Energy Saving Tips for Industries Consumers

Tips for Energy Conservation for Industries
THERMAL UTILITIES

Boilers

• Preheat combustion air with waste heat
  (22 0C reduction in flue gas temperature increases boiler efficiency by 1%).
  
• Use variable speed drives on large boiler combustion air fans with variable flows.
  
• Burn wastes if permitted.
  
• Insulate exposed heated oil tanks.
  
• Clean burners, nozzles, strainers, etc.
  
• Inspect oil heaters for proper oil temperature.
  
• Close burner air and/or stack dampers when the burner is off to minimize heat loss
  up the stack.
  
• Improve oxygen trim control (e.g. -- limit excess air to less than 10% on clean fuels).
  (5% reduction in excess air increases boiler efficiency by 1% or: 1% reduction of
  residual oxygen in stack gas increases boiler efficiency by 1%.)
  
• Automate/optimize boiler blowdown. Recover boiler blowdown heat.
  
• Use boiler blowdown to help warm the back-up boiler.
  
• Optimize deaerator venting.
  
• Inspect door gaskets.
  
• Inspect for scale and sediment on the water side
  (A 1 mm thick scale (deposit) on the water side could increase fuel consumption by 5 to 8%).
  
• Inspect for soot, flyash, and slag on the fire side
  (A 3 mm thick soot deposition on the heat transfer surface can cause an increase in fuel consumption to the tune of 2.5%.)
  
• Optimize boiler water treatment.
  
• Add an economizer to preheat boiler feedwater using exhaust heat.
  
• Recycle steam condensate.
  
• Study part-load characteristics and cycling costs to determine the most-efficient
  mode for operating multiple boilers.
  
• Consider multiple or modular boiler units instead of one or two large boilers.
  
• Establish a boiler efficiency-maintenance program. Start with an energy audit and
  follow-up, then make a boiler efficiency-maintenance program a part of your continuous energy management program.
  
  Steam System
  
  • Fix steam leaks and condensate leaks
    (A 3 mm diameter hole on a pipe line carrying 7 kg/cm2 steam would waste 33 kilo litres of fuel oil per year).
    
  • Accumulate work orders for repair of steam leaks that can't be fixed during the heating season due to system shutdown requirements. Tag each such leak with a durable tag with a good description.
    
  • Use back pressure steam turbines to produce lower steam pressures.
    
  • Use more-efficient steam desuperheating methods.
    
  • Ensure process temperatures are correctly controlled.
    
  • Maintain lowest acceptable process steam pressures.
    • Reduce hot water wastage to drain

• Remove or blank off all redundant steam piping.
  
• Ensure condensate is returned or re-used in the process
  (6 0C raise in feed water temperature by economiser/condensate recovery
  corresponds to a 1% saving in fuel consumption, in boiler).
  
• Preheat boiler feed-water.
  
• Recover boiler blowdown.
  
• Check operation of steam traps.
  
• Remove air from indirect steam using equipment
  (0.25 mm thick air film offers the same resistance to heat transfer as a 330 mm thick
  copper wall.)
  
• Inspect steam traps regularly and repair malfunctioning traps promptly.
  
• Consider recovery of vent steam (e.g. -- on large flash tanks).
  
• Use waste steam for water heating.
  
• Use an absorption chiller to condense exhaust steam before returning the
  condensate to the boiler.
  
• Use electric pumps instead of steam ejectors when cost benefits permit
  
• Establish a steam efficiency-maintenance program. Start with an energy audit and
  follow-up, then make a steam efficiency-maintenance program a part of your continuous energy management program. 
• 
  

Furnaces

• Check against infiltration of air: Use doors or air curtains.
  
• Monitor O2 /CO2/CO and control excess air to the optimum level.
  
• Improve burner design, combustion control and instrumentation.
  
• Ensure that the furnace combustion chamber is under slight
  positive pressure.
  
• Use ceramic fibres in the case of batch operations.
  
• Match the load to the furnace capacity.
  
• Retrofit with heat recovery device.
  
• Investigate cycle times and reduce.
  
• Provide temperature controllers.
  
• Ensure that flame does not touch the stock.
  Insulation
  

• Repair damaged insulation
  (A bare steam pipe of 150 mm diameter and 100 m length, carrying saturated steam at 8 kg/cm2 would waste 25,000 litres furnace oil in a year.)
  
• Insulate any hot or cold metal or insulation.
  
• Replace wet insulation.
  
