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Project Title

Energy Efficiency Improvement Projects at KOEL


Submitted by

Sagar B. Dhage
Roll No. 2008 ENE 01

Under the Guidance of

Mr. Milind B Deore


Energy Manager, KOEL

School of Energy Study University of Pune Date: 29th Dec., 2009


1

Project Details
Project Title : Energy Efficiency Improvement Project at Kirloskar Oil Engines Ltd.
Mr. M.B. Deore Energy Manager Kirloskar Oil Engines Ltd, Khadki. Pune Starts : 16th June, 2009

Project Guide: Designation: Organisation Name:

Project Duration

Project Application / Use of project after completion


The aim of the project is to identified ENCON opportunities in Khadki (excluding R-HA & SL-90) & Ahemadnagar units of KOEL. This will help to optimize operating strategy Explore improvement opportunities for energy efficiency by applying best practices. Energy Cost Reduction

Coverage
KOEL Nagar Plant Electricity Bill Study PF analysis TOD incentives MD reduction Compressed Air System Reduction in Compressed air Pressure Energy efficient motor Efficient transmission system Exhaust air recovery Study of Illumination system Natural Daylight Energy Efficient illumination system Performance Analysis of Furnaces Excess air control Reduction in heat loss KOEL Khadki Plant Compressed Air System FAD Trap Survey Bearing Plant Motor survey TOD benefits Load Rescheduling ENCON opportunity for Compressed air Tech Centre Energy consumption trend Cooling Tower Assessment Illumination System Compressor assessment

Training Centre Cooling Tower Assessment Illumination System


IT Dept Cooling load estimation DV shop Cooling Tower Motor survey Transformer Assessment HT shop Furnace Assessment Excess air control Reduction in heat losses

Energy Policy
Sr. No. Parameters 1 Vision/Mission committed for Nation 2 Objective of ENCON 3 Commitment from Top Management 4 Reduction in SEC 5 Energy Efficient Operation 6 Energy Efficient Products 7 Efficient use of energy 8 Minimise wastage 10 Energy Efficient Building Projects Continuous study & measures 11 implementations 12 Benchmarking 13 Renewable Energy 14 Information shearing 15 Recycling /reuse 16 Employee Involvement 17 Training / awareness 18 Efforts recognition 19 Issue Date 20 Revise date KOEL X X X X X X X KFIL X X X X X X X X KBL, KBL, KBL, Kirloskarwadi Kodhapur Dewas i X X X X X X X X X X X X X X X X X X X Kolhapur KPCL, Steel Ltd. Hadapsar X X Designation not mention X X x X X X X X X X X X X

Assisting ENCON Activities


1. Contribution in documenting Award Winning ENCON Report for K-group

ENCON Competition.
2. Contribution in documenting National Energy Conservation Award

Winning ENCON Report of Nasik unit organised by Bureau of Energy Efficiency.


3. Contribution in documenting ENCON Report for State level ENCON

Competition organised by MEDA.


4. Assisting issues after implementing ENCON projects 5. Assisting external agencies like KBL. 6. Assisting in Procuring Energy Efficient Equipments/Products 7. Assisting in Procuring Energy Audit Instruments

8. Developing Vendor Bank


6

ENCON Awareness
ENCON Awareness Activities in Schools ENCON Lectures ENCON Essay Competitions ENCON Poster Competitions ENCON Awareness Activities in KOEL Chalta Bolta Quize Competition ENCON Awareness Activities for Household Womens ENCON Lectures ENCON workshops

Compressed Air System


Compressor Assessment
Parmeters Initial Pressure Final Pressure Atm. Pressure Receiver Storage Volume including pipe work Time taken to build up Final Pressure Actual measured I/P power Initial Temp. Final Temp. P1 P2 P0 V T P T1 T2 1.013 8.03 1.013 2.092 1.25 58 27 102 Units kg/cm2 kg/cm2 kg/cm2 m3 min kW C C

Actual Free Air Delivery = 11.6 m3/min = 409.65 cfm Volumetric Efficiency = Actual FAD* 100/ Rated FAD = 409.65 *100/ 500 = 82 % Specific Energy Consumption = Actual FAD/ Actual Power Consumed = 409.65 / 51.06 = 8.02 cfm/kWh
8

