TUBA PLAST Survey Report

Conducted By: Green Line Company

Power Factor Readings:

Off Load: 66%

Load Percentage:

Predicting the Energy savingsBefore Installing Powerboss

Off Load: 5.055 / 15.938 (100) = 31.71

Formula: Ave kW / Ave Kvar (100) = Saving Factor

Power Readings:

INJECTION MOULDING (47kW Motor)INJECTION MOULDING (47kW Motor)

On Load: 34%

On Load: 33.597 / 22.361 (100) = 150.24

Full Load

Full §Load

Off Load

Off Load

Off Load

Formula: Saving Factor Vs. kW Saving % X Load Percentage = Saving %

Total Kw Saving % = 17.68%

Off Load: 31.71 --------- 26.8% X 66% = 17.68%

Formula: Saving Factor Vs. kvar Saving % X Load Percentage = Saving %

Formula: Saving Factor Vs. kva Saving % X Load Percentage = Saving %

On Load: 150.24 --------- 0% X 34% = 0%

Total Kvar Saving % = 30.34%

Total Kva Saving % = 34.96%

Off Load: 31.71 --------- 46% X 66% = 30.34%

On Load: 150.24 --------- 0% X 34% = 0%

Off Load: 31.71 --------- 53% X 66% = 34.96%

On Load: 150.24 --------- 0% X 34% = 0%

Power Savings

Consumption & Savings

1.028kWh per 5mins.12.336kWh per Hour296.064kWh per Day1776.384kWh per Week

Power Consumption kW: Power Saving kW: 17.68%15703.2kWh per Year

1.413Kvarh per 5mins.16.956Kvarh per Hour406.944Kvarh per Day2441.664Kvarh per Week

Power Consumption Kvar:88819.2kWh per Year

Note: Operation is 24 hours a day, 6 days a week and 50 weeks a year.

122083.2Kvarh per Year

Power Saving Kvar: 30.34 %37040Kvarh per Year

Power Factor Readings:

Off Load: 38%

Load Percentage:

Predicting the Energy savingsBefore Installing Powerboss

Off Load: 7.102 / 30.274 (100) = 23.45

Formula: Ave kW / Ave Kvar (100) = Saving Factor

Power Readings:

INJECTION MOULDING (100Hp Motor)INJECTION MOULDING (100Hp Motor)

Mid Load: 55.5%

Mid Load: 17.529 / 31.565 (100) = 55.53

Off Load

Full Load

Off Load

Full Load

Mid Load

Full Load: 28.234 / 31.381 (100) = 89.97

Full Load: 6.5%

Formula: Saving Factor Vs. kW Saving % X Load Percentage = Saving %

Total Kw Saving % = 16.94%

Power Savings

Off Load: 23.45 --------- 31.5% X 38% = 11.94%

Formula: Saving Factor Vs. kvar Saving % X Load Percentage = Saving %

Formula: Saving Factor Vs. kva Saving % X Load Percentage = Saving %

Mid Load: 55.53 --------- 9% X 55.5% = 4.99%

Total Kvar Saving % = 35.2%

Total Kva Saving % = 39.206%

On Load: 89.97 --------- 0% X 6.5% = 0%

Off Load: 23.45 --------- 51% X 38% = 19.33%

Mid Load: 55.53 --------- 28.6% X 55.5% = 15.87%

On Load: 89.97 --------- 0% X 6.5% = 0%

Off Load: 23.45 --------- 59.5% X 38% = 22.55%

Mid Load: 55.53 --------- 30% X 55.5% = 16.64%

On Load: 89.97 --------- 0% X 6.5% = 0%

Consumption & Savings

1.202kWh per 5mins.14.424kWh per Hour346.176kWh per Day2077.056kWh per Week

Power Consumption kW: Power Saving kW: 16.94%17592.66kWh per Year

2.503Kvarh per 5mins.30.996Kvarh per Hour743.904Kvarh per Day4463.424Kvarh per Week

Power Consumption Kvar:103852.8kWh per Year

Note: Operation is 24 hours a day, 6 days a week and 50 weeks a year.

223171.2Kvarh per Year

Power Saving kW: 35.2 %78556.26Kvarh per Year

Power Factor Readings:

Off Load: 39%Load Percentage:

Predicting the Energy savingsBefore Installing Powerboss

Off Load: 17.986 / 79.579 (100) = 23.79

Formula: Ave kW / Ave Kvar (100) = Saving Factor

Power Readings:

MIXER (185kW Motor)MIXER (185kW Motor)

On Load: 61%

On Load: 152.809 / 106.311 (100) = 13.737

Off LoadFull Load

Off Load

Full Load

Power Savings

Saving Factor Vs Saving graph (Laoding %) =Total SavingOFFLOAD 23.79761574 Is equal to 31 0.393194707 12.18903592LOW LOAD #DIV/0! Is equal to 0 0 0MID LOAD #DIV/0! Is equal to 0 0 0HIGH LOAD #DIV/0! Is equal to 0 0 0FULL LOAD 143.7377129 Is equal to 0 0.606805293 0

12.189

OFFLOAD 23.79761574 Is equal to 51 0.393194707 20.05293006LOW LOAD #DIV/0! Is equal to 0 0 0MID LOAD #DIV/0! Is equal to 0 0 0HIGH LOAD #DIV/0! Is equal to 0 0 0FULL LOAD 143.7377129 Is equal to 0 0.606805293 0

20.0529

OFFLOAD 23.79761574 Is equal to 59 0.393194707 23.19848771LOW LOAD #DIV/0! Is equal to 0 0 0MID LOAD #DIV/0! Is equal to 0 0 0HIGH LOAD #DIV/0! Is equal to 0 0 0FULL LOAD 143.7377129 Is equal to 0 0.606805293 0

23.1985

Kva Saving %

TOTAL Kva Savings

kW Saving %

TOTAL Kw Savings

TOTAL Kvar Savings

Kvar Saving %

Consumption & Savings

1.028kWh per 5mins.12.336kWh per Hour296.064kWh per Day1776.384kWh per Week

Power Consumption kW: Power Saving kW: 17.68%15703.2kWh per Year

1.413Kvarh per 5mins.16.956Kvarh per Hour406.944Kvarh per Day2441.664Kvarh per Week

Power Consumption Kvar:88819.2kWh per Year

Note: Operation is 24 hours a day, 6 days a week and 50 weeks a year.