• Use an infrared gun to check for cold wall areas during cold
  weather or hot wall areas during hot weather.
  
• Ensure that all insulated surfaces are cladded with aluminum
  
• Insulate all flanges, valves and couplings
  
• Insulate open tanks
  (70% heat losses can be reduced by floating a layer of 45 mm diameter polypropylene (plastic) balls on the surface of 90 0C hot liquid/condensate).
  

Waste heat recovery

• Recover heat from flue gas, engine cooling water, engine exhaust, low pressure waste steam, drying oven exhaust, boiler blowdown, etc.
  
• Recover heat from incinerator off-gas.
  
• Use waste heat for fuel oil heating, boiler feedwater heating,
  outside air heating, etc.
  
• Use chiller waste heat to preheat hot water.
  
• Use heat pumps.
  
• Use absorption refrigeration.
  
• Use thermal wheels, run-around systems, heat pipe systems, and air-to-air
  exchangers.
  
  
  ELECTRICAL UTILITIES
  
  Electricity Distribution System
  
  
  • Optimise the tariff structure with utility supplier
    
  • Schedule your operations to maintain a high load factor
    
  • Shift loads to off-peak times if possible.
    
  • Minimise maximum demand by tripping loads through a demand
    controller
    
  • Stagger start-up times for equipment with large starting currents to
    minimize load peaking.
    
  • Use standby electric generation equipment for on-peak high load periods.
    
  • Correct power factor to at least 0.90 under rated load conditions.
    
  • Relocate transformers close to main loads.
    
  • Set transformer taps to optimum settings.
    
  • Disconnect primary power to transformers that do not serve any active loads
    
  • Consider on-site electric generation or cogeneration.
    
  • Export power to grid if you have any surplus in your captive generation
    
  • Check utility electric meter with your own meter.
    
  • Shut off unnecessary computers, printers, and copiers at night.
    
    Motors
    
    • Properly size to the load for optimum efficiency.
      (High efficiency motors offer of 4 - 5% higher efficiency than standard motors)
      
    • Use energy-efficient motors where economical.
      
    • Use synchronous motors to improve power factor.
      
    • Check alignment.
      
    • Provide proper ventilation
      (For every 10 oC increase in motor operating temperature over recommended peak,
      the motor life is estimated to be halved)
      
    • Check for under-voltage and over-voltage conditions.
      
    • Balance the three-phase power supply.
      (An imbalanced voltage can reduce 3 - 5% in motor input power)
      
    • Demand efficiency restoration after motor rewinding.
      (If rewinding is not done properly, the efficiency can be reduced by 5 - 8%)
      

Drives

• Use variable-speed drives for large variable loads.
  
• Use high-efficiency gear sets.
  
• Use precision alignment.
  
• Check belt tension regularly.
  
• Eliminate variable-pitch pulleys.
  
• Use flat belts as alternatives to v-belts.
  
• Use synthetic lubricants for large gearboxes.
  
• Eliminate eddy current couplings.
  
• Shut them off when not needed.
  Fans
  

• Use smooth, well-rounded air inlet cones for fan air intakes.
  
• Avoid poor flow distribution at the fan inlet.
  
• Minimize fan inlet and outlet obstructions.
  
• Clean screens, filters, and fan blades regularly.
  
• Use aerofoil-shaped fan blades.
  
• Minimize fan speed.
  
• Use low-slip or flat belts.
  
• Check belt tension regularly.
  
• Eliminate variable pitch pulleys.
  
• Use variable speed drives for large variable fan loads.
  
• Use energy-efficient motors for continuous or near-continuous operation
  
• Eliminate leaks in ductwork.
  
• Minimise bends in ductwork
  
• Turn fans off when not needed.
  Blowers
  

• Use smooth, well-rounded air inlet ducts or cones for air intakes.
  
• Minimize blower inlet and outlet obstructions.
  
• Clean screens and filters regularly.
  
• Minimize blower speed.
  
• Use low-slip or no-slip belts.
  
• Check belt tension regularly.
  
• Eliminate variable pitch pulleys.
  
• Use variable speed drives for large variable blower loads.
  
• Use energy-efficient motors for continuous or near-continuous operation.
  
• Eliminate ductwork leaks.
  
• Turn blowers off when they are not needed.
  Pumps
  

• Operate pumping near best efficiency point.
  
• Modify pumping to minimize throttling.
  
• Adapt to wide load variation with variable speed drives or
  sequenced control of smaller units.
  
