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IMPROVIA ENERGIEfficiency QualityReliability
IMPROVIA
Our Competence
Why Audit?
Improvement is no doubt a necessity in industrial process. Every design, calculation, forecasting and decision are dinamically done by internal management. We undestand the requirement of second opinion at those steps. By performing audit we deliver recommendations, engineering solutions, objective judgments and other activities related to the audit results to improve efficiency. By improving efficiency, we can also at the same time improving productivity and finally a better quality. Just like common auditors, we put ourself independent so we can recommend the best optimization and improvement.
We use different approach in each case. The method used in auditing process start from the simple way, visual inspection. It is one of few steps to do pre-eliminary inspection. The other thing we need in pre-eliminary/preparation step is technical data, spesification, PFD and P&ID, operation data & maintenance history. We build communication with users, engineers, technicians, planner, operator, production staff and other in order to get the required facts.
Efficiency - Reliability - Quality
Our competence is build according to these 3 important terms in industry; Efficiency, Reliability and Quality. We believe that these 3 terms are related to each others. It becomes basic, goal, purpose and even soul in each work and services we provide.
Energy Audit
?Operational Data
?Maintenance History
?PFD and P&ID
?Technical Drawing
?Specification, Material
?Interview
?On site Measurement
Quality
?Vibration Monitoring
?Oil Analysis
?Thermal Imaging
?Machinery
performance diagnoze
Condition Monitoring
IMPROVIA
How to improve Efficiency?
?Recommendations
?SOP Review
?Energy Saving
Campaign
?Energy Services
Contract
?Recommendations
?Corrective
Maintenance
?Maintenance Set up &
Planning
?Repair, overhaul
How to improve Reliability?
Energy Audit
Commercial Audit
Operational cost allocated in power generation generally raised up to 30-40%. Using Cost Benefit Analysis and also by analyzing each equipments used in operational such as air conditioner, heater, lightings, plumbing etc, we give the best recommendation to you!
Energy Audit - Power Plant
Performance monitoring and analysis of power plant equipment have become an essential activity in today’s increasingly energy intensive and competitive power industry. An energy audit will identify the degraded plant components and their contribution to overall thermal efficiency loss. By doing so, it will improve the efficiency. The audit will also give a significant input to operations and maintenance. To examine steam/gas turbine power plant we use Heat Balance Analysis method.
Industrial activity (process or production plant) usually spend many power. To become a leader in the competition ofcourse each industry must to improve efficieny, productivity and quality. For Industrial Facility Audit we provide services such as :
Industrial Facility Audit
Pre-eliminary Assessment (data collection)?Planning and scheduling Assessment/Audit ?activityFormulate Energy Audit concept for each ?equipments or componentsDefine the methods and prepare the forms?Site visit including assessment on the existing ?equipments, analyze, measure and diagnose lossess/deratingFinal reporting and Recommendation?Energy Conservation Training and Consultancy?
Energy AuditPower Plant
Performance monitoring and analysis of power plant
equipment have become an essential activity in today’s
increasingly energy intensive and competitive power
industry. An energy audit will identify the degraded
plant components and their contribution to overall
thermal efficiency loss. By doing so, it will improve the
efficiency. The audit will also give a significant input to
operations and maintenance. To examine steam/gas
turbine power plant we use Heat Balance Analysis
method.
When we implement Energy Audit for Power Plant, we
calculate efficiency, performance, and also losses that
might occur in system. These parameters are measured
and calculated during the project such as Main Steam
Pressure and Temperature, Main Steam flow, Gross
Power generated, Nett Power Generated, Reheater
Temperature to Turbine, Fuel Rate, FeedWater flow etc.
Our analysis focussed on plant main equipment
including Boiler, HP/IP/LP Turbine, Condenser, Boiler
Feed Pump (BFP), Air Heater, Economizer, Superheater,
Reheater, HP/LP Heater, Generator, Fan, Pumps, Coal
Feeder, Pulverizer. By analyze Heat Balance we
calculate Boiler Efficiency, Heat Loss, Steam Turbine
Performance, Plant Heat Rate, Flue Gas Analysis. Then
we will compare with the commisioning test or the best
achievable efficiency.