Compressed Air System


Compressor Assessment
Compressor No. Rated Capacity (cfm) Actual FAD (cfm) Volumetric Efficiency (%) Specific Energy Consumptio n (cfm/kWh) 8.02 Remark

Compressor No. 5 Compressor No. 6

500 300

409.65 173

82 % 57.66 %

Vol. Efficiency is good. But further can be improve up to 90%

Poor , Needs urgent


investigation

Action: Maintenance was done. Performance test again conducted on compressor no. 5 Vol. Efficiency of compressor no 5 found to be 87 %
Comp. No. Before After Annual Energy Saving in kWh Annual Energy Saving in Rs. 15,162

Volumetric Efficiency Specific Energy Consumption (cfm/kWh)

82 % 8.02

87.5 % 8.56

3032

Compressed Air System


Suggestions: 1. Compressor efficiency further can be improved up to 90%. 2. Install manometers across the filter and monitor the pressure drop as a guide to replacement of element. 3. During test it was observed that receiver contains significant amount of moisture and oil content. Oil content in moisture indicates that internal oil leakages may be occurred in the compressor which urgently needs to be investigates.

10

Compressed Air System


Air traps survey
Observations: 1. Total 14 no's are manual 2. 4 nos of drain valves are installed out of which only 2 are in operating conditions. 3. Remaining valves are manually operated. 4. At the compressor shop, both auto drain valves were not in operation. Suggestions: 1. Manual operation leads to wastage of compressed air, use Float type bucket air traps 2. It is learnt that auto drain valves not suitable for longer applications. Float type bucket air traps should be considered. 3. As at compressor shop, both auto drain valves were not in operation; which is not desirable. Action taken: 1. Procedure has been begun to install float type traps

11

Bearing Shop
Process Flow Diag.
Pressing Electrical Energy Compressed air Nicking Electrical energy Compressed air
F2 : Water Cooling Tower, TR A/C Plant, Radial Drilling M/c F3 : 4R Crank case line, Milling M/C line

Electrical Distribution

Transformer
F1 : (Dispatch Section, Packing Section)

Nick milling Electrical energy Compressed air J/F broaching Electrical Energy Compressed air Oil hole punching Electrical energy Compressed air Oil hole sinking Electrical energy Compressed air ABB - Auto bore broaching Electrical energy Compressed air Insepection

F4 : DLW line, 4R 1040-2 line F5 : Arjun line, Engg office

F6 : Arjun 5 & 6
F7 : Arjun 3 & 4 F8 : Arjun 1 & 2, Packing section, Purchase dept, elect dept

Oiling

Packing Electrical energy

12

Bearing Shop
Energy Distribution

F8 27%

F1 5%

F2 11% F3 8% F4 4%

F7 18%
F6 17%

F5 10%

13

Bearing Shop
Energy Consumption Trend

kWh
07:00- 08:00- 09:00- 10:00- 11:00- 12:00- 13:00- 14:00- 15:00- 16:00- 17:00- 18:00- 19:00- 20:00- 21:00- 22:00- 23:00- 00:00- 01:00- 02:00- 03:00- 04:00- 05:00- 06:0008:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 00:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00

