Energy Consumption Analysis for Manufacturing Facilities
Program Overview
Course Modules
- Energy measurement in industrial settings
- Power monitoring equipment setup
- Data logging strategies
- Baseline establishment
- Compressed air system optimization
- Leak detection and quantification
- Pressure requirements versus setpoints
- Compressor control strategies
- Motor and drive systems
- Load profiling for motor replacement
- VFD retrofit economics
- Power factor correction
- Thermal process efficiency
- Heat recovery opportunities
- Insulation assessment
- Combustion optimization
- Building the business case
- Payback calculation methods
- Utility incentive programs
- Presenting to management
Detailed Information
Industrial energy audits often produce reports nobody implements. This program teaches you to find savings that operations managers will actually approve.
You will learn measurement techniques that work in noisy manufacturing environments, identify which processes waste the most energy, and calculate payback periods that account for production downtime. We use compressed air systems, motor drives, and thermal processes as primary examples because they represent 60-80% of consumption in most facilities.
The focus is on quick wins
You will analyse power quality issues that inflate bills, find motors running at partial load indefinitely, and spot thermal losses that cost thousands monthly. Every technique includes the business case aspect because technical solutions need budget approval.
We work with real facility data from food processing, metal fabrication, and chemical plants. You should understand industrial processes at a basic level and be comfortable with power measurement tools.