At a 1,200 MW plant, significant heat loss and resulting high gas consumption were identified through detailed surveys, thermography, and heat transfer analysis.
A massive project was executed aimed at improving thermal efficiency. To make improvements, we utilized custom insulation jackets for components operating above 150°C, restored failed insulation and arrested leaks across the plant. Our approach was to leverage data-driven thermal analysis, safety compliance and cross-functional collaboration.
This initiative reduced heat loss by 4,061 MW / year, mitigated burn / fire risks and achieved a 0.73-year payback. The annual savings were $59,000 USD.