F1

8.6

10.7 32.1 25.8 15.2 24.0 39.2 41.5 68.1

11.4 32.5 28.1 19.4 29.1 40.4 42.0 71.9

13.2 32.8 25.0 14.7 27.2 38.9 43.5 68.7

13.8 30.8 18.6 10.6 21.7 37.7 42.2 59.6

13.8 29.3 25.4 16.9 25.8 39.8 44.0 72.8

14.1 30.3 26.1 18.4 29.6 41.2 44.3 71.3

13.8 30.3 26.3 18.8 29.8 41.5 45.2 73.5

11.1 28.5 13.8 9.3 22.3 33.5 31.6 54.9

12.5 29.1 24.0 13.4 30.6 38.4 38.7 73.0

11.6 28.4 24.5 11.7 29.9 40.2 40.0 70.8

12.7 21.1 23.7 11.0 26.4 39.9 41.9 65.5

13.5 19.0 20.4 6.7 20.8 40.1 44.1 59.3

13.0 19.6 12.6 4.1 13.0 35.2 38.7 47.1

13.4 21.1 17.5 7.6 19.9 41.4 43.9 55.8

12.7 20.5 19.7 8.9 20.4 41.7 43.1 59.7

11.2 19.4 13.8 4.5 15.4 38.9 40.1 51.3

8.6 18.5 13.2 2.2 13.6 33.2 34.2 47.6

9.2 18.1 16.0 2.1 16.1 41.1 43.2 54.5

9.0 18.0 14.6 2.1 16.3 40.8 44.6 52.5

8.8 17.9 10.7 2.0 11.6 35.7 38.0 44.7

8.9 17.8 8.6 2.0 14.0 39.9 42.9 49.6

7.9 19.0 11.7 2.0 16.3 40.1 44.0 48.7

6.7 20.1 6.9 1.8 10.5 32.2 31.6 37.7

F2 28.9 F3 14.9 F4 6.1 F5 12.5 F6 28.1 F7 27.2 F8 42.2

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Bearing Shop
Motor Survey Guideline for Energy Saving in Motor Application
For Permanent Star Connection Estimated Energy Saving (% of Actual Loading) 15% 12% 10% 8%

Sr. No.

Under Loading (%)

1. 2. 3. 4.

Upto 30% Between 30% to 40% Between 40% to 50% Between 50% to 55%

Annual Energy Saving = 38, 530 kWh Annual Cost Saving @Rs. 5.29/kWh = Rs. 2.35 Lakh Investment = Nil Payback = Immediate
15

BEARING SHOP - Motor Survey


Machine Line Name Sr. No. no. ARJUN 1 1 Auto Facing 675 Cutter Motor 3 8 ABB 6401 Hyd Motor 1 2.2 22.0 86.4 91.5 4.8 39.0 2.2 19.0 1.9 17.5 2.1 14.6 2.1 17.0 1.0 8.5 40% 35% 10.0 12.0 0.1 1.0 TOTAL ARJUN 2 1 Auto Facing 6962 HYD Cutter Motor 3 3 4 5 6 8 Nicking Broaching (J/F) Measuring Punching ABB 6961 6322 * 914 6414 Hyd Hyd Hyd Hyd Hyd Motor 1 Motor 1 Motor 1 Motor 1 Motor 1 5.5 22.0 89.2 91.5 10.6 40.0 8.5 5.5 88.0 89.2 11.0 5.7 7.0 5.6 6.9 16.0 5.7 7.5 5.2 6.8 17.2 5.7 7.5 5.4 6.7 17.4 5.7 7.3 5.4 6.8 16.9 2.8 3.6 2.7 3.4 8.4 55% 35% 9.0 12.0 0.3 1.0 TOTAL ARJUN 3 1 Auto Facing 6966 HYD Cutter Motor 3 2 Grooving 6976 Hyd Hyd 8 ABB 6413 Hyd Motor 1 Motor 2 Motor 1 22.0 91.5 40.0 2.2 5.5 86.4 89.2 4.8 10.7 0.5 4.3 0.5 21.0 0.9 3.6 0.6 21.0 0.5 4.1 0.7 22.0 21.3 10.6 44% 10.0 1.1 TOTAL ARJUN 5 1 Auto Facing Hyd Cutter Motor 3 2 Grooving 6977 Hyd Cutter 3 4 5 6 8 Nicking Broaching (J/F) Measuring Punching ABB 6954 6917 801 936 Hyd Hyd Hyd Hyd Motor 1 Motor 2 Motor 1 Motor 1 Motor 1 Motor 1 Motor 1 5.5 15 89.2 89.2 10.6 28.6 5.5 89.2 10.5 2.2 5.5 86.4 89.2 4.8 10.6 2.3 3.2 1.9 5.6 6.7 4.6 4.5 17 6.8 6.7 4.7 4.9 18 4.9 6.67 5.7 4.3 18.5 4.6 17.8 2.3 8.9 37% 53% 12 9 0.3 0.8 TOTAL GRAND TOTAL 2039.7 5974.1
7845.5

Machine

Type

Rated

Eff.

Rated

Current

Avg Amp Measured kW % Load

Estimated Saving in %

kWh Saving

Annual kWh Saving

Annual Saving in Rs.

