Error in heat exchanger installation made it useless at meat packing plant
Following a professional advice from a prior audit, an advanced meat packing plant redirected reject heat from refrigeration plant to preheat hot water. A $200K heat exchanger was installed and run 24/7.
However, installation was performed without an oversight from prior auditor. Who needs extra costs, right?
Two years later a new audit submetered newly installed heat exchanger and found that electrical cost of pumping exceeded savings on natural gas in water heating. A mistake in installation caused very low delta-T, thus rendering the whole heat exchanger highly inefficient.
Correction of mistake cost less than $2K, but wasted energy could not be recovered.
Energy audit, as annual physical, must be done regularly to ensure money is not wasted.
These examples were suggested by our partners at Enviro-Stewards.