommendation 25 aving of 2% with repect to initial equipment conumption

18 only if more than a cooling device at the ame Temp Cooling equipment Are your equipment fitted with inverter technology and variable peed drive? In all cae General recommendation 29 I it uual that the equipment work at half the capacity? If age > 10 year, maintenance le than once a year and bad joint, then I the pipe ection from compreor to evaporator inulated? Recommendation 26 Recommendation 27: replacement aving of 40% with repect to preent Recommendation 28 aving of 3% with repect to preent

19 Engine, pump, fan, compreor Total intalled power of electric engine? ---- CV ---- kw Only one input allowed, other are automatically calculated Any engine older than 10 year? In thi cae, no quetion about operating hour per day Any engine older than 10 year work for more than 15 hour/day? Recommendation 30: Replace by a high efficiency engine Are there periodical reviion? Le than once a year More than once a year aving of 40%with repect to the initial equipment conumption. If more than once a year Recommendation 31 Conumption = Power x 20 hour/day x working day / year Recommendation 31

20 Engine, pump, fan, compreor Introduction to variable frequency drive Variable frequency drive are device that are placed in the AC motor and are ued to control both the boot proce and the operation. Thi i very intereting when working under variable load. They are recommendable for: Engine powering pump Engine powering extractor Engine powering fan Engine powering compreor

21 Engine, pump, fan, compreor Any engine with variable load > 4 kw? End of engine quetionnaire Only one input allowed Power kw CV Operating hour/year h/year QUESTIONNAIRE(name) Load Factor (lf): Default value: 0.75 Number? ---- Fan/extractor pump ---- compreor Fill in one heet per device Apply the formula: Energy aving =Power* time* lf*((1/rv)-(1/0.993) Enter each engine performance (Rv) Recommendation 32 Pump and compreor: Rv= *lf *(lf)^2 Fan: Rv= *lf *(lf)^2 Final aving in kwh/year i the um of all the equipment' energy aving

22 equipment name furnace General recommendation 40 To be given in all cae Ak in any cae Type of conumption: Natural Ga Gaoil electric croll up lit retricted to the conumption pecified at the beginning Ak only if a fuel conumption ha been pecified Temp exhaut gae: ºC unknown if unknown Recommendation 41 Power: ---- kw ---- Kcal/h ---- CV Only one input allowed. The ret will be automatically calculated Age: < 5 year 5-10 year > 10 year Are there periodical reviion? Le than once a year More than once a year Recommendation 42 If more than once a year Recommendation 42

23 furnace Ak in any cae Temp proce: ºC unknown I there an exce of heat around the furnace? I there a heat recovery ytem? Number of full load operating hour? if unknown Recommendation 41 Recommendation 43 Revie heat-reitant material and boiler external inulation ----hour/year aving of 1.5% with repect to initial conumption

24 Concluion baed on the anwer 1 Temp exhaut gae 230ºC Recommendation 44: Reue exhaut gae heat Clarification: The Temp in red change according to the fuel ued. If: conumption Natural Ga: 175ºC conumption ga-oil: 230ºC conumption propane:175ºc conumption Bioma: conumption fuel-oil: 230ºC 2 aving of 15% with repect to preent If there i a heat recovery ytem and the recommendation i "Reue exhaut gae heat Recommendation 45: revie the maintenance and/or dimenioning of the current heat recovery ytem

25 group 2 Meat product Alcoholic and nonalcoholic drink Bakery and confectionery

26 Mark a many a applie conumption: conumption electricity kwh/year conumption Natural Ga kwh/year conumption ga-oil Liter/year conumption propane kwh/year conumption Bioma kg/year conumption fuel-oil Liter/year Pleae pecify price per unit in I natural ga available? only if no conumption of natural ga pecified group 2 number of thermal equipment: boiler X ud furnace X ud one quetionnaire per equipment Recommendation 3 Saving with repect to initial thermal conumption: 1% if 1-10m 2% if m 3% If >50m How many m of defective inulation? Only in cae of thermal conumption Inulation? I any of thee point viible? Crack Change in appearance inulation at ome point Temp very high. Vegetable wate in any proce? Recommendation 4 Recommendation 2 Saving with repect to initial thermal conumption: 3%

27 group 2 I there Cooling equipment? The Cooling equipment quetionnaire ha to be filled in once per equipment Number of cooling equipment X I there any type of engine, pump, compreor in the facilitie? Go to engine/pump quetionnaire I there an automatic proce control? Recommendation 5 Temperature etpoint per equipment: 1. Temp 2. Temp 3. Temp General recommendation to be included in all cae Recommendation 6: cleaning

28 What i your company' main activity? 151: Drying / curing of meat product? 158: Preparation of freh bread and patry? 159: Wine making? In group 2: Drying / curing of meat product(151) Preparation of freh bread and patry (158) Wine (159) Are there heat pump Recommendation: Intall heat pump in the proce

29 LIGHTING Type of light? incandecent incandecent halogen Low conumption and Fluorecent lamp High preure mercury vapour lamp Sodium vapour lamp LED (Chooe all the option that apply) How often do you perform maintenance and cleaning for the lamp? yearly Every two year Never

30 LIGHTING Do you have electronic ballat primer for the dicharge lamp? Only in cae of fluorecent, low conumption or Na, Hg vapour lamp Recommendation

31 Type of conumption: electric Natural Ga fuel-oil Power: ---- kw ---- Kcal/h ---- CV Age: Only one input allowed. The Scroll up with the previouly ret will be automatically mentioned fuel calculated < 10 year > 10 year boiler When checking the boiler performance, do you apply corrective action to reach the recommended combution parameter? Boiler name Are there periodical reviion? Le than once a year More than once a year Full load operating time per year? ----hour/year Recommendation 8 If more than once a year Recommendation 8 Recommendation 7 aving with repect to the initial equipment conumption 6.5%

32 boiler The boiler i ued for: Hot Water Temp exhaut gae: I there an exce of heat around the boiler? High temp team(>130ºc) Low temp team(<130ºc) Steam Temp unknown ºC unknown Recommendation 11 If unknown If not hot water If unknown Recommendation 10 aving for the equipment 2% Recommendation 10 I there a condenate recovery ytem? Recommendation 9 If Temp>130º, aving with repec to thermal conumption 4% If Temp<130º, aving 2% If unknown Temp, aving 3%

33 Concluion baed on the anwer 1 If Temp exhaut gae >230 2 If Temp exhaut gae >230 and High Proce Temp Recommendation 12 cleaning Recommendation 13 intall a heat recovery ytem aving of 1% with repect to the current conumption for every 20º of exhaut gae temp exceeding the table data. Low temp proce = hot water and/or low temp team (<130º)) aving of 15% with repect to the current conumption 3 Age >10 year + Temp exhaut gae>230 and Low Temp Proce + boiler room temp high if acce to Natural Ga Recommendation 14 Boiler replacement by a Natural Ga boiler if NO acce to Natural Ga Recommendation 15 Boiler replacement by a new boiler with ame fuel Clarification: The Temp in red change according to the fuel ued. If: conumption Ga fuel: 175ºC conumption Liquid fuel: 230ºC conumption Solid fuel: 230ºC aving 15% with repect to the current conumption if previouly not a Natural Ga and aving of 10% if previouly Natural Ga aving of 10% with repect to the initial equipment conumption

34 Power: ---- CV ---- kw ---- kcal/hour Only one input allowed. Other are calculated automatically Age: < 5 year 5-10 year > 10 year Proce Temp? Cooling equipment Are there periodical reviion? Le than once a year More than once a year Recommendation 20 I there uually ice covering the cabinet wall and coil? equipment name Recommendation 21 I the preure witch adapted to changing condition (winter/ummer)? Recommendation 22 If more than once a year aving of 2% with repect to initial equipment conumption Recommendation 20 Conumption i obtained by multiplying power time number of operating hour 4 hour for equipment operating at Temp > 5º (fridge) 7 hour for equipment operating at Temp < 5º (freezer) conumption = Power * time

35 Cooling equipment I it fitted with an open door enor? Are joint in good condition? The target temp i below the value on the table? Show Table I the heat exchanger covered from unhine? Recommendation 22 Recommendation 23 Recommendation 24 Recommendation 25 aving of 2% with repect to initial equipment conumption

36 only if more than a cooling device at the ame Temp I it uual that the equipment work at half the capacity? Recommendation 26 Cooling equipment Are your equipment fitted with inverter technology and variable peed drive? If age > 10 year, maintenance le than once a year and bad joint, then Recommendation 27: replacement aving of 40% with repect to preent I the pipe ection from compreor to evaporator inulated? In all cae General recommendation 29 Recommendation 28 aving of 3% with repect to preent

37 Engine, pump, fan, compreor Total intalled power of electric engine? ---- CV ---- kw Only one input allowed, other are automatically calculated Any engine older than 10 year? In thi cae, no quetion about operating hour per day Any engine older than 10 year work for more than 15 hour/day? Recommendation 30: Replace by a high efficiency engine Are there periodical reviion? Le than once a year More than once a year aving of 40%with repect to the initial equipment conumption. If more than once a year Recommendation 31 Conumption = power x 20 hour/day Recommendation 31

