Power quality
Extremely fast fluctuating load profile iTDD exceeding limits set as per IEEE 519 standard Low PF (both leading and lagging)
High load unbalance
Increased losses due to high harmonics
Failure of welding transformers
Tripping of relays, protective circuits etc.
Failure of capacitor banks
Over harmonics creates transient leading to burnout of capacitor banks
Reduced lifespan of welding machines
Significant overvoltage
Motor & Drive applications
Low efficiency of motors
Thermal efficiency
Insufficient cooling
Heat transfer due to inadequate insulation of roof
Heat transfer due to lower quality of window panes
Overall heating in the facility
HVAC efficiency 
Fresh Air Supply-  Insufficient
–  Energetically inefficient without Heat Recovery units
Insufficient cooling
Excessive humidity
Odor & mould
Most factories do not have air-conditioning leading to difficult working conditions for its workers.
Lighting- Conventional vs. LEDs
High operating cost due to higher consumption of electricity by Halogens and conventional flood lights/hi-bays
Higher replacement costs due to shorter lifespan
High thermal impact on cooling
Indoor air quality
High Humidity
High temperatures
Bacteria and fungus develop in high temperatures and humidity
Presence of highly toxic chemicals in the environment during the welding process
Power quality
Double phase welding loads are identified as major non-linear Loads
Improper reactive compensation
3rd,5th,7th,9th &15th Harmonics leading to overheating of capacitor banks
Inappropriate capacitor bank technology which are contactor switching and not suitable for such fast changing loads.
High voltages lead to lower lifespan of end loads like welding machines
Motor & Drive applications
Higher ambient temperatures lead to significant de-rating of motors and drives
Lack of sufficient air flows lead to low dissipation of heat leading to de-rating of motors
Thermal efficiency
 Insufficient thermal insulation of windows & doors
Over burden on HVAC
Corrugated steel roof leading to massive heat transfer
HVAC efficiency 
Incorrect choice  of the chiller plant- this may be due to incorrect sizing or incorrect technology
Poor Maintenance of chiller plants
High Humidity (Desiccant dehumidification best solutions as no heat is produced)
Incorrect configuration
Imbalance in air pressure
High ambient temperature
No air conditioning available
Lighting- Conventional vs. LEDs
Old technology of conventional lightings
Inadequate light output
Significant light depreciation within 6-9 months of installation
Indoor air quality
Lack of dehumidification
Lack of cooling/ insulation
Lack of indoor air treatment
Excess use high temperatures for welding
Lack of indoor air filtration
Welding process
Power quality
Active Harmonic Filter at major DBs for the purpose of harmonic mitigation, reactive compensation and load balancing
Hybrid Filter with Neutral Compensator best suited when power factor is low
Voltage optimizer
Dynamic Power Factor Correction with detuned filter reactor
Motor & Drive applications
Reduction of heat with use of pre-cooling mechanisms to bring down temperatures where motor performance can be optimsed
Use of high CFM fans to create air low and improve performance
Thermal efficiency
Special coating which arrests heat transfer up to 70%.
Air curtains and open space cooling
Arresting leakage of hot air from doors and delivery sections
Cool roof coatings
Heat Recovery Unit
HVAC efficiency 
Yearly audit and maintenance of HVAC and proper configuration of chiller plant.
Refurbish existing Heat Recovery units by chemical cleaning of Heat Wheels, Enthalpy Wheel or Desiccant Wheel
Additional upgrade of  HRU with Horse Shoe Heat Pipe or Desiccant Dehumidification
Consider advance air distribution technologies such as Bosch Clemotion or Composite air ducts.
Chiller replacement for highest energy savings and lowest cost of ownership – Heat Pump
-Water cooled chiller
-Invertor based chiller
Shading of chiller plant and Wet wall
Open space cooling solutions are the cheap alternative to air-conditioning systems like FAHU
Lighting- Conventional vs. LEDs
Replacement by LED with following specs:
-160 lumens/watt
-less than 10% depreciation in light output over the expected life of 5 years
– TL-21 certified
– LM 79 and LM-80 compliant
Indoor air quality
Heat Recovery Unit
Horse Shoe Heat pipe
Desiccant dehumidification
Indoor air purification
HEPA and Carbon filters
Oxygen concentrators to improve air quality
Smoke extractors during welding process
Power quality
Current harmonic distortion <8% at welding PCC Relatively balanced load profile Reduced (almost negligible) failure rate
Relatively smooth reactive compensation
Reduced losses due to simultaneous reduction in harmonic, reactive and negative sequence losses
Safe operations without flashover and transient events which may lead to fire
Savings in energy costs
Motor & Drive applications
Higher performance of the motor will lead to higher output
Less heating of motor will lead to significant savings in energy costs.
Thermal efficiency
HVAC is no more over burdened
Lower energy cost
HVAC efficiency 
Lower cost of utilities (DEWA bills)
Adequate cooling
Improved life of chiller plant
Less downtime or break downs thereby savings in maintenance costs
Overall well being
Lighting- Conventional vs. LEDs
Better light output
Well being
Reduction in heat load on HVAC
70-80% reduction in electricity bills
Significant reduction in maintenance costs due to longer asset life
Indoor air quality
Less maintenance problems
Better air quality

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