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Equipments & Systems Study

The basic objectives of the studies shall conduct detailed energy audit of the specific equipments (like Pumps, Air Compressors, Refrigeration Chillers, Cooling Towers, Fans & Blowers, Boilers, Thermopacs, Furnaces & Ovens) or systems (Compressed air Leakages, Steam Traps, Insulation, Power Quality & Harmonics) as per the plant requirements. This can be carried out either through an annual contract or one time study. The typical coverage shall include

Pump Performance:

• Measuring the flow with non-contact ultrasonic transit time flow meter
• Gauging Pressure with digital pressure gauge
• Determining Power with clamp on power meter
• Computing Hydraulic Power to assess overall Efficiency of the pump (and motor).
• Assessing the performance and suggesting ways for improvement, as applicable
• Submitting the report

Chillers Performance:

• Measuring the flow of chilled fluid with non-contact ultrasonic transit time flow meter
• Gauging temperature drop across the chiller with digital temperature indicator
• Determining Power with clamp on power meter
• Computing Chilling Effect and assessing Specific Power Consumption as well as Energy Efficiency Ratio (EER)
• Measuring the flow of cooling water with non-contact ultrasonic transit time flow meter
• Gauging temperature rise across the condenser with digital temperature indicator
• Computing Heat Load on the condenser and comparing the same with chiller data
• Noting down the key parameters including suction & discharge pressure
• Assessing the performance and suggesting ways for improvement, as applicable
• Submitting the report

Chilling System - Heat Load Balance:

• Measuring the flow of cooling water fluid with non-contact ultrasonic transit time flow meter
• Gauging temperature drop across the cooling tower with digital temperature indicator
• Computing Cooling Effect
• Noting down / assessing average cooling effect delivered by the system
• Measuring the flow of cooling water for all the major consumers
• Gauging temperature rise across the individual consumers
• Computing Heat Load the individual consumers
• Noting down the key other parameters like operating period, load variations
• Assessing overall load on the cooling system
• Analyzing the performance and suggesting ways for improvement, as applicable
• Submitting the report

Cooling Water System - Heat Load Balance:

• Measuring the flow of cooling water fluid with non-contact ultrasonic transit time flow meter
• Gauging temperature drop across the cooling tower with digital temperature indicator
• Computing Cooling Effect
• Noting down / assessing average cooling effect delivered by the system
• Measuring the flow of cooling water for all the major consumers
• Gauging temperature rise across the individual consumers
• Computing Heat Load the individual consumers
• Noting down the key other parameters like operating period, load variations
• Assessing overall load on the cooling system
• Analyzing the performance and suggesting ways for improvement, as applicable
• Submitting the report

Cooling Tower Performance:

• Measuring the flow of cooling water fluid with non-contact ultrasonic transit time flow meter
• Measuring the flow of cooling water with non-contact ultrasonic transit time flow meter
• Gauging temperature drop across the cooling tower with digital temperature indicator
• Computing Heat Load on the cooling tower and delivered cooling effect
• Determining fan Power with clamp on power meter
• Noting down the key parameters including ambient dry bulb and wet bulb temperature
• Measuring air flow rate to determine water to air to ratio
• Assessing the performance and suggesting ways for improvement, as applicable
• Submitting the report

Heat exchanger performance :

• Measuring the flow of process fluid with non-contact ultrasonic transit time flow meter
• Gauging temperature change across the heat exchanger with digital temperature indicator
• Computing Heat transferred for the process side
• Measuring the flow of the utility fluid with non-contact ultrasonic transit time flow meter
• Gauging temperature change across the heat exchanger with digital temperature indicator
• Computing Heat transferred for the process side and comparing the same with process data
• Noting down the key parameters including pressure drops on both the sides
• Estimating Heat Transfer Coefficient based on the design data
• Assessing the performance and suggesting ways for improvement, as applicable
• Submitting the report

Liquid Flow Rates :

• Measuring the flow with non-contact ultrasonic transit time flow meter at mutually decided locations
• Submitting the report

Fans & Blowers Performance:

• Measuring the flow with Anemometer or Pitot Tube
• Gauging Pressure with digital manometer
• Determining Power with clamp on power meter
• Computing Pneumatic Power to assess overall Efficiency of the fan (and motor).
• Assessing the performance and suggesting ways for improvement, as applicable
• Submitting the report

Boiler performance :

• Measuring Oxygen, Carbon Mono-Oxide & Temperature
• Contents in flue gas at Air Preheater / Economizer outlet
• Measuring Oxygen Contents in flue gas at outlet of APH & inlet of ID Fan.
• Computing Combustion Efficiency of the boiler
• Estimating air ingress in Air Preheater, Bag Filter / Electrostatic Precipitator (ESP)
• Submitting the report

Steam Trap Performance:

• Checking the traps with thermal imager and / or ultrasonic trap tester
• Qualitatively assessing the performance
• Tagging the points (if the tags are provided by the plant)
• Submitting the report

Thermopac performance:

• Measuring Oxygen, Carbon Mono-Oxide & Temperature Contents in flue gas at Thermopac outlet
• Measuring Oxygen Contents in flue gas at outlet of APH & inlet of ID Fan.
• Computing Combustion Efficiency of the thermopac
• Estimating air ingress in Air Preheater, Bag Filter / Electrostatic Precipitator (ESP)
• Submitting the report

Compressed Air Leakages:

• Checking the entire system for identifying leakages with Ultrasonic Leak Detector
• Qualitatively assessing & categorizing the leakages in major, moderate or minor
• Tagging the points (if the tags are provided by the plant)
• Submitting the report

Thermography:

• Checking the entire electrical system for identifying hot spots
• Capturing & Providing visual and thermal images for the hot spots
• Qualitatively assessing & categorizing the hot spots in major, moderate or minor
• Submitting the report