38 Engine, pump, fan, compreor Introduction to variable frequency drive Variable frequency drive are device that are placed in the AC motor and are ued to control both the boot proce and the operation. Thi i very intereting when working under variable load. They are recommendable for: Engine powering pump Engine powering extractor Engine powering fan Engine powering compreor

39 Engine, pump, fan, compreor Any engine with variable load > 4 kw? End of engine quetionnaire Only one input allowed Power kw CV Operating hour/year h/year QUESTIONNAIRE(name) Load Factor (lf): Default value: 0.75 Number? ---- Fan/extractor pump ---- compreor Fill in one heet per device Apply the formula: Energy aving =Power* time* lf*((1/rv)-(1/0.993) Enter each engine performance (Rv) Recommendation 32 Pump and compreor: Rv= *lf *(lf)^2 Fan: Rv= *lf *(lf)^2 Final aving in kwh/year i the um of all the equipment' energy aving

40 equipment name furnace General recommendation To be given in all cae Ak in any cae Type of conumption: Natural Ga Gaoil electric croll up lit retricted to the conumption pecified at the beginning Ak only if a fuel conumption ha been pecified Temp exhaut gae: ºC unknown if unknown Recommendation 41 Power: ---- kw ---- Kcal/h ---- CV Only one input allowed. The ret will be automatically calculated Age: < 5 year 5-10 year > 10 year Are there periodical reviion? Le than once a year More than once a year Recommendation 42 If more than once a year Recommendation 42

41 furnace Ak in any cae Temp proce: ºC unknown I there an exce of heat around the boiler? I there a heat recovery ytem? Number of full load operating hour? if unknown Recommendation Recommendation 43 Revie heat-reitant material and boiler external inulation ----hour/year aving of 1.5% with repect to initial conumption

42 Concluion baed on the anwer 1 2 Temp exhaut gae 230ºC Recommendation 44 Reue exhaut gae heat aving of 15% with repect to preent Clarification: The Temp in red change according to the fuel ued. If: conumption Natural Ga: 175ºC conumption ga-oil: 230ºC conumption propane:175ºc conumption Bioma: conumption fuel-oil: 230ºC If there i a heat recovery ytem and the recommendation i "Reue exhaut gae heat Recommendation 45: revie the maintenance and/or dimenioning of the current heat recovery ytem

43 ALGORITHM OF CHARACTERIZATION METAL

44 GENERAL INFORMATION. COMPANY NAME * VAT NUMBER* CUPS CONTACT PERSON * ADDRESS * TEL * REGION / DEPARTMENT * FAX * TOWN * POSTAL CODE * NACE CONCRETO DE LA EMPRESA * (LISTA DESPLEGABLE) HOURS/DAY OF ACTIVITY * NUMBER OF WORKING DAYS PER YEAR * NUMBER OF WORKERS * COMPANY INCOMES * LOGIN * PASSWORD * repeat PASSWORD * COMPULSORY DATA *

45 GENERAL INFORMATION. ADDITIONAL QUESTION Ak thi quetion to all companie I there an Energy Manager in the company? Recommendation 1 THIS GROUP IS DIVIDED INTO 2 CATEGORIES WITH DIFFERENT QUESTIONS group 1: NACE 282, 284, 287, 291, 292, 293 and 295 group 2: NACE 285

46 INITIAL INFORMATION TO COLLECT: Quantity of final product per year m 3 /year Liter /year Tone /year Kg /year Fill in one or more cell. Pleae fill in the type of product and packaging. 1 Example: a bottled water company. Liter/year -> Bottled water in 5 l, 1.5 l and 0.5 l bottle.

47 group 1 Machinery, tank, equipment manufacturing

48 group 1 I there Cooling equipment? The Cooling equipment quetionnaire ha to be filled in once per equipment Number of cooling equipment. X I there any type of engine, pump, compreor in the facilitie? Go to engine/pump quetionnaire I there an automatic proce control? Recommendation 5 Temperature etpoint per equipment: 1. Temp 2. Temp 3. Temp

49 LIGHTING Type of light? incandecent incandecent halogenou Low conumption and Fluorecent lamp High preure mercury vapour lamp Sodium vapour lamp LED (Chooe all the option that apply) How often do you perform maintenance and cleaning for the lamp? yearly Every two year Never

50 LIGHTING Do you have electronic ballat primer for the dicharge lamp? Only in cae of fluorecent, low conumption or Na, Hg vapour lamp Recommendation 90

51 HVAC Doe the company operate any HVAC ytem? NO End of the HVAC quetionnaire HVAC ytem upply: Heating Cooling Both If "Heating", then go to the Heating quetionnaire If "Cooling", then go to the Cooling quetionnaire If "Both", then go to the Heating quetionnaire, and then to the Cooling quetionnaire

52 Type of conumption: electric Natural Ga fuel-oil Power: ---- kw ---- Kcal/h ---- CV Age: Only one input allowed. The ret will be automatically Scroll up with the previouly calculated mentioned fuel < 10 year > 10 year boiler When checking the boiler performance, do you apply corrective action to reach the recommended combution parameter? Boiler name Are there periodical reviion? Le than once a year More than once a year Full load operating time per year? ----hour/year Recommendation 8 If more than once a year Recommendation 8 Recommendation 7 aving with repect to the initial equipment conumption 6.5%

53 boiler The boiler i ued for: Hot Water Temp exhaut gae: I there an exce of heat around the boiler? High temp team(>130ºc) Low temp team(<130ºc) Steam Temp unknown ºC unknown Recommendation 11 If unknown Recommendation 10 If not hot water I there a condenate recovery ytem? If unknown Recommendation 10 aving for the equipment 2% Recommendation 9 If Temp>130º, aving with repect to initial thermal conumption 4% If Temp<130º, aving 2% If unknown Temp, aving 3%

54 Concluion baed on the anwer 1 If Temp exhaut gae >230 2 If Temp exhaut gae >230 and High Proce Temp Recommendation 12 cleaning Recommendation 13 intall a heat recovery ytem aving of 1% with repect to the current conumption for every 20º of exhaut gae temp exceeding the table data. Low temp proce = hot water and/or low temp team (<130º)) aving of 15% with repect to the current conumption 3 Age >10 year + Temp exhaut gae>230 and Low Temp Proce + boiler room temp high if acce to Natural Ga Recommendation 14: Boiler replacement by a Natural Ga boiler if NO acce to Natural Ga Recommendation 15: Boiler replacement by a new boiler with ame fuel Clarification: The Temp in red change according to the fuel ued. If: conumption Ga fuel: 175ºC conumption Liquid fuel: 230ºC conumption Solid fuel: 230ºC aving 15% with repect to the current conumption if previouly not a Natural Ga and aving of 10% if previouly Natural Ga aving of 10% with repect to the initial equipment conumption

55 Power: ---- CV ---- kw ---- kcal/hour Only one input allowed. Other are calculated automatically Age: < 5 year 5-10 year > 10 year Proce Temp? Cooling equipment Are there periodical reviion? Le than once a year More than once a year Recommendation 20 I there uually ice covering the cabinet wall and coil? equipment name Recommendation 21 I the preure witch adapted to changing condition (winter/ummer)? Recommendation 22 If more than once a year Recommendation 20 aving of 2% with repect to initial equipment conumption Conumption i obtained by multiplying power time number of operating hour 4 hour for equipment operating at Temp > 5º(fridge) 7 hour for equipment operating at Temp < 5º(freezer) conumption = Power * time

56 Cooling equipment I it fitted with an open door enor? Are joint in good condition? The target temp i below the value on the table? Show Table I the heat exchanger covered from unhine? Recommendation 22 Recommendation 23 Recommendation 25 Recommendation 24 aving of 2% with repect to initial equipment conumption

57 only if more than a cooling device at the ame Temp I it uual that the equipment work at half the capacity? Recommendation 26 Cooling equipment Are your equipment fitted with inverter technology and variable peed drive? If age > 10 year, maintenance le than once a year and bad joint, then Recommendation 27: replacement aving of 40% with repect to preent I the pipe ection from compreor to evaporator inulated? In all cae General recommendation 29 Recommendation 28 aving of 3% with repect to preent

58 Engine, pump, fan, compreor Total intalled power of electric engine? ---- CV ---- kw Only one input allowed, other are automatically calculated Any engine older than 10 year? In thi cae, no quetion about operating hour per day Any engine older than 10 year work for more than 15 hour/day? Recommendation 30: Replace by a high efficiency engine Are there periodical reviion? Le than once a year More than once a year aving of 40%with repect to the initial equipment conumption. If more than once a year Recommendation 31 Conumption = power x 20 hour Recommendation 31

59 Engine, pump, fan, compreor Introduction to variable frequency drive Variable frequency drive are device that are placed in the AC motor and are ued to control both the boot proce and the operation. Thi i very intereting when working under variable load. They are recommendable for: Engine powering pump Engine powering extractor Engine powering fan Engine powering compreor

60 Engine, pump, fan, compreor Any engine with variable load > 4 kw? End of engine quetionnaire Only one input allowed Power kw CV Operating hour/year h/year QUESTIONNAIRE(name) Load Factor (lf): Default value: 0.75 Number? ---- Fan/extractor pump ---- compreor Fill in one heet per device Apply the formula: Energy aving =Power* time* lf*((1/rv)-(1/0.993) Enter each engine performance (Rv) Recommendation 32 Pump and compreor: Rv= *lf *(lf)^2 Fan: Rv= *lf *(lf)^2 Final aving in kwh/year i the um of all the equipment' energy aving

