The Challenge
A manufacturing facility had six production lines fed from a central distribution panel 120–180 meters away. Each line had multiple cable runs of varying gauges, some dating to original 1998 installation, some added over the years.
What Became Visible
Electrical loss analysis (I2R calculation) on each production line revealed cable resistance losses totaling 4.8 kW continuous — equivalent to 38 MWh annually. The oldest cable runs (1998) had the highest losses. Line 3 had three separate cable feeds that had been added incrementally, each undersized for their current load. Total resistance loss on Line 3 was 1.4 kW despite only 18 kW load. Loss factor was 7.8% — far above acceptable 2–3% standard.
What Changed
Cable assessment and targeted replacement program. Three high-loss cable runs were replaced with appropriately sized cables. Central distribution panel was reconfigured to reduce run lengths by consolidating feeds.
How it worked: The three worst-performing cable runs (Lines 2, 3, and 4) accounting for 2.8 kW loss were replaced with larger gauge cables. Line 3's three separate undersized feeds were replaced with a single appropriately sized run. The consolidation also freed up electrical panel space for future expansion. Total cable resistance losses dropped from 4.8 kW to 1.1 kW.
Results
continuous
within standard
−₹6.2 lakhs
18-month payback
Cable resistance losses are linear to current and quadratic to resistance. Undersized or aging cables compound over decades. Modern cabling analysis reveals losses that were invisible but cost thousands annually.
Operational Reality
Most facilities with 10+ year old electrical distribution lose 3–8% of energy to cable and distribution resistance. Identification requires analysis; fix requires replacement capex but has 12–24 month payback.