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Project Name: Turkish Textile Company - Energy Survey
Country: Turkey
Description: An energy survey was completed at a large vertical textile facility. The plant includes slashing, weaving, dyeing, and finishing for apparel products. The total savings identified was $362,800. The opportunities centered on boiler issues and compressed air. The review of energy opportunities included a compressed air generation and distribution system evaluation, steam generation and distribution systems evaluation, HVAC system review, lighting evaluation, and a plant walk-through to identify other energy saving opportunities. The following primary opportunities were identified and may be accomplished through utilization of plant maintenance resources: • Monitor GA 90 compressor for high pressure; • Reduction of compressed air leaks; • Reduction of steam leaks; • Performance of electrical rate analysis; • Performance of as many operations as possible during off peak hours; • Elimination of energized idle equipment; and • Implementation of an energy conservation program. The following additional opportunities were identified which will require capital investment: • Installation of metering on boiler systems; • Conversion of boilers to natural gas when available; • Improvement to condensate return fraction to boiler; • Repair economizer on 20 ton boiler; • Installation of duct to capture combustion air from boiler house ceiling; • Insulation of exposed steam pipes; • Repair of steam traps; • Replacement of lighting with more efficient fixtures; • Installation of central AC unit for office building; • Pursuit Berdan-identified energy projects; and • Implementation of data management and system optimization. The Client's Facility is a slashing, weaving, dyeing, and finishing facility for apparel products. The primary equipment included: air jet looms, rapier looms, dye jets, finishing tenters, and inspection frames. Energy utilization for the plant included fuel oil No. 6, steam, compressed air, hot oil, water, and electricity. The typical operating schedule for the plant was 300 days per year. The plant operated 7 days per week, 3 shifts, and 24 hours per day. The review of energy opportunities included a compressed air generation and distribution system evaluation, steam generation and distribution systems evaluation, HVAC system review, lighting evaluation, and a plant walk-through to identify other energy saving opportunities.
 

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