61 equipment name furnace General recommendation 40 To be given in all cae Ak in any cae Type of conumption: Natural Ga Gaoil electricity croll up lit retricted to the conumption pecified at the beginning Ak only if a fuel conumption ha been pecified Temp exhaut gae: ºC unknown if unknown Recommendation 41 Power: ---- kw ---- Kcal/h ---- CV Only one input allowed. The ret will be automatically calculated Age: < 5 year 5-10 year > 10 year Are there periodical reviion? Le than once a year More than once a year Recommendation 42 If more than once a year Recommendation 42

62 furnace Ak in any cae Temp proce: ºC unknown I there an exce of heat around the boiler? I there a heat recovery ytem? Number of full load operating hour? if unknown Recommendation 41 Recommendation 43 Revie heat-reitant material and boiler external inulation ----hour/year aving of 1.5% with repect to initial conumption

63 Concluion baed on the anwer 1 2 Temp exhaut gae 230ºC Recommendation 44: Reue exhaut gae heat aving of 15% with repect to preent Clarification: The Temp in red change according to the fuel ued. If: conumption Natural Ga: 175ºC conumption ga-oil: 230ºC conumption propane:175ºc conumption Bioma: conumption fuel-oil: 230ºC If there i a heat recovery ytem and the recommendation i "Reue exhaut gae heat Recommendation 45: revie the maintenance and/or dimenioning of the current heat recovery ytem

64 Heating What i the company' yearly conumption for Heating? kwh/year What i the uual temperature etpoint? ºC Recommendation 50 If above 20º C Heating What type of heating ytem i in place? Boiler Electric heating with heat torage Heat Pump Other Every ºC above 20º C, 6% aving in heating conumption What i the heat ditribution ytem? Water radiator underfloor heating Fan-coil Other If no Heat Pump then-> Recommendation 51 If no underfloor heating then -> Recommendation 52 I there any regulation and control ytem to adequate the heating to the ambient external condition? NO Recommendation 53 aving of 20% of heating conumption

65 Cooling Recomendacione generale 59 What i the company' yearly conumption in cooling? kwh/year What i the uual temperature etpoint? ºC Do you ue eave, awning or canopie to keep out direct unlight in ummer? Every degree below 25ºC, 8% aving in cooling conumption If below 25ºC Recommendation 50 NO Recommendation 54 Cooling I the heat exchanger expoed to the unhine? Recommendation 55 NO Are the temp controller in appropriate location? NO Recommendation 56 Doe your company carry out regular cleaning and maintenance of the cooling ytem? NO Recommen dation % aving in cooling conumpti on

66 group 2 Metal treatment and coating indutry

67 Mark a many a applie conumption: conumption electric kwh/year conumption Natural Ga kwh/year conumption ga-oil Liter/year conumption propane kwh/year conumption Bioma kg/year conumption fuel-oil Liter/year Pleae pecify price per unit in I natural ga available? only if no conumption of natural ga pecified group 2 number of thermal equipment: boiler X ud furnace X ud one quetionnaire per equipment Recommendation 3 Saving with repect to initial thermal conumption: 1% if 1-10m 2% if m 3% If >50m How many m of defective inulation? Only in cae of thermal conumption Inulation? I any of thee point viible? Crack Change in appearance inulation at ome point Temp very high. Vegetable wate in any proce? Recommendation 2 Saving with repect to initial thermal conumption: 3% Recommendation 4

68 group 2 I there Cooling equipment? The Cooling equipment quetionnaire ha to be filled in once per equipment Number of cooling equipment. X I there any type of engine, pump, compreor in the facilitie? Go to engine/pump quetionnaire I there an automatic proce control? Recommendation 5 Temperature etpoint per equipment: 1. Temp 2. Temp 3. Temp

69 LIGHTING Type of light? incandecent incandecent halogen Low conumption and Fluorecent lamp High preure mercury vapour lamp Sodium vapour lamp LED (Chooe all the option that apply) How often do you perform maintenance and cleaning for the lamp? yearly Every two year Never

70 LIGHTING Do you have electronic ballat primer for the dicharge lamp? Only in cae of fluorecent, low conumption or Na, Hg vapour lamp Recommendation 90

71 HVAC Doe the company operate any HVAC ytem? NO End of the HVAC quetionnaire The HVAC ytem upply: Heating Cooling Both ne If "Heating", then go to the Heating quetionnaire If "Cooling", then go to the Cooling quetionnaire If "Both", then go to the Heating quetionnaire, and then to the Cooling quetionnaire

72 Type of conumption: electric Natural Ga fuel-oil Power: ---- kw ---- Kcal/h ---- CV Age: Only one input allowed. The ret will be automatically Scroll up with the previouly calculated mentioned fuel < 10 year > 10 year boiler When checking the boiler performance, do you apply corrective action to reach the recommended combution parameter? Boiler name Are there periodical reviion? Le than once a year More than once a year Full load operating time per year? ----hour/year Recommendation 8 If more than once a year Recommendation 8 Recommendation 7 aving with repect to the initial equipment conumption 6.5%

73 boiler The boiler i ued for: Hot Water Temp exhaut gae: I there an exce of heat around the boiler? High temp team(>130ºc) Low temp team(<130ºc) Steam Temp unknown ºC unknown Recommendation 11 If unknown Recommendation 10 If not hot water I there a condenate recovery ytem? If unknown Recommendation 10 aving for the equipment 2% Recommendation 9 If Temp>130º, aving with repect to initial thermal conumption 4% If Temp<130º, aving 2% If unknown Temp, aving 3%

74 Concluion baed on the anwer 1 If Temp exhaut gae >230 2 If Temp exhaut gae >230 and High Proce Temp Recommendation 12 cleaning Recommendation 13 intall a heat recovery ytem aving of 1% with repect to the current conumption for every 20º of exhaut gae temp exceeding the table data. Low temp proce = hot water and/or low temp team (<130º)) aving of 15% with repect to the current conumption 3 Age >10 year + Temp exhaut gae>230 and Low Temp Proce + boiler room temp high if acce to Natural Ga Recommendation 14: Boiler replacement by a Natural Ga boiler if NO acce to Natural Ga Recommendation 15: Boiler replacement by a new boiler with ame fuel Clarification: The Temp in red change according to the fuel ued. If: conumption Ga fuel: 175ºC conumption Liquid fuel: 230ºC conumption Solid fuel: 230ºC aving 15% with repect to the current conumption if previouly not a Natural Ga and aving of 10% if previouly Natural Ga aving of 10% with repect to the initial equipment conumption

75 Power: ---- CV ---- kw ---- kcal/hour Only one input allowed. Other are calculated automatically Age: < 5 year 5-10 year > 10 year Proce Temp? Cooling equipment Are there periodical reviion? Le than once a year More than once a year Recommendation 20 I there uually ice covering the cabinet wall and coil? equipment name Recommendation 21 I the preure witch adapted to changing condition (winter/ummer)? Recommendation 22 If more than once a year Recommendation 20 aving of 2% with repect to initial equipment conumption Conumption i obtained by multiplying power time number of operating hour 4 hour for equipment operating at Temp > 5º(fridge) 7 hour for equipment operating at Temp < 5º(freezer) conumption = Power * time

76 Cooling equipment I it fitted with an open door enor? Are joint in good condition? The target temp i below the value on the table? Show Table I the heat exchanger covered from unhine? Recommendation 22 Recommendation 23 Recommendation 25 Recommendation 24 aving of 2% with repect to initial equipment conumption

77 only if more than a cooling device at the ame Temp I it uual that the equipment work at half the capacity? Recommendation 26 Cooling equipment Are your equipment fitted with inverter technology and variable peed drive? If age > 10 year, maintenance le than once a year and bad joint, then Recommendation 27: replacement aving of 40% with repect to preent I the pipe ection from compreor to evaporator inulated? In all cae General recommendation 29 Recommendation 28 aving of 3% with repect to preent

78 Engine, pump, fan, compreor Total intalled power of electric engine? ---- CV ---- kw Only one input allowed, other are automatically calculated Any engine older than 10 year? In thi cae, no quetion about operating hour per day Any engine older than 10 year work for more than 15 hour/day? Recommendation 30: Replace by a high efficiency engine Are there periodical reviion? Le than once a year More than once a year aving of 40%with repect to the initial equipment conumption. If more than once a year Recommendation 31 Conumption = power x 20 hour Recommendation 31

79 Engine, pump, fan, compreor Introduction to variable frequency drive Variable frequency drive are device that are placed in the AC motor and are ued to control both the boot proce and the operation. Thi i very intereting when working under variable load. They are recommendable for: Engine powering pump Engine powering extractor Engine powering fan Engine powering compreor

80 Engine, pump, fan, compreor Any engine with variable load > 4 kw? End of engine quetionnaire Only one input allowed Power kw CV Operating hour/year h/year QUESTIONNAIRE(name) Load Factor (lf): Default value: 0.75 Number? ---- Fan/extractor pump ---- compreor Fill in one heet per device Apply the formula: Energy aving =Power* time* lf*((1/rv)-(1/0.993) Enter each engine performance (Rv) Recommendation 32 Pump and compreor: Rv= *lf *(lf)^2 Fan: Rv= *lf *(lf)^2 Final aving in kwh/year i the um of all the equipment' energy aving

