What is an “Efficiency Survey”? An efficiency or energy survey is a series of electrical and mechanical tests that help define the health of machinery within a facility or factory and identify areas and components that may need attention. Better efficiency correlates to lower energy costs and longer equipment life. Energy expenses generally account for around fifty percent of the operating expenditures at any facility and motors consume more than half of all the energy produced worldwide.
Numerous studies indicate that between five and ten percent of the rotating equipment in any plant or facility will have some minor issue(s) that can be easily corrected. Those issues include misalignment, imbalance, poor connections, voltage imbalance, numerous vibration concerns, etc. Some motors will have two or more minor issues such as slight misalignment and some voltage imbalance neither of which is critical but the combination causes the motor to be inefficient and shortens its life. Loose connections within the motor, at its junction box or even at the contactor create excessive heat and degrade the connection and will eventually lead to a failure.
It is important to note that motors are only one part of a machine. The driven load and the power supplying the motor also have a great deal to do with operating efficiency. A minor difference in voltage balance often leads to an exponential discrepancy in current which means uneven heating and lower efficiency. Motors being controlled by VFDs usually have unhealthy levels of distortion and harmful harmonics. Loose fan belts, misaligned couplings and related issues can create bearing problems and vibration complications. Worn contacts in magnetic contactors can cause power quality issues and may lead to major motor problems.
World class “efficiency surveys” will uncover those areas and in most cases only minor adjustments or repairs are necessary to improve the efficiency and longevity of the machine. An efficiency survey will include vibration analysis, static and dynamic electrical testing and thermography. Trained and experienced technicians can diagnose collected data and quickly determine which equipment needs attention and to what degree. Minor adjustments can then be made and in most cases only a few issues will require more detailed attention. In most cases the costs associated with an efficiency survey are offset by the enhanced operation and improved longevity.
If left undetected those minor issues will eventually cause a failure usually resulting in lost production, emergency repairs and in some cases safety issues. Knowing the condition of all equipment is paramount to maintaining safe and continued production and puts the operator in control. Being able to dictate to any equipment, when it gets the attention it needs means no unplanned down time, no emergency repairs and lower operating costs.
An efficiency survey requires some planning and usually results in some minor adjustments but the cost of implementing a complete survey will almost certainly be offset by the improvements in operation, efficiency and longevity. And, there is the peace of mind and confidence that comes with knowing!