Process Plus partners with you to improve your gross margin by applying Energy Reduction Strategies (ERS). ERS systematically helps manufacturers reduce energy costs. Through our energy recovery and conservation analysis we recommend tactical plans to optimize your manufacturing operations.

PHASE I: Preliminary Energy Audit

Working with plant personnel, our engineers isolate root causes for specific energy loss and identify opportunities to reduce energy costs. We provide an audit with an accurate and cost effective course of action for the most urgent and relevant concerns of your manufacturing operations.

Deliverable:
A report that includes:

• Potential areas for corrective measures
• Preliminary estimates of implementation cost
• Potential operating cost savings
• Simple payback periods

While the level of detail presented is not sufficient for reaching a final decision on implementation, it is adequate to prioritize energy efficiency projects and to determine the need for a more detailed audit.

PHASE II: Definition Grade Engineering & Design

After the client has prioritized projects, Process Plus can present a proposal(s) to perform Definition Engineering. By applying ERS, we conduct an in-depth analysis generating data that helps us define projects with the greatest Return on Investment (ROI).

Data Analysis

1. Analysis of energy demand rate structures & energy usage profiles
2. Evaluation of short and long-term consumption patterns

Audit Areas

Process & Utility Systems

• Flue gas waste heat recovery
• Process heating optimization
• Cooling system optimization
• Heat exchange integration

Steam Systems

• Condensate recovery
• Leak minimization
• Steam trap sizing and maintenance
• Insulating steam and condensate lines

Pump Systems

• Efficiency optimization
• Speed adjustment / control
• Impeller trimming
• Minimization of throttling and bypass
• Piping configuration optimization

Electrical Systems

• Motor efficiency
• Variable speed drive application
• Short circuit analysis
• Power factor improvement
• Harmonics minimization

Deliverables:

• Drawings
• Specifications
• Budgetary capital cost estimate.

This data will allow the client to either secure Guaranteed Maximum Pricing (GMP) from contractors for a Design-Build approach or enable them to follow the traditional Design-Bid-Build approach by beginning with full detail engineering and design.

Arrange On-site Audit

To arrange an on-site audit call John Koehler at (513) 742-7590 or e-mail him.