81 equipment name furnace General recommendation 40 To be given in all cae Ak in any cae Type of conumption: Natural Ga Gaoil electric croll up lit retricted to the conumption pecified at the beginning Ak only if a fuel conumption ha been pecified Temp exhaut gae: ºC unknown if unknown Recommendation 41 Power: ---- kw ---- Kcal/h ---- CV Only one input allowed. The ret will be automatically calculated Age: < 5 year 5-10 year > 10 year Are there periodical reviion? Le than once a year More than once a year Recommendation 42 If more than once a year Recommendation 42

82 furnace Ak in any cae Temp proce: ºC unknown I there an exce of heat around the boiler? I there a heat recovery ytem? Number of full load operating hour? if unknown Recommendation 46 Recommendation 43 Revie heat-reitant material and boiler external inulation ----hour/year aving of 1.5% with repect to initial conumption

83 Concluion baed on the anwer 1 2 Temp exhaut gae 230ºC Recommendation 44: Reue exhaut gae heat aving of 15% with repect to preent Clarification: The Temp in red change according to the fuel ued. If: conumption Natural Ga: 175ºC conumption ga-oil: 230ºC conumption propane:175ºc conumption Bioma: conumption fuel-oil: 230ºC If there i a heat recovery ytem and the recommendation i "Reue exhaut gae heat Recommendation 45: revie the maintenance and/or dimenioning of the current heat recovery ytem

84 Heating What i the company' yearly conumption for Heating? kwh/year What i the uual temperature etpoint? ºC Recommendation 50 If above 20º C Heating What type of heating ytem i in place? Boiler Electric heating with heat torage Heat Pump Other Every ºC above 20º C, 6% aving in heating conumption What i the heat ditribution ytem? Water radiator underfloor heating Fan-coil Other If no Heat Pump then-> Recommendation 51 If no underfloor heating then -> Recommendation 52 I there any regulation and control ytem to adequate the heating to the ambient external condition? NO Recommendation 53 aving of 20% of heating conumption

85 Cooling Recomendacione generale What i the company' yearly conumption in cooling? kwh/year What i the uual temperature etpoint? ºC Do you ue eave, awning or canopie to keep out direct unlight in ummer? Every degree below 25ºC, 8% aving in cooling conumption If below 25ºC Recommendation 50 NO Recommendation 54 Cooling I the heat exchanger expoed to the unhine? Recommendation 55 NO Are the temp controller in appropriate location? NO Recommendation 56 Doe your company carry out regular cleaning and maintenance of the cooling ytem? NO Recommen dation % aving in cooling conumpti on

86 In thi group 2 a general recommendation will be hown for improvement in furnace and bathing

87 ALGORITHM OF CHARACTERIZATION CHEMICAL

88 GENERAL INFORMATION. COMPANY NAME * VAT NUMBER* CUPS CONTACT PERSON * ADDRESS * TEL * REGION / DEPARTMENT * FAX * TOWN * POSTAL CODE * NACE CONCRETO DE LA EMPRESA * (LISTA DESPLEGABLE) HOURS/DAY OF ACTIVITY * NUMBER OF WORKING DAYS PER YEAR * NUMBER OF WORKERS * COMPANY INCOMES * LOGIN * PASSWORD * repeat PASSWORD * COMPULSORY DATA *

89 GENERAL INFORMATION. ADDITIONAL QUESTION Ak thi quetion to all companie I there an Energy Manager in the company? Recommendati on 1

90 INITIAL INFORMATION TO COLLECT: Quantity of final product per year m 3 /year Liter /year Tone /year Kg /year Fill in one or more cell. Pleae fill in the type of product and packaging. 1 Example: a bottled water company. Liter/year -> Bottled water in 5 l, 1.5 l and 0.5 l bottle.

91 Mark a many a applie conumption: conumption electric kwh/year conumption Natural Ga kwh/year conumption ga-oil Liter/year conumption propane kwh/year conumption Bioma kg/year conumption fuel-oil Liter/year Pleae pecify price per unit in I natural ga available? only if no conumption of natural ga pecified group number of thermal equipment: boiler X ud furnace X ud one quetionnaire per equipment Recommendation 3 Saving with repect to initial thermal conumption: 1% if 1-10m 2% if m 3% If >50m How many m of defective inulation? Only in cae of thermal conumption Inulation? I any of thee point viible? Crack Change in appearance inulation at ome point Temp very high. Vegetable wate in any proce? Recommendation 2 Saving with repect to initial thermal conumption: 3% Recommendation 4

92 group I there Cooling equipment? The Cooling equipment quetionnaire ha to be filled in once per equipment Number of cooling equipment. X I there any type of engine, pump, compreor in the facilitie? Go to engine/pump quetionnaire I there an automatic proce control? Recommendation Temperature etpoint per equipment: 1. Temp 2. Temp 3. Temp Indutrial Cooling quetionnaire Are there Indutrial Cooling procee

93 LIGHTING Type of light? incandecent incandecent halogen Low conumption and Fluorecent lamp High preure mercury vapour lamp Sodium vapour lamp LED (Chooe all the option that apply) How often do you perform maintenance and cleaning for the lamp? yearly Every two year Never

94 LIGHTING Do you have electronic ballat primer for the dicharge lamp? Only in cae of fluorecent, low conumption or Na, Hg vapour lamp Recommendation 90

95 HVAC Doe the company operate any HVAC ytem? NO End of the HVAC quetionnaire The HVAC ytem upply: Heating Cooling Both If "Heating", then go to the Heating quetionnaire If "Cooling", then go to the Cooling quetionnaire If "Both", then go to the Heating quetionnaire, and then to the Cooling quetionnaire

96 Type of conumption: electric Natural Ga fuel-oil Power: ---- kw ---- Kcal/h ---- CV Age: Only one input allowed. The ret will be automatically Scroll up with the previouly calculated mentioned fuel < 10 year > 10 year boiler When checking the boiler performance, do you apply corrective action to reach the recommended combution parameter? Boiler name Are there periodical reviion? Le than once a year More than once a year Full load operating time per year? ----hour/year Recommendation 8 If more than once a year Recommendation 8 Recommendation 7 aving with repect to the initial equipment conumption 6.5%

97 boiler The boiler i ued for: Hot Water Temp exhaut gae: I there an exce of heat around the boiler? High temp team(>130ºc) Low temp team(<130ºc) Steam Temp unknown ºC unknown Recommendation 11 If unknown If not hot water If unknown Recommendation 10 aving for the equipment2% Recommendation 10 I there a condenate recovery ytem? Recommendation 9 If Temp>130º, aving with repect to initial thermal conumption 4% If Temp<130º, aving 2% If unknown Temp, aving 3% I the recovered heat ued? Recommendation19 If Temp> 130º, aving with repect to initial thermal conumption 4% If Temp< 130º, aving 2% If unknown Temp, aving 3%

98 Concluion baed on the anwer 1 If Temp exhaut gae >230 2 If Temp exhaut gae >230 and High Proce Temp Recommendation 12 cleaning Recommendation 13 intall a heat recovery ytem aving of 1% with repect to the current conumption for every 20º of exhaut gae temp exceeding the table data. Low temp proce = hot water and/or low temp team (<130º)) aving of 15% with repect to the current conumption 3 Age >10 year + Temp exhaut gae>230 and Low Temp Proce + boiler room temp high if acce to Natural Ga Recommendation 14: Boiler replacement by a Natural Ga boiler if NO acce to Natural Ga Recommendation 15: Boiler replacement by a new boiler with ame fuel Clarification: The Temp in red change according to the fuel ued. If: conumption Ga fuel: 175ºC conumption Liquid fuel: 230ºC conumption Solid fuel: 230ºC aving 15% with repect to the current conumption if previouly not a Natural Ga and aving of 10% if previouly Natural Ga aving of 10% with repect to the initial equipment conumption

99 Power: ---- CV ---- kw ---- kcal/hour Only one input allowed. Other are calculated automatically Age: < 5 year 5-10 year > 10 year Proce Temp? Cooling equipment Are there periodical reviion? Le than once a year More than once a year Recommendation 20 I there uually ice covering the cabinet wall and coil? equipment name Recommendation 21 I the preure witch adapted to changing condition (winter/ummer)? Recommendation 22 If more than once a year Recommendation 20 aving of 2% with repect to initial equipment conumption Conumption i obtained by multiplying power time number of operating hour 4 hour for equipment operating at Temp > 5º(fridge) 7 hour for equipment operating at Temp < 5º(freezer) conumption = Power * time

100 Cooling equipment I it fitted with an open door enor? Are joint in good condition? The target temp i below the value on the table? Show Table I the heat exchanger covered from unhine? Recommendation 22 Recommendation 23 Recommendation 25 Recommendation 24 aving of 2% with repect to initial equipment conumption

101 only if more than a cooling device at the ame Temp I it uual that the equipment work at half the capacity? Recommendation 26 Cooling equipment Are your equipment fitted with inverter technology and variable peed drive? If age > 10 year, maintenance le than once a year and bad joint, then Recommendation 27: replacement aving of 40% with repect to preent I the pipe ection from compreor to evaporator inulated? In all cae General recommendation 29 Recommendation 28 aving of 3% with repect to preent

102 Indutrial Cooling Proce cooling i generated by mean of: Cooling tower (fan and engine quetionnaire) Compreion Cooling (compreor In quetionnaire) the cae if cooling tower and compreion cooling go to engine, aborption fan and Cooling compreor (no action) quetionnaire. The number of operating hour will be taken from the working day / year and working hour / day of the company.