In this Audit Work we use several tools such as
thermometer with type-K thermocouple, digital clamp
meter, anemometer, Gas Analyzer and other auxiliary
tools.
Energy AuditCommercial Building
There are several reasons why do we need energy audit
in commercial building. One of the reason is conducted
from the unpredictable condition on energy availability
nowadays. Because of this situation we have to reduce
our operational cost. Our company would survive by
reducing the unnecessary expenses.
Improving energy efficiency will save more money from
energy expenses. Energy Audit on Commercial Building
is an activity to monitoring the energy usage at
equipments such as HVAC, lighting system, utilities and
etc. By doing so, we can identify the energy saving and
give recommendations about that chance.
Scope of work on Building Energy Audit consist of :
Perform assessment on Heating, Ventilation and
Air Conditioning (HVAC) system. This one
including on-site measurement in order to get the
actual data
Perform assessment on Building Lighting System
Perform assessment on Air compression system (if
any)
Analysis at Building Envelope
Assessment on Building Electrical system
Possibility to use Renewable Energy
Inspect other utilities
The important thing in Building Energy Audit is to
improve efficiency without decreasing quality and
comfort.
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Level of Audit
Building Energy Audit consist of 3 Level, Walk Through
Audit, Audit Level 1 and Audit Level 2. This Level of audit
was developed by American Society of Heating Air
Conditioning and Refrigeration Engineers (ASHRAE).
Walk Through AuditAudit is done by walking through the facilities, identify
the chance to saving energy, perform interview with the
personel in charge, and also quick review of the energy
bill paid by building company. This audit will give the
road map ahead about how to gain energy savings.
Level 1 AuditThis audit is more intensive rather than Walk Through
Audit. The activity consist of more assessment on HVAC,
lighting system and other utilities, also consider energy
conservation with low-cost/no-cost. This level of audit
also can identify category of Green Building.
Level 2 AuditLevel 2 ASHRAE Audit will identify the whole possibility
to saving energy at building facilities, analyze the
financial aspect including implementation cost,
operational cost and cost saving achievement. Analysis
of Payback periode of the planned recommendations is
also considered here. Assessment and investigation
conducted in this level is more detail rather than Level 1
Audit. ASHRAE Level 2 will also discuss the change of
Standard Operating Procedure (SOP) and maintenance
activity.
At Improvia Energi, we adopt this Level of audit and
provide services according to our clients’ need and
budget.
Work on Building Energy Audit
As explained in previous chapter, in Building Energy
Audit we do these activities :
interview with the personal in charge
monitoring the equipments
collect ing equipments’ data including
spesifications, technical details, manufacturer’s
manual book etc
gathering information such as operational
conditions, procedures, maintenance history
on-site measurement
When we conduct On-Site measurement, there will be
several devices we need to use. To analyze building load
distribution we need Power Analyzer. This instrument
also can measure major electrical parameters such as
kVA, kW, PF, Amps and Volts. To measure surface
temperatures we might need Infrared Thermometer.
This is a non-contact type measurement which when
directed at a heat source directly gives the temperature
read out. Air velocity in ducts can be measured using a
pitot tube and inclined manometer for further
calculation of flows. To measure water flow we can use a
non-contact flow measuring device using Doppler
effect/Ultrasonic principle. There is a transmitter and
receiver which are positioned on opposite sides of the
pipe. The meter directly gives the flow. Illumination
levels are measured with a lux meter. It consists of a
photo cell which senses the light output, converts to
electrical impulses which are calibrated as lux.
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Energy Services Contract
The Contract
It is important to ensure our customers that the output of
Energy Audit is right on the target. By doing so, we also
can monitor how efficiency gained. Each time the audit
performed by combining the assessment & inspection
result, technical evaluation, cost benefit analysis and
also management consideration. As an output, the
recommendations consist of 2 (two) options :Improvement with Low Cost such as SOP Review,
habit fixes, energy saving campaign etcImprovement with High Cost including
maintenance review, repair & overhaul, parts
replacement or upgrading etc
By Energy Services Contract, all the improvement cost
stated above and also the implementation become our
responsibility. The cost saving achievement will be
shared between Improvia Energi and clients. The share
percentage depend on agreement.
