Experience with 113 Retrofit Insulation Surveys

Abstract

We have surveyed 113 plants for thirteen clients. The results of 21 recent surveys at today's average fuel price, show an average project scope generation of $151,000 while saving about 5MMBTU/hour with a 72% DCF rate of return. The size of the retrofit project generated, or scope, is of course sensitive to the fuel price. This is an important consideration because of the variability of fuel price. A study of the effect of fuel price on project scope generation and on return has been made using sophisticated computer programs designed for this purpose. These results indicate that scope generation may vary from $50,000 for $3.00 fuel up to $80,000 for $6.00 fuel. When this happens, the project return will increase from 100% up to 165% per year. The main problem that we have found with retrofit insulation surveys is the processing of detail in existing plants. The solution is the preparation or selection of the right system for approaching the problem utilizing computer programs. The time required to generate systematic approaches to insulation surveys and the generation of retrofit projects are sizable. The continued heat losses while studying the project are also significant. Thus, the heat losses suffered while deciding how to insulate can be sufficient to pay for an insulation survey.