103 Engine, pump, fan, compreor Total intalled power of electric engine? ---- CV ---- kw Only one input allowed, other are automatically calculated Any engine older than 10 year? In thi cae, no quetion about operating hour per day Any engine older than 10 year work for more than 15 hour/day? Recommendation 30: Replace by a high efficiency engine aving of 40%with repect to the initial equipment conumption. Are there periodical reviion? Le than once a year More than once a year If more than once a year Recommendation 31 Conumption = power x 20 hour

104 Engine, pump, fan, compreor Introduction to variable frequency drive Variable frequency drive are device that are placed in the AC motor and are ued to control both the boot proce and the operation. Thi i very intereting when working under variable load. They are recommendable for: Engine powering pump Engine powering extractor Engine powering fan Engine powering compreor

105 Engine, pump, fan, compreor Any engine with variable load > 4 kw? End of engine quetionnaire Only one input allowed Power kw CV Operating hour/year h/year QUESTIONNAIRE(name) Load Factor (lf): Default value: 0.75 Number? ---- Fan/extractor pump ---- compreor ---- haker mixer Recommendation 32 Fill in one heet per device Apply the formula: Pump, compreor, haker and mixer: Rv= *lf *(lf)^2 Fan: Rv= *lf *(lf)^2 Energy aving =Power* time* lf*((1/rv)-(1/0.993) Enter each engine performance (Rv) Final aving in kwh/year i the um of all the equipment' energy aving

106 I the compreor air inlet outide? Additional quetion for compreor Recommendati I there a leakage on 33 preventive maintenance? Recommendati on 31 I the compreor witched off during the idle weekend? Recommendatio n

107 equipment name furnace General recommendation 40 To be given in all cae Ak in any cae Type of conumption: Natural Ga Gaoil electric croll up lit retricted to the conumption pecified at the beginning Ak only if a fuel conumption ha been pecified Temp exhaut gae: ºC unknown if unknown Recommendation 41 Power: ---- kw ---- Kcal/h ---- CV Only one input allowed. The ret will be automatically calculated Age: < 5 year 5-10 year > 10 year Are there periodical reviion? Le than once a year More than once a year Recommendation 42 If more than once a year Recommendation 42

108 furnace Ak in any cae Temp proce: ºC unknown I there an exce of heat around the boiler? I there a heat recovery ytem? Number of full load operating hour? if unknown Recommendation 46 Recommendation 45 Revie heat-reitant material and boiler external inulation ----hour/year aving of 1.5% with repect to initial conumption

109 Concluion baed on the anwer 1 2 Temp exhaut gae 230ºC Recommendation 44: Reue exhaut gae heat aving of 15% with repect to preent Clarification: The Temp in red change according to the fuel ued. If: conumption Natural Ga: 175ºC conumption ga-oil: 230ºC conumption propane:175ºc conumption Bioma: conumption fuel-oil: 230ºC If there i a heat recovery ytem and the recommendation i "Reue exhaut gae heat Recommendation 45: revie the maintenance and/or dimenioning of the current heat recovery ytem

110 Heating What i the company' yearly conumption for Heating? kwh/year What i the uual temperature etpoint? ºC Recommendation 50 If above 20º C Heating What type of heating ytem i in place? Boiler Electric heating with heat torage Heat Pump Other Every ºC above 20º C, 6% aving in heating conumption What i the heat ditribution ytem? Water radiator underfloor heating Fan-coil Other If no Heat Pump then-> Recommendation 51 If no underfloor heating then -> Recommendation 52 I there any regulation and control ytem to adequate the heating to the ambient external condition? NO Recommendation 53 aving of 20% of heating conumption

111 Cooling Recomendacione generale What i the company' yearly conumption in cooling? kwh/year What i the uual temperature etpoint? ºC Do you ue eave, awning or canopie to keep out direct unlight in ummer? Every degree below 25ºC, 8% aving in cooling conumption If below 25ºC Recommendation 50 NO Recommendation 54 Cooling I the heat exchanger expoed to the unhine? Recommendation 55 NO Are the temp controller in appropriate location? NO Recommendation 56 Doe your company carry out regular cleaning and maintenance of the cooling ytem? NO Recommen dation % aving in cooling conumpti on

112 Wherever applie, recommend a COGENERATION: If the addition of all the boiler operating hour >= 5000 h /year and the addition of all the boiler power >= 1 MW then recommend cogeneration.

113 ALGORITHM OF CHARACTERIZATION NON METALLIC MINERALS GLASS CARTON AND PAPER

114 GENERAL INFORMATION. COMPULSORY DATA * COMPANY NAME * VAT NUMBER* CUPS CONTACT PERSON * ADDRESS * TEL * REGION / DEPARTMENT * FAX * TOWN * POSTAL CODE * NACE CONCRETO DE LA EMPRESA * (LISTA DESPLEGABLE) HOURS/DAY OF ACTIVITY * NUMBER OF WORKING DAYS PER YEAR * NUMBER OF WORKERS * COMPANY INCOMES * LOGIN * PASSWORD * repeat PASSWORD *

115 GENERAL INFORMATION. ADDITIONAL QUESTION Ak thi quetion to all companie I there an Energy Manager in the company? 2 group, group 1: NACE 261 group 2: NACE 262, 263 and 264 Recommendati on 1

116 INITIAL INFORMATION TO COLLECT: Quantity of final product per year m 3 /year Liter /year Tone /year Kg /year Fill in one or more cell. Pleae fill in the type of product and packaging. 1 Example: a bottled water company. Liter/year -> Bottled water in 5 l, 1.5 l and 0.5 l bottle.

117 group 1 GLASS INDUSTRY

118 Mark a many a applie conumption: conumption electric kwh/year conumption Natural Ga kwh/year conumption ga-oil Liter/year conumption propane kwh/year conumption Bioma kg/year conumption fuel-oil Liter/year Pleae pecify price per unit in I natural ga available? only if no conumption of natural ga pecified group 1 number of thermal equipment: boiler X ud furnace X ud one quetionnaire per equipment Recommendation 3 Saving with repect to initial thermal conumption: 1% if 1-10m 2% if m 3% If >50m How many m of defective inulation? Only in cae of thermal conumption Inulation? I any of thee point viible? Crack Change in appearance inulation at ome point Temp very high. Vegetable wate in any proce? Recommendation 2 Saving with repect to initial thermal conumption: 3% Recommendation 4

119 Group 1 I there any type of engine, pump, compreor in the facilitie? I there any automatic control ytem for the thermal equipment? Go to engine/pump quetionnaire Recommendation 47

120 LIGHTING Type of light? incandecent incandecent halogen Low conumption and Fluorecent lamp High preure mercury vapour lamp Sodium vapour lamp LED (Chooe all the option that apply) How often do you perform maintenance and cleaning for the lamp? yearly Every two year Never

121 LIGHTING Do you have electronic ballat primer for the dicharge lamp? Only in cae of fluorecent, low conumption or Na, Hg vapour lamp Recommendation 90

122 Type of conumption: electric Natural Ga fuel-oil Power: ---- kw ---- Kcal/h ---- CV Age: Only one input allowed. The ret will be automatically Scroll up with the previouly calculated mentioned fuel < 10 year > 10 year boiler When checking the boiler performance, do you apply corrective action to reach the recommended combution parameter? Boiler name Are there periodical reviion? Le than once a year More than once a year Full load operating time per year? ----hour/year Recommendation 8 If more than once a year Recommendation 8 Recommendation 7 aving with repect to the initial equipment conumption 6.5%

123 boiler The boiler i ued for: Hot Water Temp exhaut gae: I there an exce of heat around the boiler? High temp team(>130ºc) Low temp team(<130ºc) Steam Temp unknown ºC unknown Recommendation 11 If unknown If not hot water If unknown Recommendation 10 aving for the equipment2% Recommendation 10 I there a condenate recovery ytem? Recommendation 9 If Temp>130º, aving with repect to initial thermal conumption 4% If Temp<130º, aving 2% If unknown Temp, aving 3% I the recovered heat ued? Recommendation19 If Temp> 130º, aving with repect to initial thermal conumption 4% If Temp< 130º, aving 2% If unknown Temp, aving 3%

124 Concluion baed on the anwer 1 If Temp exhaut gae >230 2 If Temp exhaut gae >230 and High Proce Temp Recommendation 12 cleaning Recommendation 13 intall a heat recovery ytem aving of 1% with repect to the current conumption for every 20º of exhaut gae temp exceeding the table data. Low temp proce = hot water and/or low temp team (<130º)) aving of 15% with repect to the current conumption 3 Age >10 year + Temp exhaut gae>230 and Low Temp Proce + boiler room temp high if acce to Natural Ga Recommendation 14: Boiler replacement by a Natural Ga boiler if NO acce to Natural Ga Recommendation 15: Boiler replacement by a new boiler with ame fuel Clarification: The Temp in red change according to the fuel ued. If: conumption Ga fuel: 175ºC conumption Liquid fuel: 230ºC conumption Solid fuel: 230ºC aving 15% with repect to the current conumption if previouly not a Natural Ga and aving of 10% if previouly Natural Ga aving of 10% with repect to the initial equipment conumption