• Stop running both pumps -- add an auto-start for an on-line
  spare or add a booster pump in the problem area.
  
• Use booster pumps for small loads requiring higher pressures.
  
• Increase fluid temperature differentials to reduce pumping rates.
  
• Repair seals and packing to minimize water waste.
  
• Balance the system to minimize flows and reduce pump power requirements.

• Use siphon effect to advantage: don't waste pumping head with a free-fall (gravity) return.

Compressors

• Consider variable speed drive for variable load on positive displacement compressors.
  
• Use a synthetic lubricant if the compressor manufacturer permits it.
  
• Be sure lubricating oil temperature is not too high (oil degradation and lowered viscosity) and not too low (condensation
  contamination).
  
• Change the oil filter regularly.
  
• Periodically inspect compressor intercoolers for proper functioning.
  
• Use waste heat from a very large compressor to power an absorption chiller or
  preheat process or utility feeds.
  
• Establish a compressor efficiency-maintenance program. Start with an energy audit
  and follow-up, then make a compressor efficiency-maintenance program a part of your continuous energy management program.
  
  Compressed air
  

• Install a control system to coordinate multiple air compressors.
  
• Study part-load characteristics and cycling costs to determine
  the most-efficient mode for operating multiple air compressors.
  
• Avoid over sizing -- match the connected load.
  
• Load up modulation-controlled air compressors. (They use
  almost as much power at partial load as at full load.)
  
• Turn off the back-up air compressor until it is needed.
  
• Reduce air compressor discharge pressure to the lowest acceptable setting.
  (Reduction of 1 kg/cm2 air pressure (8 kg/cm2 to 7 kg/cm2) would result in 9% input
  power savings. This will also reduce compressed air leakage rates by 10%)
  
• Use the highest reasonable dryer dew point settings.
  
• Turn off refrigerated and heated air dryers when the air compressors are off.
  
• Use a control system to minimize heatless desiccant dryer purging.
  
• Minimize purges, leaks, excessive pressure drops, and condensation accumulation.
  (Compressed air leak from 1 mm hole size at 7 kg/cm2 pressure would mean power
  loss equivalent to 0.5 kW)
  
• Use drain controls instead of continuous air bleeds through the drains.
  
• Consider engine-driven or steam-driven air compression to reduce electrical demand
  charges.
  
• Replace standard v-belts with high-efficiency flat belts as the old v-belts wear out.
  
• Use a small air compressor when major production load is off.
  
• Take air compressor intake air from the coolest (but not air conditioned) location.
  (Every 50C reduction in intake air temperature would result in 1% reduction in
  compressor power consumption)
  
• Use an air-cooled aftercooler to heat building makeup air in winter.
  
• Be sure that heat exchangers are not fouled (e.g. -- with oil).
  
• Be sure that air/oil separators are not fouled.
  
• Monitor pressure drops across suction and discharge filters and clean or replace
  filters promptly upon alarm.
  
• Use a properly sized compressed air storage receiver. Minimize disposal costs by
  using lubricant that is fully demulsible and an effective oil-water separator.

• Consider alternatives to compressed air such as blowers for cooling, hydraulic rather than air cylinders, electric rather than air actuators, and electronic rather than pneumatic controls.
  
• Use nozzles or venturi-type devices rather than blowing with open compressed air lines.
  
• Check for leaking drain valves on compressed air filter/regulator sets. Certain rubber- type valves may leak continuously after they age and crack.
  
• In dusty environments, control packaging lines with high-intensity photocell units instead of standard units with continuous air purging of lenses and reflectors.
  
• Establish a compressed air efficiency-maintenance program. Start with an energy audit and follow-up, then make a compressed air efficiency-maintenance program a part of your continuous energy management program.
  
  Chillers
  

• Increase the chilled water temperature set point if possible.
  
• Use the lowest temperature condenser water available that
  the chiller can handle.
  (Reducing condensing temperature by 5.5 0C, results in a 20 -
  25% decrease in compressor power consumption)
  
• Increase the evaporator temperature
  (5.50C increase in evaporator temperature reduces compressor power consumption by 20 - 25%)
  
• Clean heat exchangers when fouled.
  (1 mm scale build-up on condenser tubes can increase energy consumption by 40%)
  
• Optimize condenser water flow rate and refrigerated water flow rate.
  
• Replace old chillers or compressors with new higher-efficiency models.
  
• Use water-cooled rather than air-cooled chiller condensers.
  