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The Idea
Through the energy audit we deliver recommendations about how to uprate efficiency or how to save energy. Energy saving is also connected to Cost Saving. Beside the recommendations, we also offer to our valued customers an Energy Services Contract. This contract made by agreement from both of sides. The idea is that customer only pay us for each ‘cost saving’ we deliver.The benefits for clients are :
The energy audit result can be justified by monitoring the implementationLow risk for clients because all cost, preparation and activities in order to implement the energy conservation will be conducted by our company
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Condition Base Monitoring
Vibration Monitoring is one of the method used in Condition Base
Monitoring (CBM). Vibration monitoring is defined in this 2 area :
Rotating Engine (pump, turbine, generator, motor, ?compressor, fan, blower etc)
Reciprocating (Diesel Engine, Gas Engine, Recip ?Compressor)
Vibration Monitoring
Review, Audit and Assessment for existing monitoring ?procedures
Design, setup and install the new Vibration Monitoring ?System
Analyze vibration machinery problems?Examination Planning & Scheduling?Training & Consultancy?
Reliability is no doubt an important key in modern maintenance
management system. One of methods to improve reliability is the
implementation of Condition Based Monitoring (CBM). This
method is more comprehensive and cost effective concepts. The
concept is based on the belief that if equipment can be evaluated
and yet still remain in service, the overall cost of maintenance will
go down. Beside reducing the level time based maintenance,
CBM will catch ill conditioned components before they break and
cause unplanned outages. By implementing CBM we can
measure the health of the machinery, engine performance,and
also engine vibration.
By implementing Vibration Monitoring we can detect :?Unbalance?Misalignment?Bearing problems?Mechanical looseness?etc
We provide services :
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Our Experiences
Software Maintenance System, RS Pondok Indah, December 2010.
We develop and design a system to make the maintenance activity efectively.
Root Cause Failure Analysis on Shell Crack at Feed-End Shell Dryer #3D, PT INCO, Sorowako, 2010
We analyze the crack failure by visual inspection & Fractography, In-situ Metallography, hardness testing, ultrasonic thickness measurement and also finite element simulation methode
HSE Consultancy, PT Indah Dewi, Tarakan, 2011
In this service we develop Health, Safety and Environment (HSE) Procedures for PT Indah Dewi, one of the heavy equipment contractor in Tarakan, East Kalimantan
Assist on Predictive Maintenance (PdM) Activity at Star Energy (Kakap) Natuna, KH-KRA-KG-KF Platform, 2011
The activity consist of Vibration Monitoring on Rotating and Reciprocating Engine, Thermography, and Oil Analysis. The main equipments are Gas Engine, Diesel Engine, Gas Turbine, Gas Compressor, Air Compressor, Pumps, Fan etc.
Jasa Audit Energi PLTU Unit 5-7 Tahap l, PT Indonesia Power UBP Suralaya, 2011
We perform full assessment at the plant to examine the real net plant efficiency, plant heat rate and losses. We do the audit works at Boiler, Turbine, Condenser, Boiler Feed Pump (BFP), Air Heater etc.
Vibration Analysis at Boiler FeedWater Pump #1, PLTU Sebalang, Lampung, 2012
The assessment was conducted on BFP #1 due to high vibration on axial side. We analyzed the engine by using CSI-2130.
Vibration Analysis of 89 (Eighty Nine) Equipments, Cilegon Plant, PT. Cabot Indonesia, 2012
Vibration analysis was performed for plant equipments such as Pumps, Fans, Compressors, Turbine, Gearbox etc.
Contact us :
PT. Improvia Energi
Jl. Kalibata Tengah No. 35 C
Jakarta Selatan 12740
Phone : (+6221) 7919 8450
Fax : (+6221) 799 7907
Email : [email protected]
http://www.improvia.co
IMPROVIA ENERGI
Efficiency QualityReliabilityIMPROVIA
