Power Systems Manufacturer

JPR provided a range of services to a Global Power Systems Manufacturer including: 

  • Asset Energy Certificate (AEC) survey

  • Identification of energy savings opportunities

  • Recommendations for energy improvements with costs for justification

  • Reverse engineering to specify an ‘A’ rating for new assets

  • OEM engagement

Savings Identified:

Annual savings are estimated at approximately £75k with a further £120k on future replacement assets.

Working with this client to improve energy efficiency, JRP engineers carried out Asset Energy Certificate surveys on a number of existing similar production assets, and established that they were operating at below their optimum efficiency levels (column i), and that even the maximum possible efficiency level of these existing assets (column ii) was still below the requirements of an A-Rated Asset. Influences that affect the ability to reach an A rating are sometimes found to be inherent in the building or production support services and column ii reflects this in the existing facility.

In the short term, a number of actions were identified to improve the operational efficiency and to achieve ratings in column ii.  Efficiencies were made as follows:

  • From programmed or automatic switching off where practical

  • Creating suitable gaps in production processes

  • Software re-programming for improved asset response to process needs

  • Optimising the overall efficiency of cooling systems

  • Offsetting the need to continuously use the vacuum pumps systems by using inert gas and watchdog control to mitigate risk

Temperature set back to reduce losses in an induction coil heating system

Detailed examination and reverse engineering of the elements of each asset to identify improvements that could be made to the asset design and ease of operation without loss of productivity or output, JRP engineers developed asset specifications with a target A rating going forward to manage supplier relationships and contracts to deliver these design improvements in new additional equipment.

Download case study as a pdf