• Use energy-efficient motors for continuous or near-continuous operation.
  
• Specify appropriate fouling factors for condensers.
  
• Do not overcharge oil.
  
• Install a control system to coordinate multiple chillers.
  
• Study part-load characteristics and cycling costs to determine the most-efficient
  mode for operating multiple chillers.
  
• Run the chillers with the lowest energy consumption. It saves energy cost, fuels a
  base load.
  
• Avoid oversizing -- match the connected load.
  
• Isolate off-line chillers and cooling towers.
  
• Establish a chiller efficiency-maintenance program. Start with an energy audit and
  follow-up, then make a chiller efficiency-maintenance program a part of your continuous energy management program.
  
  HVAC (Heating / Ventilation / Air Conditioning)
  
  • Tune up the HVAC control system.
    
  • Consider installing a building automation system (BAS) or energy
    management system (EMS) or restoring an out-of-service one.
    
  • Balance the system to minimize flows and reduce blower/fan/pump
    power requirements.
    
  • Eliminate or reduce reheat whenever possible.
    
  • Use appropriate HVAC thermostat setback.
    
  • Use morning pre-cooling in summer and pre-heating in winter (i.e. -- before electrical
    peak hours).
    
  • Use building thermal lag to minimize HVAC equipment operating time.

• In winter during unoccupied periods, allow temperatures to fall as low as possible without freezing water lines or damaging stored materials.
  
• In summer during unoccupied periods, allow temperatures to rise as high as possible without damaging stored materials.
  
• Improve control and utilization of outside air.
  
• Use air-to-air heat exchangers to reduce energy requirements for heating and cooling
  of outside air.
  
• Reduce HVAC system operating hours (e.g. -- night, weekend).
  
• Optimize ventilation.
  
• Ventilate only when necessary. To allow some areas to be shut down when
  unoccupied, install dedicated HVAC systems on continuous loads (e.g. -- computer
  rooms).
  
• Provide dedicated outside air supply to kitchens, cleaning rooms, combustion
  equipment, etc. to avoid excessive exhausting of conditioned air.
  
• Use evaporative cooling in dry climates.
  
• Reduce humidification or dehumidification during unoccupied periods.
  
• Use atomization rather than steam for humidification where possible.
  
• Clean HVAC unit coils periodically and comb mashed fins.
  
• Upgrade filter banks to reduce pressure drop and thus lower fan power requirements.
  
• Check HVAC filters on a schedule (at least monthly) and clean/change if appropriate.
  
• Check pneumatic controls air compressors for proper operation, cycling, and
  maintenance.
  
• Isolate air conditioned loading dock areas and cool storage areas using high-speed
  doors or clear PVC strip curtains.
  
• Install ceiling fans to minimize thermal stratification in high-bay areas.
  
• Relocate air diffusers to optimum heights in areas with high ceilings.
  
• Consider reducing ceiling heights.
  
• Eliminate obstructions in front of radiators, baseboard heaters, etc.
  
• Check reflectors on infrared heaters for cleanliness and proper beam direction.
  
• Use professionally-designed industrial ventilation hoods for dust and vapor control.
  
• Use local infrared heat for personnel rather than heating the entire area.
  
• Use spot cooling and heating (e.g. -- use ceiling fans for personnel rather than
  cooling the entire area).
  
• Purchase only high-efficiency models for HVAC window units.
  
• Put HVAC window units on timer control.
  
• Don't oversize cooling units. (Oversized units will "short cycle" which results in poor
  humidity control.)
  
• Install multi-fueling capability and run with the cheapest fuel available at the time.
  
• Consider dedicated make-up air for exhaust hoods. (Why exhaust the air conditioning
  or heat if you don't need to?)
  
• Minimize HVAC fan speeds.
  
• Consider desiccant drying of outside air to reduce cooling requirements in humid
  climates.
  
• Consider ground source heat pumps.
  
• Seal leaky HVAC ductwork.
  
• Seal all leaks around coils.
  
• Repair loose or damaged flexible connections (including those under air handling
  units).
  
• Eliminate simultaneous heating and cooling during seasonal transition periods.
  
• Zone HVAC air and water systems to minimize energy use.
  
• Inspect, clean, lubricate, and adjust damper blades and linkages.

• Establish an HVAC efficiency-maintenance program. Start with an energy audit and follow-up, then make an HVAC efficiency-maintenance program a part of your continuous energy management program.

Refrigeration

• Use water-cooled condensers rather than air-cooled condensers.
  
