Energy Cost Reduction Detailed Approach
| Stage | Deliverable |
| Energy Awareness Training | -Training Man-hour |
| Heat Loss Analysis -Furnace heat analysis -Wall & Separation Material -Heat Emitting Sources analysis -Ventilation System |
-Heat Loss Reduction |
| Pump Efficiency Analysis -Power Consumption -Component Vibration -Component Temperature -Cavitation Checking -Sound Pressure -Fluid Properties Test -Seal Leakage Test -Flow Rate Test -Net Positive Suction Head (NPSH) Test |
-Pump Efficiency Improvement |
| Motor Efficiency Analysis | -Motor Efficiency Improvement |
| Air Leakage Analysis -Compressor Running Time -Air Pressure Head Drop |
-Air Compressor Running Cost Reduction |
| Compressor Performance -Power Consumption -Component Vibration -Component Temperature -Sound Pressure -Seal Leakage Test |
-Compressor Performance Improvement |
| Diesel Usage Analysis -Diesel Consumption |
-Diesel consumption reduction |
| Workplace Lighting (LUX Audit) -Office Lightings -Shop floor Lighting systems -Work station Lightings |
-Workplace Lighting Improvement |
| Other Expertise |
| Manufacturing Excellence |
| Plant Layout Design |
| Manufacturing Audit |
| ISO Implementation |
| Energy Cost Reduction |
| Supply Chain & Logistics Cost Optimization |
| Competency Mapping |
| DOJO Implementation |
Case Studies
Energy Cost Reduction Project Implementation
(Leading Gear Manufacturer (Faridabad))
Challenges :
Before TMS –
- High Energy Consumption
- No tracking of Heat loss
- No Energy saving project implemented
Approaches :
Tetrahedron energy consultant team conducted a on site energy audit and inspect the individual energy consuming devices and track their performance and loss %. Some devices were found old, defective and energy inefficient. Energy isolation system were developed and energy efficient devices implemented. Energy KPI established to track the energy consumption.
Results :
- 25 Energy Saving Project Identified
- 18% Energy Cost Reduced
- Energy efficient devices were installed across the plant.
Energy Saving Projects Funnel Created
(Leading Heavy Equipment Manufacturer(Odisha))
Challenges : Before Tetrahedron:
Monthly Energy Cost was too high
Management team was serious towards reduction of plant running cost.
Approaches :
Tetrahedron Energy auditor team delivered a training on Energy Management System (EMS) to the plant staff and operator level. 4 Energy auditor conducted a Level 3 energy audit across the plant and presented the Energy Management Opportunities (EMO)s to the plant management team and identified energy savings projects for energy team.
Following results were achieved:-
Results :
- Developed a internal energy team including 3 Management persons, 5 technical Staff & 10 technicians.
- 65 Energy Savings Project Funnel created
Benefits Of Energy Cost Reduction
To get the best Energy Efficiency approach for your manufacturing process
