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



  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



  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



  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



  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






  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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