Energy loss surveys offer cost savings

Energy loss surveys have identified over GBP 3/4 million annual energy cost savings for a leading pharmaceutical manufacturer, providing an opportunity to significantly reduce energy consumption.

Monition's Energy Loss Surveys have recently identified in-excess of GBP 3/4 million annual energy cost savings for one of the world's leading pharmaceutical manufacturers, providing an opportunity to significantly reduce energy consumption in line with Carbon Trust targets.

Monition's unique approach combined a range of Asset Management techniques to analyse energy usage, quantify energy losses and to show the customer precisely where to target corrective measures to achieve the greatest and quickest returns on their investment.

In this instance, the energy-savings are relatively easy for the manufacturer to attain, with cost calculations for repair work indicating a return on investment achievable in a little over three months.

Monition conducted Energy-Loss surveys of steam, compressed air and refrigeration infrastructure at 12 Manufacturing Sites across the globe, including plants in Australia, Singapore, Mainland Europe, Ireland and the UK.

The surveys took place during normal plant operation, requiring no interruption to process or intrusion to plant items.

Thermography and ultrasonic airleak detection were two of the technologies used to identify common faults that included: damaged/worn and missing insulation, leaking valves and seals, and exposed pipework and flanges.

Whilst these faults may sound insignificant in isolation, numerous faults over a large site quickly amount to considerable energy losses.

For instance, one un-insulated 16in stop valve radiating heat at 210 deg C was calculated to be costing an additional GBP 1,705 annually in energy expenses.

Incidentally, the cost to correctly insulate this valve was calculated at a mere GBP 52.80.

Throughout the process, Monition documented the precise location of each fault, calculated the additional energy cost being incurred and offset this cost against the expense of repair.

Each site was provided with a comprehensive list of faults, prioritised to target the 'quick wins' and greatest cost-saving opportunities first.

Monition's reports highlighted the measurable cost-benefits for each site and provided clear justification for corrective repairs to be sanctioned.

"We were able to deliver very clear information to the client showing how to reduce energy bills at a relatively low cost through fairly straightforward housekeeping measures," said Tom Clayton, contract services manager - Monition.

"We also provided the customer with a secure website resource where all the reports, calculations and thermal images were posted for easy access.

At the customer's request we also built a 'League Table' to demonstrate which manufacturing sites had the greatest potential to make savings.

The Energy Managers at each site have really come onboard, and we've also provided them presentation materials to communicate the benefits of the Energy-Saving measures within their own organisation." Monition is currently engaged in Energy Loss Surveys for manufacturing and processing sites in both the UK and overseas.

The service provides customers with a clear roadmap for making targeted and measurable efficiencies in their operations, by creating substantial cost and environmental benefits through the reduction of energy consumption.

Energy managers are invited to contact Monition to receive a copy of 'Making The Saving' - a short presentation that illustrates the benefits that can be achieved from Energy Loss Surveys.

Back to top