• Challenge the need for refrigeration, particularly for old batch
  processes.
  
• Avoid oversizing -- match the connected load.
  
• Consider gas-powered refrigeration equipment to minimize electrical
  demand charges.
  
• Use "free cooling" to allow chiller shutdown in cold weather.
  
• Use refrigerated water loads in series if possible.
  
• Convert firewater or other tanks to thermal storage.
  
• Don't assume that the old way is still the best -- particularly for energy-intensive low
  temperature systems.
  
• Correct inappropriate brine or glycol concentration that adversely affects heat
  transfer and/or pumping energy.
  If it sweats, insulate it, but if it is corroding, replace it first.
  
• Make adjustments to minimize hot gas bypass operation.
  
• Inspect moisture/liquid indicators.
  
• Consider change of refrigerant type if it will improve efficiency.
  
• Check for correct refrigerant charge level.
  
• Inspect the purge for air and water leaks.
  
• Establish a refrigeration efficiency-maintenance program. Start with an energy audit
  and follow-up, then make a refrigeration efficiency-maintenance program a part of your continuous energy management program.
  Cooling towers
  

• Control cooling tower fans based on leaving water temperatures.
  
• Control to the optimum water temperature as determined from
  cooling tower and chiller performance data.
  
• Use two-speed or variable-speed drives for cooling tower fan
  control if the fans are few. Stage the cooling tower fans with on-off
  control if there are many.
  
• Turn off unnecessary cooling tower fans when loads are reduced.
  
• Cover hot water basins (to minimize algae growth that contributes to fouling).
  
• Balance flow to cooling tower hot water basins.
  
• Periodically clean plugged cooling tower water distribution nozzles.
  
• Install new nozzles to obtain a more-uniform water pattern.
  
• Replace splash bars with self-extinguishing PVC cellular-film fill.
  
• On old counterflow cooling towers, replace old spray-type nozzles with new square-
  spray ABS practically-non-clogging nozzles.
  
• Replace slat-type drift eliminators with high-efficiency, low-pressure-drop, self-
  extinguishing, PVC cellular units.
  
• If possible, follow manufacturer's recommended clearances around cooling towers
  and relocate or modify structures, signs, fences, dumpsters, etc. that interfere with air
  intake or exhaust.
  
• Optimize cooling tower fan blade angle on a seasonal and/or load basis.
  
• Correct excessive and/or uneven fan blade tip clearance and poor fan balance.
  
• Use a velocity pressure recovery fan ring.
  
• Divert clean air-conditioned building exhaust to the cooling tower during hot weather.

• Re-line leaking cooling tower cold water basins.
  
• Check water overflow pipes for proper operating level.
  
• Optimize chemical use.
  
• Consider side stream water treatment.
  
• Restrict flows through large loads to design values.
  
• Shut off loads that are not in service.
  
• Take blowdown water from the return water header.
  
• Optimize blowdown flow rate.
  
• Automate blowdown to minimize it.
  
• Send blowdown to other uses (Remember, the blowdown does not have to be
  removed at the cooling tower. It can be removed anywhere in the piping system.)
  
• Implement a cooling tower winterization plan to minimize ice build-up.
  
• Install interlocks to prevent fan operation when there is no water flow.
  
• Establish a cooling tower efficiency-maintenance program. Start with an energy audit
  and follow-up, then make a cooling tower efficiency-maintenance program a part of your continuous energy management program.
  
  Lighting
  

• Reduce excessive illumination levels to standard levels using switching, delamping, etc. (Know the electrical effects before doing delamping.)
  
• Aggressively control lighting with clock timers, delay timers, photocells, and/or occupancy sensors.
  
• Install efficient alternatives to incandescent lighting, mercury vapor
  lighting, etc. Efficacy (lumens/watt) of various technologies range from best to worst approximately as follows: low pressure sodium, high pressure sodium, metal halide, fluorescent, mercury vapor, incandescent.
  
• Select ballasts and lamps carefully with high power factor and long-term efficiency in mind.
  
• Upgrade obsolete fluorescent systems to Compact fluorescents and electronic ballasts
  
• Consider daylighting, skylights, etc.
  
• Consider painting the walls a lighter color and using less lighting fixtures or lower
  wattages.
  
• Use task lighting and reduce background illumination.
  
• Re-evaluate exterior lighting strategy, type, and control. Control it aggressively.
  