Kw HYD Motor 1 Motor 2 1.5 2.2

% 85.0 86.4

Amp 3.5 4.8

I1 2.2 2.2

I2 2.1 1.9

I3 2.7 2.1

I 2.3 2.1 1.2 1.0 66% 40% NIL 10.0 NIL 0.1 NIL 769.2 769.2 7608.1 9146.60 699.8 781.7 NIL Rs. 4,069 Rs. 4,069 Rs. 40,247 Rs. 48,386 Rs. 3,702 Rs. 4,135

Motor 1 Motor 2

2.0 2.2

86.4 86.4

3.5 4.8

1.7 1.4

1.3 1.4

1.7 1.4

1.6 1.4

0.8 0.7

34% 27%

12.0 15.0

0.1 0.1

59%

NIL

NIL

NIL

NIL

2278.0 7533.7 11293.05 NIL

Rs. 12,050 Rs. 39,853 Rs. 59,740 NIL

Motor 1 Motor 2

1.8 2.2

85.0 86.4

3.4 4.8

2.4

2.6

2.1

2.4

1.3

60%

NIL

NIL

0.6 4.0

0.3 2.1

13% 35%

15.0 12.0

0.1 0.3

378.9 1925.4

Rs. 2,004 Rs. 10,185

7940.6 10244.9

Rs. 42,006 Rs. 54,196

Motor 1 Motor 2 2.2 86.4 4.8 2.13 2.1 2.1 4.2 2.76 2.7 4.8 2.3 2.4 4.1 1.2 1.2 2.0 45% 46% 33% 10 10 12 0.1 0.1 0.2 867.3 880.9 1816.4 Rs. 4,588 Rs. 4,660 Rs. 9,609

6.7

3.3

54%

0.3

2241.1

Rs. 11,856

Rs. 10,790 Rs. 31,603 Rs. 73,105

16
38530.0 Rs. 2,35,427

Bearing Shop
Exhaust Air Recovery
Description : Energy saving calculations: Total nos of machines = 4 Cylinder dia = 12 Stroke length = 1 Volume = 0.0654 f3 Cycle time = 20 stroke/min Air available = 20 x 0.0654 = 1.308cfm Per day saving in CA = 1.308 x 18hr =23.54 cfm Per annum saving = 7345.72 cfm Total saving on all ABB machines = 7345.72 cfm x 4 = 29,383 cfm Total saving in kWh = 29,383 cfm / 5 cfm/kWh = 5877 kWh Total Annual Cost Saving = Rs. 29,383/-

The saving in compressed air can be achieved by using this exhaust air for cleaning & machining application.

Total Investment in Rs. (approx.) Annual Energy Savings in kWh


Annual Cost Savings in Rs. (Rs.5.29/kWh) Payback Period

8,000/5877 29,383 /4 months

17

Technical Centre
The electrical distribution :

Tech Centre Incomer

Emmision / Endurance lab

Test Cell

Old design office + blower

Reliability lab + canteen + Old PR assembly

Jig mill + machine shop

Store + New PR assembly + New design office

18

Technical Centre
Percentage Energy Distribution
Reliab lab+canteen+PR asssly Old design+blower Test cell Jig mill+mc shop emission/endurance lab store, new PR assly

4%

10%

9% 23%

16%

38%

19

Technical Centre
Energy consumption trend
80.0

Rs. 0/kWh
70.0

Rs. 0.8/kWh

Rs. 0/kWh

Rs. 1.10/kWh

Rs. - 0.85/kWh

60.0

50.0

kWh

40.0

30.0

20.0

10.0

0.0

06:00 07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 00:00 01:00 02:00 03:00 04:00 05:00 07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 00:00 01:00 02:00 03:00 04:00 05:00 06:00 4.7 6.6 10.9 24.2 24.5 25.4 23.4 22.3 20.5 19.8 12.7 6.4 5.7 5.6 5.6 5.8 6.0 6.2 6.3 6.4 6.3 6.3 6.4 6.4 15.7 20.4 25.8 28.4 29.7 30.9 29.1 30.9 34.0 34.6 33.5 34.0 35.7 35.7 35.4 36.7 38.7 34.3 25.9 25.2 25.2 25.1 24.1 22.8 15.5 56.9 65.5 73.7 73.6 73.6 69.8 70.9 71.4 66.5 68.8 63.8 61.8 53.7 48.1 38.6 35.2 28.9 26.9 25.2 24.3 24.3 23.8 21.4 10.7 16.4 25.5 35.9 37.3 39.7 38.4 39.4 44.2 42.7 40.7 31.9 18.8 10.8 2.5 1.6 6.5 8.9 10.5 9.8 6.1 7.4 7.3 8.5 6.5 3.6 0.6 9.3 2.7 3.7 3.2 2.2 14.6 27.4 35.9 32.3 29.1 22.5 31.4 35.7 35.4 26.5 7.6 3.0 1.0 6.7 3.1 1.0 6.8 3.2 1.1 7.0 3.3 1.1 6.8 3.4 1.1 6.8 3.3 1.2 6.8 3.3 1.2 6.8 3.3 1.2 6.8 3.3 1.2 7.0 3.2 1.2

