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Production Process Waste

The size and type of production processes occurring in your facility have a big impact on what kind of energy waste you will find. Production processes and other building systems that rely on electro-mechanical equipment, steam or compressed air are excellent candidates for easy energy savings. Fluke tools can help you inspect these systems and quantify consumption, giving you the data you need to calculate motor efficiency, as well as steam efficiency, air compressor efficiency and other types of production processes.

Hover your mouse over the illustration below to learn how to identify and measure waste at each point in the system.

Common wastes:
1.	Less waste at a controlled-load, though poor power quality and other motor/drive inefficiencies may result.
2.	Un-controlled loads are commonly left on after hours, run at peak rate times, create more output than required, and suffer from over voltage/current conditions and phase unbalance.
Identify and quantify:
1.	Log power over time: How much power consumed at what time of day and with what amount of waste; check total kWh, power factor, peak demand, unbalance, harmonics.
2.	Thermally scan electrical components.

Common wastes:
1.	Aging mechanical devices consume so much more power than new high-efficiency models that early replacement may be justified in reduced kWh consumption alone.
Identify and quantify:
1.	Check current and voltage levels.
2.	Thermally scan termination/junction box and windings, conduct insulation resistance testing.

Common wastes:
1.	Excess friction from alignment, bearing, imbalance and looseness issues overworks the motor, consuming excessive power.
Identify and quantify:
1.	Test vibration levels against standards and identify maintenance solutions such as rebalancing.
2.	Thermally scan couplings/shaft/belts, bearings, fan.