Plant management

Simple changes to the way you manage your plant and processes can deliver significant energy savings.

Regular plant and machine maintenance improves efficiency and makes for a safer working environment. A well managed maintenance programme can cut your maintenance costs by up to 25% a year.

Boilers

If you are managing a boiler plant and its associated distribution systems, consider the following actions:

• use the lowest steam pressure and water temperature needed to operate machinery
• regularly check boilers - the cost of quarterly checks will be paid back in savings from a well-tuned boiler
• monitor fuel use, and steam and hot water output
• review your condensate return system - lost condensate increases water treatment and energy costs
• have a water treatment programme
• try to time your power use for times of maximum boiler efficiency
• repair leaking flanges, valves and pumps
• check for hot spots, which are signs of insulation gaps
• keep excess air at correct levels with periodic calibration
• keep the fire-side surfaces of boiler tubes clean.

Water systems

If you are managing water systems, consider the following actions: 

• monitor the amount and cost of your water supply with water meters
• treat water as a variable cost and charge each cost centre separately
• look for various uses for your water so it's not just a ‘once through' cooling source
• look for areas where unnecessary pumping occurs
• fix all leaks
• use variable speed drives and efficient equipment for systems with excessive or irregular demand
• install flow regulators and pressure valves.

Better plant management in action

Auckland Meat Processors introduced automated controls into their business and in the process reduced their energy bill by over $200,000 in the first year alone.

Read the Auckland Meat Processors case study.

More information

Switch Off, Better Off provides you with stickers and posters to remind staff to turn off un-needed lights, appliances, machinery and vehicles.