We are pleased to announce that we have started conducting energy audit of steel plants. Our energy audit includes various systems of the steel plants ie electrical systems, water systems, air compressors & lighting systems etc. This section will give you detailed scope of work, expected output of the audit and other aspects pertaining to the energy audit.

A.   Scope of Work:

1. Electrical Distribution Network & Usage:

• Metering and Monitoring Status: Review of existing energy meters for adequate monitoring requirements. Feasibility study for continuous energy monitoring
• Electricity Bills: Study of present consumption pattern and recommendations for optimisation of electricity bill parameters.
• Logging of all electrical parameters at main incomer
• Thermal imaging of all major incomers, capacitor panels and other loads in the panel rooms for safety & energy saving opportunity.

2. Electrical Loads of rolling machines:

• Measurement of all major electrical parameters viz. voltage, current, power(kwh), power factor, frequency etc. of major motors used in the section
• Logging of electrical parameters over a period of time for hydraulic power packs for determining their operational loads
• Proper evaluation of kWh / ton production and comparison with industrial benchmarks for optimization
• Recommendations for enhancing performance/ replacement/ retrofit of present systems
• Recommendations for optimal usage of machines to avoid idle time operation and proper use of utilities
• Thermal Imaging of total machine motors
• Checking the health of motor in-case of rewinded motor

3. AIR COMPRESSORS AND COMPRESSED AIR SYSTEM

• To observe the present status of compressors and distribution piping, note points of leakage wherever possible and assess compressed air wastage.
• Study compressed air applications to optimize air usage and pressure for applications.
• To broadly study the existing air distribution piping and estimate pressure losses in the present compressed air system.
• To work out operating performance of compressors.
• Direct instantaneous measurement of kW consumed by motors driving the compressors. Logging over a period of time to determine unloading / loading & VFD operations.
• Based on the above study and analysis, work out suggestions for improvement, this will result in energy conservation. The suggestions will cover the following area :
  • Improvement in efficiency of compressed air generation
  • Reduction in leakage / losses
  • Improvements in the distribution system

4. Water System / Cooling Towers :

• Measurement of operating efficiencies of major water pumps including cooling water pumps etc. Measurement of flow, head and power so as to determine this operating efficiency
• Study the performance of cooling towers in terms of range and effectiveness and recommendations for optimization
• Study the cooling loads catered by the cooling towers and optimization of the same

5. Other Loads in the plant:

• Study of blowers and recommendations for optimization
• Study of lighting loads and recommendations for optimization
• Study of other miscellaneous loads for optimization

B.      Expected output of the audit

The results of the audit will be submitted in the form of a report containing:

• Energy profile with percentage share of major equipment, utilities etc., so that it becomes a basic document for future monitoring.
• Energy saving proposals with little or no investment. These will include operational changes, minor modifications and retrofits.
• Investment proposals (involving more efficient equipment/processes) with payback period calculations for energy conservation in the systems audited.
• Analysis of data from the logbooks and that taken from field measurements with the help of portable energy audit instruments provided by us.