Background of the plant manufacturing
activities and major energy consuming
areas-Thermal and Electrical
consumption & Electricity Billing:
Summary for the past year’s monthly
electricity consumption and production
data. Calculation of specific energy consumption,
KWH/Rs. of material produced etc. and
comments on the same.
Calculation of load factor and exploring
reduction of maximum Demand. Comments
on average power factor and methods to
improve power factor. Exploring possibility
of better use of time of demand tariff.
Scope of Thermal
To study Heat Balancing, estimate efficiencies
of Heat exchangers
To study and identify Thermal losses,
insulation up gradation
To study distribution network in plant-air/steam/gas
To explore heat recovery potentials
Any change in process, alternate fuel
Improvement in composition of fuel purchased
Performance Evaluation of Major Utilities
and Process Equipment:
Transformers: Performance evaluation through
simultaneous measurements of major electrical
parameters on HT side and rationalization
of transformers, if needed.
Power Factor: Measurements of distortion
& displacement power factor at various
points viz., PCC, MCC, load centers etc.,
and analysis of the same for optimizing
the network losses.
Metering & Monitoring Status: Review
of existing meters for adequate monitoring
Electrical measurements of all major electrical
parameters viz., voltage, current, power
factor, KW, frequency etc., of important
equipment (motors, lighting, etc.), with
significant energy consumption. Loads
susceptible to generation of harmonics
shall be checked for present harmonic
level. System unbalance with respect to
voltage and current shall be checked.
Cabling shall be checked for any avoidable
Measurement of Head/pressure, flow, power
and determination of pump/blower efficiencies
based on measured parameters and critical
study of piping/ducting/valves/dampers
pressure losses, system layout etc.
Determination of compressor capacities,
specific power consumption, KW/CFM, leakage
detection and quantification, pressure
losses in auxiliary equipment/ piping,
identify point using unnecessary high
pressure and identify application with
[CNC Machines etc]:
Determination of specific power consumption
for every major process step through measurements.
Review of data with process personnel.
Review of performance including major
auxiliaries and suggestions for optimization.
Measurements of light intensity and all
major electrical parameters viz., voltage,
current, PF, KW. Study of type of lamps
and chokes used; day and night time lighting