Scope

• Electrical: transformer loading/losses, PF correction (fixed vs APFC/hybrid), harmonics (THD), demand & TOD tariff optimization.
• Drives & Rotating: motors/pumps/compressors/blowers—duty cycles, IE2/IE3/IE4 benchmarking, VFD retrofits, shaft power estimates.
• HVAC/Utilities: chiller COP, condenser/evaporator approach, CT performance, AHU balancing, compressed air leak mapping.
• Lighting: LUX mapping vs IS recommendations, fixture efficacy, daylight/occupancy automation & controls.
• Process/Thermal (where applicable): heat balance, waste heat recovery, insulation audits, combustion tuning.

Tools & Instruments We Use

• 3-Phase Power Quality Analyzer: V/I, kW/kWh, PF, THD, harmonic spectrum, demand profile (7–14 day logging).
• Clamp Meters/Data Loggers: current/voltage/temp/RH/dP; correlation with production & weather.
• Thermal Imaging: hotspots on panels/busbars/bearings/cables; insulation integrity & temperature rise checks.
• Ultrasonic Leak Detector: compressed air/vacuum leaks, leak tagging & quantified savings.
• Lux Meter, Anemometer/Manometer: lighting level & airflow diagnostics, duct static pressure.
• Vibration Monitoring: bearings/misalignment; conditional maintenance inputs.
• DLRO (as required), IR/PI (Megger), and for thermal plants Flue Gas Analyzer.

Indicative brands: Fluke / HT Italia / Testo or equivalents. Selection depends on rating & HIRA.

Methodology & Approach

• Baseline: SLD review, load tree, 12-month bills, interval data, production correlation & seasonality adjustments.
• Measurement plan: CT/PT ratio verification, logging strategy, safety permits & LOTO compliance.
• Diagnostics: PQ & harmonics source tracing, transformer %loading, cable temp rise, motor slip/efficiency checks.
• HVAC/Utility deep-dive: COP/delta-T, pump curves vs duty point, VFD logic, AHU optimization, leak quantification.
• Opportunity register: no/low/capex ECMs with kWh/kVAh/thermal savings & reliability impact quantified.
• Financials: payback/IRR/NPV, M&V plan (IPMVP-style), and phased implementation roadmap.

Deliverables

• Audit Report: instrument traces, heat maps, LUX charts, PQ trend plots, and root-cause analysis.
• Opportunities Matrix: savings, cost, payback, dependencies; retrofit BOM/specs.
• Implementation plan: sequencing, shutdown windows, contractor scope, risk controls & QA checks.
• M&V protocol and KPI dashboard (monthly scorecard for management review).

Standards & Codes (Indicative)

• BEE Energy Audit Guidelines; ISO 50001 EnMS framework.
• IS 3043 (Earthing), IS 732 (Electrical Installations), cable/XLPE per IS/IEC.
• IEEE 519 (Harmonics), IEC 60034 (Rotating Machines) for motor efficiency classes.
• Safety audit alignment to IS 14489; permit-to-work & LOTO procedures.

Mindset & How We Handle Projects

• System thinking: Requirements → Codes → Studies → Constructability → Maintainability.
• Risk-first planning: HIRA/JSA, PTW, LOTO, live-system interfaces, shutdown choreography.
• Governance: WBS, baseline schedule, look-ahead plans, RFI/CR registers, disciplined EOT.
• Quality at source: ITPs, stage inspections, vendor approvals, hold/witness points.
• Documentation: submittals, as-built, O&M, spares/critical inventory, training & handover.

Scope (Indicative)

• 33/11/0.433 kV substations, transformers, HT/LT switchgear, PCC/MCC, APFC/Hybrid PFC, busducts, UPS/DG sync.
• Cable sizing & routing, trays/trenches, joints/terminations, earthing & lightning protection.
• Protection & metering: CT/PT selection, relay logic, interlocks, SCADA/PLC integration.
• Solar/BESS or captive power integration: grid interaction, anti-islanding, protection coordination.
• Statutory approvals: DISCOM load sanction, CEIG approvals, CEA safety requirements.

Design Reviews & Studies

• SLD, GA, room layouts, clearances, thermal/ventilation checks.
• Load flow, short-circuit, motor starting, voltage drop, arc-flash & protection coordination (ETAP/equivalent).
• Cable ampacity (grouping/ambient), fault withstand, earthing grid design per soil resistivity.
• Panel specs: kAIC, IP degree, form type, busbar derating, temperature rise, segregation, interlocks.
• Controls: logic narrative, I/O list, network topology, basic cybersecurity baselines for SCADA/PLC.

Procurement & QA/QC

• Tech specs/datasheets, vendor evaluation, FAT protocols (CPRI/type tests, routine tests), inspection checklists.
• Incoming checks: visual, IR, torque, nameplate verification, routine electrical tests & storage/handling SOPs.
• Site QA/QC: ITPs for cable laying/terminations/glanding, earthing, tray works, labeling, red-line markups.

Pre-Commissioning & Commissioning Tests

• IR/PI (Megger), HI for transformers, Tan-Delta for MV cables/transformers (as applicable).
• DLRO for joints/busbars, Primary/Secondary injection for relays, CT/PT polarity & ratio checks.
• Protection coordination checks, trip testing, interlock sequence, SCADA signal & time-sync validation.
• Functional trials on load, thermal scanning, PQ verification, relay setting sheets & final acceptance report.

Standards & Codes (Indicative)

• IS 3043 (Earthing), IS 732 (Electrical Installations), IS 1893 (Seismic—where relevant).
• IEC/IS for switchgear, cables (IS 7098 for XLPE), busducts, transformers, protection relays.
• IEEE 519 (Harmonics), IEC 60255 (Relays), IEC 60076 (Transformers).
• CEA/CEIG/DISCOM regulations; utility interface & synchronization requirements.

HIRA, Safety & Work Permits

• LOTO, PTW systems, confined space, hot work, live proximity controls, insulated tools & PPE matrices.
• Method statements, lift plans, scaffold/MEWP compliance, trench barricading & housekeeping norms.

Typical Deliverables

• Design review notes, calc sheets, approved SLD/GA, route plans, BOQs & technical specs.
• ITPs, checklists, FAT/SAT reports, test certificates, as-built drawings, O&M & training handouts.
• Handover dossier with spares list, warranty matrix, punch-list closure & MRM sign-offs.