• Change exit signs from incandescent to LED.
  DG sets
  

• Optimise loading
  
• Use waste heat to generate steam/hot water /power an absorption
  chiller or preheat process or utility feeds.
  
• Use jacket and head cooling water for process needs
  
• Clean air filters regularly
  
• Insulate exhaust pipes to reduce DG set room temperatures
  
• Use cheaper heavy fuel oil for capacities more than 1MW
  

Buildings

• Seal exterior cracks/openings/gaps with caulk, gasketing, weatherstripping, etc.
  
• Consider new thermal doors, thermal windows, roofing insulation, etc.
  
• Install windbreaks near exterior doors.
  
• Replace single-pane glass with insulating glass.
  
• Consider covering some window and skylight areas with insulated wall
  panels inside the building.
  
• If visibility is not required but light is required, consider replacing exterior windows
  with insulated glass block.
  
• Consider tinted glass, reflective glass, coatings, awnings, overhangs, draperies,
  blinds, and shades for sunlit exterior windows.
  
• Use landscaping to advantage.
  
• Add vestibules or revolving doors to primary exterior personnel doors.
  
• Consider automatic doors, air curtains, strip doors, etc. at high-traffic passages
  between conditioned and non-conditioned spaces. Use self-closing doors if possible.
  
• Use intermediate doors in stairways and vertical passages to minimize building stack
  effect.
  
• Use dock seals at shipping and receiving doors.
  
• Bring cleaning personnel in during the working day or as soon after as possible to
  minimize lighting and HVAC costs.
  
  Water & Wastewater
  

• Recycle water, particularly for uses with less-critical quality requirements.
  
• Recycle water, especially if sewer costs are based on water consumption.
  
• Balance closed systems to minimize flows and reduce pump power requirements.
  
• Eliminate once-through cooling with water.
  
• Use the least expensive type of water that will satisfy the requirement.
  
• Fix water leaks.
  
• Test for underground water leaks. (It's easy to do over a holiday shutdown.)
  
• Check water overflow pipes for proper operating level.
  
• Automate blowdown to minimize it.
  
• Provide proper tools for wash down -- especially self-closing nozzles.
  
• Install efficient irrigation.
  
• Reduce flows at water sampling stations.
  
• Eliminate continuous overflow at water tanks.
  
• Promptly repair leaking toilets and faucets.
  
• Use water restrictors on faucets, showers, etc.
  
• Use self-closing type faucets in restrooms.
  
• Use the lowest possible hot water temperature.
  
• Do not use a central heating system hot water boiler to provide service hot water
  during the cooling season -- install a smaller, more-efficient system for the cooling
  season service hot water.
  
• Consider the installation of a thermal solar system for warm water.
  
• If water must be heated electrically, consider accumulation in a large insulated
  storage tank to minimize heating at on-peak electric rates.
  
• Use multiple, distributed, small water heaters to minimize thermal losses in large
  piping systems.
  
• Use freeze protection valves rather than manual bleeding of lines.

• Consider leased and mobile water treatment systems, especially for deionized water.
  
• Seal sumps to prevent seepage inward from necessitating extra sump pump
  operation.
  
• Install pretreatment to reduce TOC and BOD surcharges.
  
• Verify the water meter readings. (You'd be amazed how long a meter reading can be
  estimated after the meter breaks or the meter pit fills with water!)
  
• Verify the sewer flows if the sewer bills are based on them
  
  Miscellaneous
  

• Meter any unmetered utilities. Know what is normal efficient use. Track down causes of deviations.
  
• Shut down spare, idling, or unneeded equipment.
  
• Make sure that all of the utilities to redundant areas are turned off -- including utilities
  like compressed air and cooling water.
  
• Install automatic control to efficiently coordinate multiple air compressors, chillers,
  cooling tower cells, boilers, etc.
  
• Renegotiate utilities contracts to reflect current loads and variations.
  
• Consider buying utilities from neighbors, particularly to handle peaks.
  
• Leased space often has low-bid inefficient equipment. Consider upgrades if your
  lease will continue for several more years.
  
• Adjust fluid temperatures within acceptable limits to minimize undesirable heat
  transfer in long pipelines.
  
• Minimize use of flow bypasses and minimize bypass flow rates.
  
• Provide restriction orifices in purges (nitrogen, steam, etc.).
  
• Eliminate unnecessary flow measurement orifices.
  
• Consider alternatives to high pressure drops across valves.
  
• Turn off winter heat tracing that is on in summer.
  

(Source: Bureau of Energy Efficiency, New Delhi)