122083.2Kvarh per Year

Power Saving Kvar: 30.34 %37040Kvarh per Year

Power Factor Readings:

Load Percentage:

Predicting the Energy savingsBefore Installing Powerboss

Formula: Ave kW / Ave Kvar (100) = Saving Factor

Power Readings:

Grinder 1 (47kW Motor)Grinder 1 (47kW Motor)

On Load: 100%

On Load: 30.4025 / 19.2865 (100) = 157.63

Power Savings

Saving Factor Vs Saving graph (Laoding %) =Total SavingOFFLOAD #DIV/0! Is equal to 0 0 0LOW LOAD #DIV/0! Is equal to 0 0 0MID LOAD #DIV/0! Is equal to 0 0 0HIGH LOAD #DIV/0! Is equal to 0 0 0FULL LOAD 157.6361704 Is equal to 0 1 0

0

OFFLOAD #DIV/0! Is equal to 0 0 0LOW LOAD #DIV/0! Is equal to 0 0 0MID LOAD #DIV/0! Is equal to 0 0 0HIGH LOAD #DIV/0! Is equal to 0 0 0FULL LOAD 157.6361704 Is equal to 0 1 0

0

OFFLOAD #DIV/0! Is equal to 0 0 0LOW LOAD #DIV/0! Is equal to 0 0 0MID LOAD #DIV/0! Is equal to 0 0 0HIGH LOAD #DIV/0! Is equal to 0 0 0FULL LOAD 157.6361704 Is equal to 0 1 0

0

Kvar Saving %

Kva Saving %

TOTAL Kva Savings

kW Saving %

TOTAL Kw Savings

TOTAL Kvar Savings

2.566kWh per 5mins.30.792kWh per Hour739.008kWh per Day4434.048kWh per Week

Power Consumption kW: Power Saving kW: 0%0kWh per Year

1.614Kvarh per 5mins.19.368Kvarh per Hour464.832Kvarh per Day2788.992Kvarh per Week

Power Consumption Kvar:221702.4kWh per Year

Note: Operation is 24 hours a day, 6 days a week and 50 weeks a year.

139449.6Kvarh per Year

Power Saving Kvar: 0 %0Kvarh per Year

Consumption & Savings

Power Factor Readings:

Load Percentage:

Predicting the Energy savingsBefore Installing Powerboss

Formula: Ave kW / Ave Kvar (100) = Saving Factor

Power Readings:

Grinder 2 (50Hp Motor)Grinder 2 (50Hp Motor)

On Load: 100%

On Load: 10.378 / 21.5835 (100) = 48.06

Power Savings

Saving Factor Vs Saving graph (Laoding %) =Total SavingOFFLOAD #DIV/0! Is equal to 0 0 0LOW LOAD #DIV/0! Is equal to 0 0 0MID LOAD #DIV/0! Is equal to 0 0 0HIGH LOAD #DIV/0! Is equal to 0 0 0FULL LOAD 48.06075902 Is equal to 15 1 15

15

OFFLOAD #DIV/0! Is equal to 0 0 0LOW LOAD #DIV/0! Is equal to 0 0 0MID LOAD #DIV/0! Is equal to 0 0 0HIGH LOAD #DIV/0! Is equal to 0 0 0FULL LOAD 48.06075902 Is equal to 31 1 31

31

OFFLOAD #DIV/0! Is equal to 0 0 0LOW LOAD #DIV/0! Is equal to 0 0 0MID LOAD #DIV/0! Is equal to 0 0 0HIGH LOAD #DIV/0! Is equal to 0 0 0FULL LOAD 48.06075902 Is equal to 34 1 34

34

Kvar Saving %

Kva Saving %

TOTAL Kva Savings

kW Saving %

TOTAL Kw Savings

TOTAL Kvar Savings

Consumption & Savings

0.599kWh per 5mins.7.188kWh per Hour172.512kWh per Day1035.072kWh per Week

Power Consumption kW: Power Saving kW: 15%7763.04kWh per Year

1.425Kvarh per 5mins.17.1Kvarh per Hour410.4Kvarh per Day2462.4Kvarh per Week

Power Consumption Kvar:51753.6kWh per Year

Note: Operation is 24 hours a day, 6 days a week and 50 weeks a year.

123120Kvarh per Year

Power Saving Kvar: 31 %38167.2Kvarh per Year

Benefits fromPowerBoss

This machines can benefit greatly from Powerboss. The softstart function will reduce both starting current drawn by the motor and mechanical strain on bearings, gears, belts and etc. The reduction in starting current will also increase motor’s life.

The optimization function will reduce the power supplied to theMotor without changing its torque and rpm. Reducing the power supplied tothe motor will significantly reduce the heat, vibration and noise. Reducing wasted energy will also reduce the maintenance cost and production downtime.