125 Engine, pump, fan, compreor Total intalled power of electric engine? ---- CV ---- kw Only one input allowed, other are automatically calculated Any engine older than 10 year? In thi cae, no quetion about operating hour per day Any engine older than 10 year work for more than 15 hour/day? Recommendation 30: Replace by a high efficiency engine Are there periodical reviion? Le than once a year More than once a year aving of 40%with repect to the initial equipment conumption. If more than once a year Recommendation 31 Conumption = power x 20 hour

126 Engine, pump, fan, compreor Introduction to variable frequency drive Variable frequency drive are device that are placed in the AC motor and are ued to control both the boot proce and the operation. Thi i very intereting when working under variable load. They are recommendable for: Engine powering pump Engine powering extractor Engine powering fan Engine powering compreor

127 Engine, pump, fan, compreor Any engine with variable load > 4 kw? End of engine quetionnaire Only one input allowed Power kw CV Operating hour/year h/year QUESTIONNAIRE(name) Load Factor (lf): Default value: 0.75 Number? ---- Fan/extractor pump ---- compreor ---- Blower (ame a Fan) ---- Mill (only Recommendation, no calculation) Recommendation 32 Fill in one heet per device Pump and compreor: Apply the formula: Rv= *lf *(lf)^2 Fan and blower: Rv= *lf *(lf)^2 Energy aving =Power* time* lf*((1/rv)-(1/0.993) Enter each engine performance (Rv) Final aving in kwh/year i the um of all the equipment' energy aving

128 furnace Specify the number of furnace by type ---Regenerative ---HEAT RECOVERY FURNACE ---Oxycombutión ---electric ---Combined (fuel + electricity) ---Batch furnace Fill in a heet per furnace

129 Regenerative: Ak : Type of conumption: Natural Ga Gaoil. Power: ---- kw ---- Kcal/h ---- CV Number of full load operating hour? alway Recommendation 48 HEAT RECOVERY FURNACE: Ak : Type of Power: Number of conumption: full load ---- kw Natural Ga operating ---- Kcal/h hour? Gaoil ---- CV. Oxycombution: action Type of conumption: Natural Ga Gaoil. Power: ---- kw ---- Kcal/h ---- CV Number of full load operating hour? Production : -----X--- Tone/day If X> 40 t/day : Recommendation 49 - Replace by Regenerative If X< 40 t/day : action

130 electric: Ak : Type of conumption: Natural Ga Gaoil. Power: ---- kw ---- Kcal/h ---- CV Number of full load operating hour? Production : -----X--- Tone/day If 20<X<40 t/day : Recommendation 50 Replace by HEAT RECOVERY FURNACE If X< 20 t/day : action If > 40 t/day: Recommendation 50 Replace by Regenerative Combined: Ak : Type of conumption: Natural Ga Gaoil. Power: ---- kw ---- Kcal/h ---- CV Batch furnace: Ak : Type of conumption: Natural Ga Gaoil. Power: ---- kw ---- Kcal/h ---- CV Number of full load operating hour? Number of full load operating hour for the dryer Exhaut gae temp: Production : -----X--- Tone/day i there an exhaut ga heat recovery ytem? If Temp< 800ºC Recommendation 51 aving 15% wrt initial conumption If Temp> 800ºC Recommendation 51 aving 20% wrt initial conumption If 20<X<40 t/day : Recommendation 52 Replace by HEAT RECOVERY FURNACE If X< 20 t/day : action If > 40 t/day: Recommendation 52 Replace by Regenerative

131 group 2 CERAMIC, TILES, BRICK INDUSTRIES

132 Mark a many a applie conumption: conumption electric kwh/year conumption Natural Ga kwh/year conumption ga-oil Liter/year conumption propane kwh/year conumption Bioma kg/year conumption fuel-oil Liter/year Pleae pecify price per unit in I natural ga available? only if no conumption of natural ga pecified group number of thermal equipment: boiler X ud furnace X ud one quetionnaire per equipment Recommendation 3 Saving with repect to initial thermal conumption: 1% if 1-10m 2% if m 3% If >50m How many m of defective inulation? Only in cae of thermal conumption Are the recovered hot air, team and hot water ditribution pipe properly inulated? I any of thee point viible? Crack Change in appearance inulation at ome point Temp very high. Vegetable wate in any proce? Recommendation 2 Saving with repect to initial thermal conumption: 3% Recommendation 4

133 group Are there dryer in the company? To fill in a many quetionnaire a number of equipment I there any type of engine, pump, compreor in the facilitie? I there any automatic control ytem for the thermal equipment? Recommendation 47 Go to engine/pump quetionnaire

134 LIGHTING Type of light? incandecent incandecent halogen Low conumption and Fluorecent lamp High preure mercury vapour lamp Sodium vapour lamp LED (Chooe all the option that apply) How often do you perform maintenance and cleaning for the lamp? yearly Every two year Never

135 LIGHTING Do you have electronic ballat primer for the dicharge lamp? Only in cae of fluorecent, low conumption or Na, Hg vapour lamp Recommendation 90

136 Type of conumption: electric Natural Ga fuel-oil Power: ---- kw ---- Kcal/h ---- CV Age: Only one input allowed. The ret will be automatically Scroll up with the previouly calculated mentioned fuel < 10 year > 10 year boiler When checking the boiler performance, do you apply corrective action to reach the recommended combution parameter? Boiler name Are there periodical reviion? Le than once a year More than once a year Full load operating time per year? ----hour/year Recommendation 8 If more than once a year Recommendation 8 Recommendation 7 aving with repect to the initial equipment conumption 6.5%

137 boiler The boiler i ued for: Hot Water Temp exhaut gae: I there an exce of heat around the boiler? High temp team(>130ºc) Low temp team(<130ºc) Steam Temp unknown ºC unknown Recommendation 11 If unknown If not hot water If unknown Recommendation 10 aving for the equipment2% Recommendation 10 I there a condenate recovery ytem? Recommendation 9 If Temp>130º, aving with repect to initial thermal conumption 4% If Temp<130º, aving 2% If unknown Temp, aving 3% I the recovered heat ued? Recommendation19 If Temp> 130º, aving with repect to initial thermal conumption 4% If Temp< 130º, aving 2% If unknown Temp, aving 3%

138 Concluion baed on the anwer 1 If Temp exhaut gae >230 2 If Temp exhaut gae >230 and High Proce Temp Recommendation 12 cleaning Recommendation 13 intall a heat recovery ytem aving of 1% with repect to the current conumption for every 20º of exhaut gae temp exceeding the table data. Low temp proce = hot water and/or low temp team (<130º)) aving of 15% with repect to the current conumption 3 Age >10 year + Temp exhaut gae>230 and Low Temp Proce + boiler room temp high if acce to Natural Ga Recommendation 14: Boiler replacement by a Natural Ga boiler if NO acce to Natural Ga Recommendation 15: Boiler replacement by a new boiler with ame fuel Clarification: The Temp in red change according to the fuel ued. If: conumption Ga fuel: 175ºC conumption Liquid fuel: 230ºC conumption Solid fuel: 230ºC aving 15% with repect to the current conumption if previouly not a Natural Ga and aving of 10% if previouly Natural Ga aving of 10% with repect to the initial equipment conumption

139 Engine, pump, fan, compreor Total intalled power of electric engine? ---- CV ---- kw Only one input allowed, other are automatically calculated Any engine older than 10 year? In thi cae, no quetion about operating hour per day Any engine older than 10 year work for more than 15 hour/day? Recommendation 30: Replace by a high efficiency engine Are there periodical reviion? Le than once a year More than once a year aving of 40%with repect to the initial equipment conumption. If more than once a year Recommendation 31 Conumption = power x 20 hour

140 Engine, pump, fan, compreor Introduction to variable frequency drive Variable frequency drive are device that are placed in the AC motor and are ued to control both the boot proce and the operation. Thi i very intereting when working under variable load. They are recommendable for: Engine powering pump Engine powering extractor Engine powering fan Engine powering compreor

141 Engine, pump, fan, compreor Any engine with variable load > 4 kw? End of engine quetionnaire Only one input allowed Power kw CV Operating hour/year h/year QUESTIONNAIRE(name) Load Factor (lf): Default value: 0.75 Number? ---- Fan/extractor pump ---- compreor ---- Blower (ame a Fan) ---- Mill (only Recommendation, no calculation) Recommendation 32 Fill in one heet per device Pump and compreor: Apply the formula: Rv= *lf *(lf)^2 Fan and blower: Rv= *lf *(lf)^2 Energy aving =Power* time* lf*((1/rv)-(1/0.993) Enter each engine performance (Rv) Final aving in kwh/year i the um of all the equipment' energy aving

142 furnace Amount of furnace continuou Dicontinuou Fill in a heet per furnace continuou Type of conumption: Natural Ga Gaoil. General recommendation 40 Power: ---- kw ---- Kcal/h ---- CV Number of full load operating hour? What i the exce of air?---x----% If X>4,5% or X< 3,5% Recommendation. It hould be within the range (3,5-4,5)

