Power Quality
- Extremely fast fluctuating load profile iTDD exceeding limits set as per IEEE 519 standard Low PF (both leading and lagging)
- High load unbalance
- Increased losses due to high harmonics
- Failure of welding transformers
- Tripping of relays, protective circuits etc.
- Failure of capacitor banks
- Over harmonics creates transient leading to burnout of capacitor banks
- Reduced lifespan of welding machines
- Significant overvoltage
Motor & Drive applications
- Low efficiency of motors
Thermal Efficiency
- Insufficient cooling
- Heat transfer due to inadequate insulation of roof
- Heat transfer due to lower quality of window panes
- Overall heating in the facility
HVAC Efficiency
- Fresh Air Supply- Insufficient – Energetically inefficient without Heat Recovery units
- Insufficient cooling
- Excessive humidity
- Odor & mould
- Most factories do not have air-conditioning leading to difficult working conditions for its workers.
Lighting- Conventional vs. LEDs
- High operating cost due to higher consumption of electricity by Halogens and conventional flood lights/hi-bays
- Higher replacement costs due to shorter lifespan
- High thermal impact on cooling
Indoor Air Quality
- High Humidity
- High temperatures
- Odor-Food/smoke/mould
- Bacteria and fungus develop in high temperatures and humidity
- Presence of highly toxic chemicals in the environment during the welding process
- Dust
- Smoke
Power Quality
- Double phase welding loads are identified as major non-linear Loads
- Improper reactive compensation
- 3rd,5th,7th,9th &15th Harmonics leading to overheating of capacitor banks
- Inappropriate capacitor bank technology which are contactor switching and not suitable for such fast changing loads.
- High voltages lead to lower lifespan of end loads like welding machines
Motor & Drive applications
- Higher ambient temperatures lead to significant de-rating of motors and drives
- Lack of sufficient air flows lead to low dissipation of heat leading to de-rating of motors
Thermal Efficiency
- Insufficient thermal insulation of windows & doors
- Over burden on HVAC
- Corrugated steel roof leading to massive heat transfer
HVAC Efficiency
- Incorrect choice of the chiller plant- this may be due to incorrect sizing or incorrect technology
- Poor Maintenance of chiller plants
- High Humidity (Desiccant dehumidification best solutions as no heat is produced)
- Incorrect configuration
- Imbalance in air pressure
- High ambient temperature
- No air conditioning available
Lighting- Conventional vs. LEDs
- Old technology of conventional lightings
- Inadequate light output
- Inadequate light output
Indoor Air Quality
- Lack of dehumidification
- Lack of cooling/ insulation
- Lack of indoor air treatment
- Excess use high temperatures for welding
- Lack of indoor air filtration
- Welding process
Power Quality
- Active Harmonic Filter at major DBs for the purpose of harmonic mitigation, reactive compensation and load balancing
- Hybrid Filter with Neutral Compensator best suited when power factor is low
- Voltage optimizer
- Dynamic Power Factor Correction with detuned filter reactor
Motor & Drive applications
- Reduction of heat with use of pre-cooling mechanisms to bring down temperatures where motor performance can be optimised
- Use of high CFM fans to create air low and improve performance
Thermal Efficiency
- Special coating which arrests heat transfer up to 70%
- Air curtains and open space cooling
- Arresting leakage of hot air from doors and delivery sections
- Yearly audit and maintenance of HVAC and proper configuration of chiller plant.
- Cool roof coatings
HVAC Efficiency
- Refurbish existing Heat Recovery units by chemical cleaning of Heat Wheels, Enthalpy Wheel or Desiccant Wheel
- Additional upgrade of HRU with Horse Shoe Heat Pipe or Desiccant Dehumidification
- Consider advance air distribution technologies such as Bosch Clemotion or Composite air ducts.
- Chiller replacement for highest energy savings and lowest cost of ownership – Heat Pump -Water cooled chiller -Invertor based chiller
- Shading of chiller plant and Wet wall
- Open space cooling solutions are the cheap alternative to air-conditioning systems like FAHU
Lighting- Conventional vs. LEDs
- Replacement by LED with following specs: -160 lumens/watt -less than 10% depreciation in light output over the expected life of 5 years – TL-21 certified – LM 79 and LM-80 compliant
Indoor Air Quality
- Heat Recovery Unit
- Horse Shoe Heat pipe
- Desiccant dehumidification
- Indoor air purification
- HEPA and Carbon filters
- Oxygen concentrators to improve air quality
- Smoke extractors during welding process
Power Quality
- Current harmonic distortion <8% at welding PCC Relatively balanced load profile Reduced (almost negligible) failure rate
- Relatively smooth reactive compensation
- Reduced losses due to simultaneous reduction in harmonic, reactive and negative sequence losses
- Safe operations without flashover and transient events which may lead to fire
- Savings in energy costs
Motor & Drive applications
- Higher performance of the motor will lead to higher output
- Less heating of motor will lead to significant savings in energy costs.
Thermal Efficiency
- HVAC is no more over burdened
- Wellbeing
- Lower energy cost
HVAC Efficiency
- Lower cost of utilities (DEWA bills)
- Adequate cooling
- Improved life of chiller plant
- Less downtime or break downs thereby savings in maintenance costs
- Overall well being
Lighting- Conventional vs. LEDs
- Better light output well-being Reduction in heat load on HVAC 70-80% reduction in electricity bills Significant reduction in maintenance costs due to longer asset life
Indoor Air Quality
- Wellbeing
- Better air quality
- Less maintenance problems