Flux Engineering is NEECA certified Energy Auditing firm as well as proud to have ISO 50001 Certified Energy Management Capabilities. Flux Engineering has conducted Energy Audits of more than 200 Manufacturing units.

The tentative activities carried out are as follows:

Electrical System Audit

At Main Metering Panel LV side:

  1. Verification of Meter Reading
  2. Electricity Bill/Genset Fuel Analysis from historical data
  3. Verification of Documents

3.1. Verification of Single Line Diagram

3.2. Electricity Metering record

3.3. Maintenance Schedules

3.4. Fitness Certificate of Transformer

3.5. Fitness Certificate of Generators

3.6. List of Electrical Staff & competency certificate

  1. Transformers physical inspection and testing report analysis
  2. Main Distribution Panel
  3. Generators
  4. Harmonics Analysis

 

At Transformers:

  1. Load Analysis of Transformers
  2. Over/Under loading
  3. Load Unbalances & Current Leakages
  4. Harmonics Analysis

 

At Generators:

  1. Analysis of Generators
  2. Fuel Efficiency from historical data
  3. Frequency Test

 

Synchronization System:

  1. Evaluation of Synchronization System
  2. Synchronization Controls and Configurations
  3. Energy Saving opportunities

 

At LV Distribution Panels:

  1. Power Distribution Analysis
  2. Power Factor Control
  3. Load Distribution
  4. Unbalanced Loads
  5. Neutral Load
  6. Harmonics Analysis

 

At Major Motors & Loads:

  1. Power Consumption
  2. MCC, Drives, Controls
  3. Operator Procedure
  4. Load Analysis
  5. Energy Saving Opportunities

Water Turbines & Pumps:

  1. Water Turbines & Pumps for Water Supply
  2. Controls
  3. Review of system for Water Flow & Pressure Analysis
  4. Load Analysis

 

At Air Blowers & Exhausts:

  1. Air analysis
  2. Valves & Dampers Analysis
  3. Provisions for AC drives to control flow through valves & dampers
  4. Energy Saving Opportunities

 

Automation System:

  1. System Architecture
  2. Operator interfaces with reference to Energy & Production Cost
  3. Online monitoring, analysis & control systems
  4. Production cost measurements analysis

 

Lighting System

  1. Measurement of light Intensity at all offices and electrical/equipment rooms
  2. Energy Efficient lights
  3. Light controls

 

Review of Maintenance Program & Schedule

  1. Electrical Maintenance Program & Schedule
  2. Addition for Energy Saving points
  3. Possible Control Loops, Configurations and Speed Controls for Energy Saving
  4. Review of Work practices
  5. Reactive, Breakdown, Preventive and Predictive Maintenance

 

Energy Management System:

 

  1. Existing Energy Management System (Manual or Digital)
  2. Recommended Energy Management System
  3. Setting Energy Saving Targets
  4. KPIs of production, electrical and maintenance departments with respect to energy cost

 

Risk Factors & Hazardous Areas

  1. Electrical Operations and Safety Signage
  2. Hazardous Area Classification & Signage
  3. Tagging & Labeling of Electrical System
  4. Safety SOPs
  5. Risk Factors analysis on visual & physical inspection
  6. Trainings review of the personnel working at work place for safety aspects, safe behavior and effective use of equipment’s to avoid any incident/accident.
  7. Electrical Safety findings, suggested actions & recommendations
  8. Personal & Equipment safety
  9. Comply with statutory regulations and standards for controlling the risks.
  10. Review of previous accidents and incidents

Best Practices of Energy Management:

  1. Best Practices for Energy Saving & Management

 

Action Plan:

  1. Action Plan in consultation with clients Technical Team

 

Compressed Air System

 

Compressor Rooms:

  1. Compressed Air System Evaluation
  2. Compressor Room layout and design evaluation
  3. On-load/Off-load control
  4. Compressors’ control and cascaded control evaluation
  5. Air Reservoir Tanks evaluation
  6. Filters, Valves, Pressure Transmitters evaluation
  7. Power Consumption
  8. Pressure control of Air
  9. Physical inspection
  10. Header layouts evaluation
  11. Energy Saving Opportunities in Compressed Air System
  12. HVAC measurements (Ambient)
  13. HVAC measurements (Production)

 

 

Cooling Towers:

  1. Cooling Towers
  2. Floating point controls

 

Chillers:

  1. Chillers Controls
  2. Ambient controls
  3. Temp., Humidity
  4. Action Plan

 

 

Energy Savings in Production

 

Production Machines:

  1. Production Machines and their operations
  2. Review of historical Utilities Cost in Production
  3. Energy Saving opportunities

 

Process Controls:

  1. Analysis of Process Control
  2. Review of historical Utilities Cost in Production
  3. Controls of Motors, Fans, Pumps, Blowers, Conveyers etc
  4. Energy Saving opportunities

 

Production Measurement:

  1. Analysis of Utilities Cost in Production
  2. Energy Saving Opportunities in Production Areas
  3. Assessment of EnPIs of Production staff
  4. Power Measurement at Machines Analysis
  5. Energy Saving Opportunities

 

 

 

Associated Services as per the requirements

 

Training:

  1. Training on Energy Management
  2. Certificates of training for ownership, motivation and official responsibility

 

 

 

Energy Management Team:

  1. A cross-functional team will be formed to implement action pan and continuously set and achieve Energy Saving Targets.

 

Implementation Support:

  1. One Month full support for implementation of Action Plan on Energy Saving Opportunities

 

HR and Best Practices

 

HR:

  1. KPIs of departments & personals with regards to production cost and energy saving
  2. Performance evaluation techniques
  3. Tools and equipments evaluation
  4. Personnels trainings evaluation
  5. Contribution of departments in energy saving and production cost saving
  6. Incentives etc

 

Management:

  1. KPIs with regards to energy saving
  2. Energy policy
  3. Review and implementation timeline for Energy Audit Action Plan
  4. Vision and support needed by higher management

 

 

Trainings

 

Trainings:

  1. “Energy Management” Training to your Technical & Production Team
  2. “Maintenance Management” training to your staff
  3. Session for implementation of Energy Audit Action Plan

 

Furthermore the following services are also performed

 

Power Plant Efficiency Calculations

  • Fuel ultimate and proximate analysis data collection
  • Monitoring of fuel to air ratio
  • Monitoring of flue gas temperature
  • Water quality analysis
  • Calculation of loses
  • Calculation of efficiency

 

Electrical Design/ Planning

  • Load flow analysis
  • Short circuit analysis
  • Transient stability analysis
  • Motor-starting analysis
  • PF improvement analysis
  • Relays coordination analysis
  • Harmonics analysis
  • Arc flash study
  • etc
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