How a walk thru audit will help? Walk thru audit basically finds out area of improvement if any. It tells you weaker and stronger areas in the system.
We will look into Combustion efficiency thru various temperature profiles such as stack, Inlet, outlet, fuel consumption, abnormalities in Various surface temp if any.( Pl note this does not include checking CO2 / O2 / stack analysis but analysis of above mentioned parameters can identify if the unit is not performing well)
Pump: Analysis of Current, Voltage, flow characteristics, Leakage etc. This will help us in deciding flow of the pump. More flow reduces ??T, Lesser flow Increases the same. Together with flow and fuel consumption we will get idea on Heat load of the unit. This will help us in adding more utilities.
General operation and maintenance practices, Safeties / controls, Any lacunae in the same. This tells about safety related issues which may be serious
Expansion tank: Location, Installation, Capacity, temp profile. Higher temperature in expansion tank leads to more oxidation.
Pipe line ??? This being walk thru audit, we will check basic sizing and layout to see if any improvement is possible. We will go thru the layout and P & I diagram to check velocities at various points.
Thermic fluid: Analysis comparison, Suggestion to reduce rate of degradation of Thermic fluid system.
The audit will be conducted by two of our best persons each having experience of more than 20 years plus. The audit will be conducted in two parts. One part will involve basic system analysis and data collection in personal visit and second part will involve necessary back up work of data analysis to submit the report.
The second report will be submitted specifying concern area where detailed calculations and detailed analysis are required. Please understand that Walk thru audit helps us in understanding the problematic areas. The detailed solution needs to be worked out separately. We will submit detailed report alongwith basic cost estimation for the detailed working on the problem. In case detailed designing is required, that will be charged / estimated separately
How our experience in this field is useful? To site some example,
In one Textile Company in Western Maharashtra, the G.M. was worried about not getting the temperature. Somebody suggested him to install booster pump to solve the problem. When consulted, we checked the pressure drop, various velocity profiles to confirm the need. Buying booster pump is very easy, spend 50k and enjoy depreciation as well good flow, but yearly recurring electrical bill expense would have been @ 10 Lacs /year. We could save this as problem was a valve which was restricting flow due to malfunction.
Where as in one company manufacturing flexible packaging used for packing wafers, chips etc. V.P wanted to go for higher sized circulation pump and remove booster pump which was already installed to save cost. Since we knew the type of Industry, we advised him against the removal as their imported heat exchanger size was smaller and it needed higher flow for proper temperature. If he would have replaced the booster pump, The cost of new circulating pump was @ 70K, the higher sized pump would have resulted in higher pressure drop, power consumption would have increased by 15-20% and still his processing time would have been atelast 25% more.
One company in North India was facing the problem of not getting the temperature. Everything was alright till they replaced a corroded pipe line. During our audit we found that one piece of pipeline was 3.5??? instead of 4???. We replaced the same and problem was sorted out.
One unit had Thermic steam generator installed just after the outlet of Thermic fluid heater. Problem was flow and solution proposed was booster pump. After the audit, we just shifted the steam generator to the end of utility ??? before return of oil to Deaearator tank. The problem got solved. No need of Booster Pump.
While comparing oil analysis report of a reputed ink manufacturer( Oil hold up 1,35,000 ltr), we found that every six month, the oil was deteriorating. They were replacing @ 30-50% oil and maintaining it because there was no shutdown. We checked / rechecked and took some samples for analysis. Our conclusion was mixing of low boilers ??? improper deaeration of oil. We developed separate / external deaeration unit for them. After one month the analysis report showed that deterioration has stopped and Flash point is improving. Here the payback was less than 3 months and they were replacing 30% oil every three months.
Few simple tips can save a lot. Tips on precautions in operations of multi unit system, Operating practices, safeties, controls, relation of stack and outlet temp monitoring this can result in safe operations, Healthy operations.