143 Dicontinuou Type of conumption: Natural Ga Gaoil. Power: ---- kw ---- Kcal/h ---- CV I there an exhaut gae heat recovery ytem? Number of full load operating hour? Recommendation aving 5% with repect to the initial equipment conumption Other Recommendation: In cae of a dicontinuou furnace ugget a replacement by continuou- aving 20% with repect to the initial equipment conumption Either continuou or dicontinuou furnace, alway Recommend Geometrie If previouly indicated acce to Natural Ga, and no ga furnace then Recommendation: replacement by a natural ga furnace aving 6%with repect to the initial equipment conumption

144 dryers Number of dryer continuou Dicontinuou 1 QUESTIONNAIRE per dryer continuou Type of conumption: Natural Ga Gaoil. General recommendation 40 Power: ---- kw ---- Kcal/h ---- CV Number of full load operating hour? What i the exce of air?---x----% If X>1,5% ó X< 1,5% Recommendation. It hould be within the range (1,3-1,5)

145 Dicontinuou Dryer Type of conumption: Natural Ga Gaoil. Power: ---- kw ---- Kcal/h ---- CV Number of full load operating hour for the dryer Recommendation: In cae of a dicontinuou dryer then ugget to replace by a continuou- aving 20%with repect to the initial equipment conumption If previouly indicated "Acce to Natural Ga", and no natural ga dryer then Recommendation: replacement by a natural ga dryer aving 10%with repect to the initial equipment conumption

146 End of furnace and dryer quetionnaire. Lat quetion: What type of burner are your furnace and dryer fitted with? High peed Auto recycler Pule combution Other Mark a many a apply If any of the three firt i marked action If Other - Recommendation

147 ALGORITHM OF CHARACTERIZATION TEXTILE

148 GENERAL INFORMATION. COMPULSORY DATA * COMPANY NAME * VAT NUMBER* CUPS CONTACT PERSON * ADDRESS * TEL * REGION / DEPARTMENT * FAX * TOWN * POSTAL CODE * NACE CONCRETO DE LA EMPRESA * (LISTA DESPLEGABLE) HOURS/DAY OF ACTIVITY * NUMBER OF WORKING DAYS PER YEAR * NUMBER OF WORKERS *

149 GENERAL INFORMATION. ADDITIONAL QUESTION Ak thi quetion to all companie I there an Energy Manager in the company? Recommendati on 1

150 INITIAL INFORMATION TO COLLECT: Quantity of final product per year m 3 /year Liter /year Tone /year Kg /year Fill in one or more cell. Pleae fill in the type of product and packaging. 1 Example: a bottled water company. Liter/year -> Bottled water in 5 l, 1.5 l and 0.5 l bottle.

151 Mark a many a applie conumption: conumption electric kwh/year conumption Natural Ga kwh/year conumption ga-oil Liter/year conumption propane kwh/year conumption Bioma kg/year conumption fuel-oil Liter/year Pleae pecify price per unit in I natural ga available? only if no conumption of natural ga pecified group number of thermal equipment: boiler X ud furnace X ud one quetionnaire per equipment Recommendation 3 Saving with repect to initial thermal conumption: 1% if 1-10m 2% if m 3% If >50m How many m of defective inulation? Only in cae of thermal conumption Are the recovered hot air, team and hot water ditribution pipe properly inulated? I any of thee point viible? Crack Change in appearance inulation at ome point Temp very high. Vegetable wate in any proce? Recommendation 2 Saving with repect to initial thermal conumption: 3% Recommendation 4

152 group I there compreed air upply? Go to compreed air QUESTIONNAIRE I there any type of engine, pump, compreor in the facilitie? I there any automatic control ytem for the thermal equipment? Recommendation 47 Go to engine/pump quetionnaire Are there Indutrial Cooling procee Indutrial Cooling quetionnaire

153 LIGHTING Type of light? incandecent incandecent halogen Low conumption and Fluorecent lamp High preure mercury vapour lamp Sodium vapour lamp LED (Chooe all the option that apply) How often do you perform maintenance and cleaning for the lamp? yearly Every two year Never

154 LIGHTING Do you have electronic ballat primer for the dicharge lamp? Only in cae of fluorecent, low conumption or Na, Hg vapour lamp Recommendation 90

155 Type of conumption: electric Natural Ga fuel-oil Power: ---- kw ---- Kcal/h ---- CV Age: Only one input allowed. The ret will be automatically Scroll up with the previouly calculated mentioned fuel < 10 year > 10 year boiler When checking the boiler performance, do you apply corrective action to reach the recommended combution parameter? Boiler name Are there periodical reviion? Le than once a year More than once a year Full load operating time per year? ----hour/year Recommendation 8 If more than once a year Recommendation 8 Recommendation 7 aving with repect to the initial equipment conumption 6.5%

156 boiler The boiler i ued for: Hot Water Temp exhaut gae: I there an exce of heat around the boiler? High temp team(>130ºc) Low temp team(<130ºc) Steam Temp unknown ºC unknown Recommendation 11 If unknown Recommendation 10 If not hot water I there a condenate recovery ytem? If unknown Recommendation 10 aving for the equipment2% Recommendation 9 If Temp>130º, aving with repect to initial thermal conumption 4% If Temp<130º, aving 2% If unknowntemp, aving 3%

157 Concluion baed on the anwer 1 If Temp exhaut gae >230 2 If Temp exhaut gae >230 and High Proce Temp Recommendation 12 cleaning Recommendation 13 intall a heat recovery ytem aving of 1% with repect to the current conumption for every 20º of exhaut gae temp exceeding the table data. Low temp proce = hot water and/or low temp team (<130º)) aving of 15% with repect to the current conumption 3 Age >10 year + Temp exhaut gae>230 and Low Temp Proce + boiler room temp high if acce to Natural Ga Recommendation 14: Boiler replacement by a Natural Ga boiler if NO acce to Natural Ga Recommendation 15: Boiler replacement by a new boiler with ame fuel Clarification: The Temp in red change according to the fuel ued. If: conumption Ga fuel: 175ºC conumption Liquid fuel: 230ºC conumption Solid fuel: 230ºC aving 15% with repect to the current conumption if previouly not a Natural Ga and aving of 10% if previouly Natural Ga aving of 10% with repect to the initial equipment conumption

158 Cooling proce Total intalled power of electric engine? Fan --- kw pump --- kw Compreion Cooling --- kw Aborption Cooling --- kw Any engine older than 10 year? In thi cae, no quetion about operating hour per day Any engine older than 10 year work for more than 15 hour/day? Inerte potencia Recommendation 30: Replace by a high efficiency engine Are there periodical reviion? Le than once a year More than once a year aving of 40%with repect to the initial equipment conumption. If more than once a year Recommendation 20 Conumption = power x 20 hour

159 Engine, pump, fan, compreor Number? pump ---- fan Compreion cooling ()follow compreor) ---- Aborption cooling ( action) Only one input allowed Power kw CV Fill in one heet per device Apply the formula: Operating hour/year h/year QUESTIONNAIRE(name) Load Factor (lf): Energy aving =Power* time* lf*((1/rv)-(1/0.993) Enter each engine performance (Rv) Default value: 0.75 Recommendation 32 Pump and compreor: Rv= *lf *(lf)^2 Fan: Rv= *lf *(lf)^2 Final aving in kwh/year i the um of all the equipment' energy aving

160 Compreed air Total Power of compreor Any of the compreor older than 10 year wrok for more than 15hour/day? Are there periodical reviion? I any of thee compreor > 4kW? Operating hour/year Total Power of thee compreor: ----CV ----kw Le than once a year More than once a year Number? ----compreor ----F/h If more than once a year Power and load factor Recommendation35: compreor replacement aving of 40% of thee compreor' conumption. P*20 * day/year Recommendation30 Recommendation 32: intall variable peed drive

161 Compreed air I the compreor' air inlet outide? Recommendation I there a preventive 33 air leakage maintenance? Recommendatio n 31 Are compreor witched off in idle time and weekend? Recommendation

162 Engine. WARNING: do not include the equipment already included in the Compreed air or Cooling proce ection. Total intalled power of electric engine? ---- CV ---- kw Only one input allowed, other are automatically calculated Any engine older than 10 year? In thi cae, no quetion about operating hour per day Any engine older than 10 year work for more than 15 hour/day? Recommendation 30: Replace by a high efficiency engine Are there periodical reviion? Le than once a year More than once a year aving of 40%with repect to the initial equipment conumption. If more than once a year Recommendation 31 Conumption = power x 20 hour

163 Number? pump ---- fan / extractor Engine. WARNING: do not include the equipment already included in the Compreed air or Cooling proce ection Only one input allowed Power kw CV Operating hour/year h/year QUESTIONNAIRE(name) Load Factor (lf): Default value: 0.75 Fill in one heet per device Apply the formula: Energy aving =Power* time* lf*((1/rv)-(1/0.993) Enter each engine performance (Rv) Recommendation 32 Pump: Rv= *lf *(lf)^2 Fan: Rv= *lf *(lf)^2 Final aving in kwh/year i the um of all the equipment' energy aving

164 DRYING PROCESSES I there any drying proce? O N If o: I the outlet air heat recovered? O N Recommendati on54

165 ALGORITHM OF CHARACTERIZATION platic

166 GENERAL INFORMATION. COMPANY NAME * VAT NUMBER* CUPS CONTACT PERSON * ADDRESS * TEL * REGION / DEPARTMENT * FAX * TOWN * POSTAL CODE * NACE CONCRETO DE LA EMPRESA * (LISTA DESPLEGABLE) HOURS/DAY OF ACTIVITY * NUMBER OF WORKING DAYS PER YEAR * NUMBER OF WORKERS * COMPANY INCOMES * LOGIN * PASSWORD * repeat PASSWORD * COMPULSORY DATA *

167 GENERAL INFORMATION. ADDITIONAL QUESTION Ak thi quetion to all companie I there an Energy Manager in the company? Recommendati on 1

168 INITIAL INFORMATION TO COLLECT: Quantity of final product per year m 3 /year Liter /year Tone /year Kg /year Fill in one or more cell. Pleae fill in the type of product and packaging. 1 Example: a bottled water company. Liter/year -> Bottled water in 5 l, 1.5 l and 0.5 l bottle.