Reliab lab+canteen+PR asssly Test cell emission/endurance lab Old design+blower Jig mill+mc shop store, new PR assly

20

Technical Centre
Key Technical Specification
Sr. No. 1 2 3 4 5 6 7 8 9 Parameter Type of Cooling Tower Number of cells per tower Area per cell Water flow Pumping power Pumping head Fan power Design hot water temperature Design cold water temperature P H Pfan m /hr kW m kW C C
3

Units Forced draft 30 3.5 8 2.237 40 30 Forced draft 30.28 3.5 8 2.237 40 30

Cooling Tower Performance


Sr. No. 1 2 3 4 5 6 7 8 9 Parameter Dry bulb temperature Wet bulb temperature CT inlet temperature CT outlet temperature Range Approach CT effectiveness Average water flow Evaporation loss 0.00085 x 1.8 x circulation rate (m3/hr) x (T1-T2) DB WB T1 T2 (T1 - T2) (T2 - WB) Range/ (Range+Approach) Units C C C C C C % m3/hr 28 18 22 19 3 1 75.0 30 0.14 28 18 21 19 2 1 66.7 30.28 0.09

21

Technical Centre
Use of Fanless Cooling Tower
Description : In the existing system induced draft type cooling tower is used. It requires 2.24W of power is needed to drive the fan. By installing fanless natural draft cooling tower leads to conserve the energy Energy saving calculations: Energy savings Calculations Existing Energy Consumption : 2.24 kW x 2 nos x 22 hrs x 26 days x 12 months = 32,148 kWh Proposed system energy consumption = 0 kWh Estimated Annual Energy Saving = 32,148 kWh Estimated Annual Cost Saving = Rs. 1.70 lakhs

Total Investment in Rs. (approx.) Annual Energy Savings in kWh


Annual Cost Savings in Rs. (Rs.5.29/kWh)

2 lakhs 32, 148 1. 7 lakhs

Payback Period

14 months
22

Technical Centre
Performance Assessment of Compressor System
Parameters Initial Pressure Final Pressure Atm. Pressure Receiver Storage Volume including pipe work Time taken to build up Final Pressure Actual measured I/P power Initial Temp. Final Temp. P1 P2 P0 V T P T1 T2 0.5 8.0 1.026 250 6.5 3.73 27 45 Units kg/cm2 kg/cm2 kg/cm2 Lit min kW C C

Actual Free Air Delivary =(80.5)/1.013 x 250/6.5 x (273+27)/(273+45) = 269 lit/min Actual Free Air Delivery = 269 lit/min Volumetric Efficiency = Actual FAD* 100/ Rated FAD = 269 *100/ 991 = 27.2 % Specific Energy Consumption = Actual FAD/ Actual Power Consumed = 9.5 cfm / 3.73kW = 2.54 cfm/kWh
23

Rated FAD Actual FAD SEC Volumetric Efficiency 991 lit/min 269 lit/min 2.54 cfm/kWh 27.2 %

Technical Centre
Performance Assessment of Compressor System

By improving output of compressor up to 90%

Reducing delivery pressure of compressor

Total Investment in Nil Rs. (approx.) Annual Energy 4320 Savings in kWh Annual Cost Savings 22, 853 in Rs. (Rs.5.29/kWh)
Payback Period Immediate

Total Investment in Nil Rs. (approx.) Annual Energy 2340 Savings in kWh Annual Cost Savings 12, 378 in Rs. (Rs.5.29/kWh) Payback Period Immediate

24

Technical Centre
Use of Natural Day-light
Description :

