Energy-Efficient Industrial Systems: Evaluation and Implementation

Abbreviations and Acronyms<br/>1 Energy Management<br/>1.1 Introduction<br/>1.2 Main Drivers for Energy Management<br/>1.3 Typical Energy Management Program<br/>1.4 Energy Policy<br/>1.5 Energy Management Team<br/>1.6 Energy Manager<br/>1.7 Energy Usage and Baseline Data<br/>1.8 Energy Accounting Centers and EnPIs<br/>1.9 Targets and Action Plans<br/>1.10 Energy Audits<br/>1.10.1 Level 1 Audit<br/>1.10.2 Level 2 Audit<br/>1.10.3 Level 3 Audit<br/>1.11 Training<br/>1.12 Awareness<br/>1.13 Documentation<br/>1.14 Internal Audit<br/>1.15 Management Review<br/>2 Motors and Drives<br/>2.1 Introduction to Motors<br/>2.1.1 AC Induction Motors<br/>2.1.2 DC Motors<br/>2.1.3 Permanent-Magnet Motors<br/>2.1.4 Synchronous Motors<br/>2.2 Speed of Motors<br/>2.3 Slip in Motors<br/>2.4 Motor Efficiency<br/>2.5 Losses in Motors<br/>2.6 High-Efficiency Motors<br/>2.7 Impact of Motor Loading on Efficiency<br/>2.8 Estimating Motor Loading<br/>2.8.1 Input Method<br/>2.8.2 Slip Method<br/>2.9 Economics of Energy-Efficient Motors<br/>2.10 Input Power Supply to Motors<br/>2.10.1 Input Power<br/>2.10.2 Supply Voltage<br/>2.10.3 Power Factor<br/>2.11 Maintenance of Motors<br/>2.11.1 Lubrication<br/>2.11.2 Cleaning<br/>2.11.3 Motor Temperature<br/>2.11.4 Voltage Testing<br/>2.11.5 Insulation Testing<br/>2.11.6 Vibration<br/>2.11.7 Alignment<br/>2.12 Motor Drives<br/>2.12.1 Couplings<br/>2.12.2 Belt Drives<br/>2.12.3 Gear Drives<br/>2.13 Variable-Frequency Drives<br/>2.13.1 Introduction<br/>2.13.2 Components of a VFD<br/>2.13.3 Features of VFDs<br/>2.13.4 Selection and Installation<br/>3 Pumping Systems<br/>3.1 Types of Pumps<br/>3.2 System and Pump Curves<br/>3.3 Pump Power<br/>3.4 Affinity Laws<br/>3.5 Pressure Losses in Pipes and Fittings<br/>3.6 Parallel and Series Pumping<br/>3.7 Pump Sizing<br/>3.8 Constant-Flow versus Variable-Flow Systems<br/>3.9 Effect of Pump Speed and Size on Efficiency<br/>3.10 Avoiding Use of Bypass Systems<br/>3.11 Use of Small Pumps to Augment Larger Pumps<br/>3.12 Designing to Minimize Pressure Losses<br/>3.13 Pump Efficiency<br/>3.14 Overall Efficiency<br/>3.14.1 Constant-Speed Pumps<br/>3.14.2 Variable-Speed Pumps<br/>4 Fan Systems<br/>4.1 Types of Fans<br/>4.2 Fan and System Characteristics<br/>4.3 Fan Selection<br/>4.4 Theoretical Fan Power Consumption<br/>4.5 Affinity Laws<br/>4.6 System Losses<br/>4.7 Fan Discharge and Inlet System Effects<br/>4.8 Filter Losses<br/>4.8.1 Face Velocity<br/>4.9 Coil Losses<br/>4.9.1 Clean Coils<br/>4.9.2 Face Velocity<br/>4.10 Fan Efficiency<br/>4.11 Right Sizing of Fans<br/>4.12 Modulating Airflow Rate<br/>5 Boilers and Steam Systems<br/>5.1 Introduction<br/>5.2 Fundamentals of Steam<br/>5.2.1 Dryness Fraction of Steam<br/>5.2.2 Sensible Heat of Water<br/>5.2.3 Latent Heat of Water<br/>5.2.4 Total Enthalpy of Steam<br/>5.2.5 Steam Tables<br/>5.3 Boilers<br/>5.4 Boiler Efficiency<br/>5.4.1 Combustion Efficiency<br/>5.4.2 Thermal Efficiency<br/>5.4.3 Overall Efficiency<br/>5.5 Energy-Saving Measures for Boiler Systems<br/>5.5.1 Improving Combustion Efficiency<br/>5.5.2 Steam Pressure<br/>5.5.3 Optimizing Operation of Auxiliary Equipment<br/>5.5.4 Standby Losses<br/>5.5.5 Minimizing Conduction and Radiation Losses<br/>5.5.6 Heat Recovery from Flue Gas<br/>5.5.7 Flash Steam Recovery<br/>5.5.8 Automatic Blowdown Control<br/>5.5.9 Heat Recovery from Blowdown<br/>5.5.10 Condensate Recovery<br/>5.5.11 Steam Traps<br/>5.5.12 Steam Leaks<br/>5.5.13 Feedwater Tank<br/>5.5.14 Fouling and Scaling in Boilers<br/>6 Process Cooling Systems<br/>6.1 Introduction<br/>6.2 Once-Through Systems<br/>6.3 Cooling Tower Systems<br/>6.3.1 Energy-Saving Measures for Cooling Tower Systems<br/>6.4 Low-Temperature Cooling Systems<br/>6.4.1 Energy-Saving Measures for Low-Temperature Cooling Systems<br/>6.5 Refrigeration Systems<br/>6.5.1 Energy-Saving Measures for Refrigeration Systems<br/>7 Compressed Air Systems<br/>7.1 Introduction<br/>7.2 Typical System Components<br/>7.3 Free Air Delivery<br/>7.4 Standard Con