169 Mark a many a applie conumption: conumption electric kwh/year conumption Natural Ga kwh/year conumption ga-oil Liter/year conumption propane kwh/year conumption Bioma kg/year conumption fuel-oil Liter/year Pleae pecify price per unit in I natural ga available? only if no conumption of natural ga pecified group number of thermal equipment: boiler X ud furnace X ud one quetionnaire per equipment Recommendation 3 Saving with repect to initial thermal conumption: 1% if 1-10m 2% if m 3% If >50m How many m of defective inulation? Only in cae of thermal conumption Are the recovered hot air, team and hot water ditribution pipe properly inulated? I any of thee point viible? Crack Change in appearance inulation at ome point Temp very high. Vegetable wate in any proce? Recommendation 2 Saving with repect to initial thermal conumption: 3% Recommendation 4

170 group Are there dryer, dehumidifier and furnace? To fill in a many quetionnaire a number of equipment I there any type of engine, pump, compreor in the facilitie? I there any automatic control ytem for the thermal equipment? Recommendation 47 Go to engine/pump quetionnaire I there compreed air upply? Are there Indutrial Cooling procee Indutrial Cooling quetionnaire

171 LIGHTING Type of light? incandecent incandecent halogen Low conumption and Fluorecent lamp High preure mercury vapour lamp Sodium vapour lamp LED (Chooe all the option that apply) How often do you perform maintenance and cleaning for the lamp? yearly Every two year Never

172 LIGHTING Do you have electronic ballat primer for the dicharge lamp? Only in cae of fluorecent, low conumption or Na, Hg vapour lamp Recommendation 90

173 Type of conumption electric Natural Ga fuel-oil Scroll up with the previouly mentioned fuel Power: ---- kw ---- Kcal/h ---- CV Age: < 10 year > 10 year Only one input allowed. The ret will be automatically calculated boiler When checking the boiler performance, do you apply corrective action to reach the recommended combution parameter? Boiler name Are there periodical reviion? Le than once a year More than once a year Full load operating time per year? ----hour/year If more than once a year Recommendation Recommendation Recommendation aving with repect to the initial equipment conumption 6.5%

174 boiler The boiler i ued for: Hot Water Temp exhaut gae: I there an exce of heat around the boiler? High temp team(>130ºc) Low temp team(<130ºc) Steam Temp unknown ºC unknown Recommendation 11 If unknown If not hot water If unknown Recommendation 10 aving for the equipment2% Recommendation 10 I there a condenate recovery ytem? if acce to Natural Ga and no ga boiler aving of 5% with repect to the initial equipment conumption Recommendation 9 If Temp>130º, aving with repect to initial thermal conumption 4% If Temp<130º, aving 2% If unknowntemp, aving 3%

175 Concluion baed on the anwer 1 If Temp exhaut gae >230 2 If Temp exhaut gae >230 and High Proce Temp Recommendation 12 cleaning Recommendation 13 intall a heat recovery ytem aving of 1% with repect to the current conumption for every 20º of exhaut gae temp exceeding the table data. Low temp proce = hot water and/or low temp team (<130º)) aving of 15% with repect to the current conumption 3 Age >10 year + Temp exhaut gae>230 and Low Temp Proce + boiler room temp high if acce to Natural Ga Recommendation 14: Boiler replacement by a Natural Ga boiler if NO acce to Natural Ga Recommendation 15: Boiler replacement by a new boiler with ame fuel Clarification: The Temp in red change according to the fuel ued. If: conumption Ga fuel: 175ºC conumption Liquid fuel: 230ºC conumption Solid fuel: 230ºC aving 15% with repect to the current conumption if previouly not a Natural Ga and aving of 10% if previouly Natural Ga aving of 10% with repect to the initial equipment conumption

176 equipment name dryer, dehumidifier and furnace Ak in any cae Type of conumption: Natural Ga Gaoil electric croll up lit retricted to the conumption pecified at the beginning Outlet air temp: ºC unknown if unknown Recommendation 41 Power: ---- kw ---- Kcal/h ---- CV Only one input allowed. The ret will be automatically calculated Age: < 5 year 5-10 year > 10 year Are there periodical reviion? Le than once a year More than once a year If more than once a year Recommendation 42

177 furnace Ak in any cae Temp proce: ºC unknown I there an exce of heat around the boiler? I there a heat recovery ytem? How many hour/ year doe your equipment work at full capacity? if unknown Recommendation 46 Recommendation 45 Revie heat-reitant material and boiler external inulation ----hour/year aving of 1.5% with repect to initial conumption

178 Concluion baed on the anwer 2 1 Temp exhaut gae 230ºC Recommendation 44: Reue exhaut gae heat aving of 15% with repect to preent Clarification: The Temp in red change according to the fuel ued. If: conumption Natural Ga: 175ºC conumption ga-oil: 230ºC conumption propane:175ºc conumption Bioma: conumption fuel-oil: 230ºC If there i a heat recovery ytem and the recommendation i "Reue exhaut gae heat Recommendation 45: revie the maintenance and/or dimenioning of the current heat recovery ytem 3 Recommendation 14: if acce to Natural Ga and no ga boiler aving of 5% with repect to the initial equipment conumption

179 Cooling proce Total intalled power of electric engine? Fan --- kw pump --- kw Compreion cooling--- kw Aborption Cooling --- kw Any engine older than 10 year? In thi cae, no quetion about operating hour per day Any engine older than 10 year work for more than 15 hour/day? Inerte potencia Recommendation 30: Replace by a high efficiency engine Are there periodical reviion? Le than once a year More than once a year aving of 40%with repect to the initial equipment conumption. If more than once a year Recommendation 20 Conumption = power x 20 hour

180 Cooling proce Number? pump ---- fan / extractor Compreion cooling (follow compreor) ---- Aborption Cooling ( action) Only one input allowed Power kw CV Fill in one heet per device Apply the formula: Operating hour/year h/year QUESTIONNAIRE(name) Load Factor (lf): Energy aving =Power* time* lf*((1/rv)-(1/0.993) Enter each engine performance (Rv) Default value: 0.75 Recommendation 32 Pump, compreor: Rv= *lf *(lf)^2 Fan: Rv= *lf *(lf)^2 Final aving in kwh/year i the um of all the equipment' energy aving

181 Compreed air Total Power of compreor Any of the compreor older than 10 year wrok for more than 15hour/day? Are there periodical reviion? I any of thee compreor > 4kW? Operating hour/year Total Power of thee compreor: ----CV ----kw Le than once a year More than once a year Number? ----compreor ----F/h If more than once a year Power and load factor Recommendation35: compreor replacement aving of 40% of thee compreor' conumption. P*20 * day/year Recommendation30 Recommendation 32: intall variable peed drive

182 Compreed air I the compreor' air inlet outide? Recommendation I there a preventive 33 air leakage maintenance? Recommendatio n 31 Are compreor witched off in idle time and weekend? Recommendation

183 Engine. WARNING: do not include the equipment already included in the Compreed air or Cooling proce ection Total intalled power of electric engine? ---- CV ---- kw Only one input allowed, other are automatically calculated Any engine older than 10 year? In thi cae, no quetion about operating hour per day Any engine older than 10 year work for more than 15 hour/day? Recommendation 30: Replace by a high efficiency engine Are there periodical reviion? Le than once a year More than once a year aving of 40%with repect to the initial equipment conumption. If more than once a year Recommendation 20 Conumption = power x 20 hour

184 Engine. WARNING: do not include the equipment already included in the Compreed air or Cooling proce Any engine with variable load > 4 kw End of engine quetionnaire Only one input allowed Power kw CV Operating hour/year h/year QUESTIONNAIRE(name) Load Factor (lf): Default value: 0.75 Number? fan/ extractor ---- pump Extruder Recommendation 32 Fill in one heet per device Pump and extruder: Apply the formula: Rv= *lf *(lf)^2 Fan: Rv= *lf *(lf)^2 Energy aving =Power* time* lf*((1/rv)-(1/0.993) Enter each engine performance (Rv) Final aving in kwh/year i the um of all the equipment' energy aving

185 Add thi quetion in the extruder quetionnaire: I the extruder cylinder heating ytem an induction heating ytem? Recommendation aving of 21% with repect to the initial equipment conumption

186 Mariano Equillor 15, Zaragoza (Spain)