c. Belief: during defrosting evaporator fan stops.
Fact: fan does not stop, it blows hot air into freezer; error in settings causes energy waste AND deteriorated storage conditions
Audit uncovered this by directly measuring power draw on fans.
d. Belief: we barely add water through this pipe, water consumption is negligible.
Fact: pipe is used 16h a day, causing waste of water and chemicals. Estimated cost is $20,000 per year.
e. Belief: temperature in this pot is maintained within a narrow range, if it exceeds range – alarm will sound and red light flash.
Fact: temperature is up by 25F, alarm wire was torn off by some disgruntled worker. Minor failure of controls triggered alarm and disgruntled worker did not like the sound. Overheating caused waste of natural gas for heating and carbon dioxide for cooling down the production process at a total estimated cost of $22,000.
These efficiency opportunities were uncovered during audit through observation and measurement. All of them were believed to be non-existent by maintenance staff.
Direct metering is a key to hidden treasures of energy savings