Bhatia Brothers Industrial Supplies Division - EPC ENERGY MANAGEMENT Energy Management Energy Management is the proactive, organized and systematic coordination of condition assessment with respect to standards and use of energy to meet the requirements. Energy Management also envisages on best energy practices which can be followed for improving efﬁciency and appropriate use of energy. The central task of Energy Management is to reduce costs for the provision of energy in industries and facilities. Energy Management encompasses: Conserving Energy Resources Enhancing Energy Efﬁciency Limiting Environmental Impact Encouraging Rational Energy Use Bhatia Brothers have a dedicated team of Engineers for performing the following tasks: Conduct Vibration Analysis – Rotational Machinery Infrared Thermography Assessment – Electrical & Mechanical Electrical Power Quality Audits Steam Audits & Boiler Performance Energy Management Continuous Improvement of Energy Efﬁciency To Quantify The Enrgy Needs Reduce Carbon Footprint Optimized Utilities Reduce Breakdown Need For Energy Management Production Techniques Benchmarking Energy Demands 01 Identify Evaluate Achive Low Production Cost Future Expansion & Energy Demands Realize Identify Energy Flows: Discover your hidden energy potentials Evaluate Saving Potential: Conduct energy studies & cosider life cycle costs of your investments Realize Efﬁciency Measures: Improve machines and processes Industrial Supplies Division - EPC Vibration Analysis Vibration Analysis like other predictive maintenance technology allows for measurement and analysis for quick and relatively inexpensive way to detect and identify mechanical problems before they become serious and force costly unscheduled plant shut downs. Worn bearings, loose belts, improperly meshed gears, unbalanced shafts, misaligned couplings, etc., are accompanied by speciﬁc changes in performance and behavior of the rotational machine. Monitoring these changes permits maintenance to be scheduled well in advance of a major break down. A vibration analyzer is also referred to as FFT spectrum analyzers. Vibration meter and vibration data collector are also common terms referring to a vibration analyzer. Vibration analysis is a powerful tool that when integrated into an overall inspection program will help save maintenance costs by: Reducing the risk of unexpected downtime Extremely effective safeguard against total loss Timely replacement parts to reduce expediting costs Advance planning shortens repair and inspection times Some of the speciﬁc types of vibration causing problems that can be detected in the analysis: Bearing defects or wears Damaged or worn teeth Misalignment; internal or external Rotating looseness or imbalance Resonance, loose components Bending or eccentricity Unequal thermal effects Bad belt drives Infrared Thermography Infrared Thermo graphic analysis is the non-contact mapping and analysis of the thermal patterns from the surface of an object. Thermal imaging scanner (Thermal Camera) can detect radiation in the infrared range of the electromagnetic spectrum (roughly 900–14,000 nanometers or 0.9–14 μm) and produce images of that radiation. According to the ‘black body radiation law’ all objects based on their temperatures emit infrared radiation; thermo graphic analysis makes it possible to "see" one's environment with or without visible illumination. The wavelength of the energy emitted differs from material to material. If the wavelength falls in the region of 400 nanometers to 720 nanometers (40 X 1015 Hz to 75 X 1015 Hz) in electromagnetic spectrum. The Infrared Thermo graphic analysis are carried out as part of safety, proactive, predictive and preventive maintenance program (conditional monitoring system) on electrical distribution systems, important electrical terminations. Industrial Supplies Division - EPC 02 Advantages of Thermography It shows a visual picture so temperatures over a large area can be compared It is capable of catching moving targets in real time It is able to ﬁnd deteriorating, i.e., higher temperature components prior to their failure It can be used to measure or observe in areas inaccessible or hazardous for other methods It is a non-destructive test method It can be used to ﬁnd defects in shafts, pipes, and other metal or plastic parts It can be used to detect objects in dark areas Compressed Air Leaks And Audit Leaks are a signiﬁcant source of wasted energy in a compressed air system, often wasting as much as 20%-30% of the compressor’s output. Compressed air leaks can also contribute to problems with system operations, including: Fluctuating system pressure, which can cause air tools and other air-operated equipment to function less efﬁciently, possibly affecting production. Excess compressor capacity, resulting in higher than necessary costs. Decreased service life and increased maintenance of supply equipment (including the compressor package) due to unnecessary cycling and increased run time. Compressed Air Usage Inappropriate Usage 15% Artificial Demands 10% Production Requirement 50% Air Leaks 25% 03 Industrial Supplies Division - EPC Leakage rates are a function of the supply pressure in an uncontrolled system and increase with higher system pressures. Leakage rates are identiﬁed in cubic feet per minute (cfm) and are also proportional to the sound (dB) measured in the ultrasonic leak detector. The air leak study is done using calibrated SDT ultra sound air leak detector. Power Quality Audits Power quality is the relative frequency and severity of deviations in the incoming power supplied to electrical equipment from the steady or fundamental frequency, sinusoidal waveform of voltage or current. These deviations may affect the safe or reliable operation of electrical equipment such as circuit breakers, motors, fans, CNC machines, computers etc. Power quality Issues diagnosing: 1. Harmonics: It is a distortion of the utility supplied waveform and is caused by “non-linear” loads, Total harmonic distortion (THD) measures the degree to which the input is distorted, and is the relative value of all the harmonics combined, as a percentage of the fundamental current. 2. Transients: Commonly called swells, surges and spikes, transients are the most frequent types of power quality problems. 3. Brownouts: These are hours-long voltage sags caused by system overload. 4. Reliability: It refers to the probability of maintaining a continuous supply of electricity without interruption. Steam Audits & Boiler Performance Study One way to ﬁnd out whether the boiler in your facility is efﬁcient is to perform a steam audit; a comprehensive analysis of energy used within a facility, process or equipment, including recommendations for energy conservation measures. Industrial Supplies Division - EPC 04 Energy savings are sought through: Identifying steam leaks Heat recovery Utilization of ﬂash steam Return of condensate Determine Steam Usage Check Steam Lines-leaks & Radiation Loss Review Maintenance Plan for Boiler Ancillary Check The Condensate & Feed Water System Boiler Flue Gas Measurement - Furnace, Stack What the audit report covers: 1. Achievable energy savings based on actual operating conditions 2. Recommended equipment to achieve energy savings, with return on investment 3. Full Steam Trap Survey and report 4. Planned preventative maintenance schedule 5. Photographic evidence 6. Boiler Efﬁciency Contact us: Aditya GR - Service Engineer - Energy Audits Tel: +971 4 813 2679, Mobile: +971 56 290 6596, Email: [email protected] Prasenjit Paul - Asst. Service Manager Tel: +971 4 813 2677, Mobile: +971 50 155 4375, Email: [email protected] Nitesh Gawali - Business Development Executive Tel: +971 4 813 2680, Mobile: +971 56 153 8433, Email: [email protected] 05 Industrial Supplies Division - EPC www.bhatia.com