Energy saving calculations: Existing Energy Consumption = (250 + 30)W x 27 nos x 8 hrs x 26 days x 12 months = 18869.7 kWh Proposed system energy consumption: 220 kWh Estimated Annual Energy Saving = 18869.7 kWh Estimated Annual Cost Saving Rs. 99,821/25

In the existing system artificial illumination system are use for lighting system. By using transparent sheet natural day light can be use which leads to reduction in energy consumption.
Total Investment in Rs. (approx.) Annual Energy Savings in kWh
Annual Cost Savings in Rs. (Rs.5.29/kWh)

1, 50,000/-

7,188
38,027/4 years

Payback Period

Technical Centre
Use of Natural day-light by Light Pipe

Total Investment in Rs. (approx.) Annual Energy Savings in kWh


Annual Cost Savings in Rs. (Rs.5.29/kWh)

84, 000 18, 869 99, 821

Existing System: FTL fitting (18W x4) Quantity : 40 nos

Payback Period

10 months
26

Technical Centre
Optimization of pumping system
Description of the energy conservation measure: By providing individual valves to each bed water flow can be made OFF when not required. It reduces water flow in the system. Therefore new system will have variable water flow but requires constant head.
Total Investment in Rs. (approx.) Annual Energy Savings in kWh
Annual Cost Savings in Rs. (Rs.5.29/kWh)

Existing System Single Pump Make : Kirloskar KDS-1537++ Power: 11 kW Measured Head : 24 m Measured flow: 32 lps Required flow: 24 lps

1, 2 lakh

51, 480
2.72 lakh 5.5 month

Payback Period

Proposed System Parallel operation of two pump Make : Kirloskar KDS- 830++ Power: 5.5 kW Measured Head : 26 m Required flow: 14 lps
27

Technical Centre
Optimization of pumping system

5 HP

Hot sink

Cold sink

11 kW Head : 24 m Flow : 32 lps (reqd: 24 lps)

By Gravity

Test Cell

28

Technical Centre
Optimization of pumping system

5 HP 5.5 kW each Head : 26m Flow : 14 lps

Hot sink

Cold sink
c

By Gravity

Test Cell

29

Training Centre
Energy efficient illumination system
Description : Existing Sytem : 1. 72W FTL fitting x 8 nos 2. 15W cfl x 9 nos Proposed System: Energy Efficient T5 , 7 nos
Total Investment in Rs. (approx.) Annual Energy Savings in kWh
Annual Cost Savings in Rs. (Rs.5.29/kWh)

Energy saving calculations: Existing Energy Consumption = 0.666 kWh Proposed system energy consumption: 0.47 kWh Estimated Annual Energy Saving = 1760 kWh Estimated Annual Cost Saving Rs. 8800/-

15, 000/-

1760
8800

Payback Period

1.7 years
30

Training Centre
Energy efficient illumination system
Description : It is found that 1 nos of FTL lamp fittings is not necessary. (Trial was taken). Existing CFL lamps are use for aesthetic purpose. Replacement of 4 FTL lamp fittings (each of 18W x 4 nos) by energy efficient 3 nos of T5 lamp fitting (14W x 4 nos). Replaced 15 nos CFL lamps by LED lamps.

Energy saving calculations: Existing Energy Consumption = 1055.81 kWh/year Proposed system energy consumption = 220 kWh/year Estimated Annual Energy Saving = 853.81 kWh Estimated Annual Cost Saving Rs. 4179/31

Total Investment in Rs. (approx.) Annual Energy Savings in kWh


Annual Cost Savings in Rs. (Rs.5.29/kWh)

11400

853.81
4179

Payback Period

2.7 years

Training Centre
Use of occupancy sensors Description : Use of occupancy sensors.
Energy saving calculations: Existing Energy Consumption = 1378 kWh/year Proposed system energy consumption = 516 kWh/year Estimated Annual Energy Saving = 862 kWh/year Estimated Annual Cost Saving Rs. 4310/32

Total Investment in Rs. (approx.) Annual Energy Savings in kWh


Annual Cost Savings in Rs. (Rs.5.29/kWh)

2, 000

862
4310

Payback Period

6 months

Training Centre
Convert Delta to Star operation of motor & Use of flat belt
Description : Fan motor was operated on lower loading. Thus by converting motor connection from delta to star connection leads to save 10% of energy. Using energy efficient flat belt, 3% saving can be achieved.
Total Investment in Rs. (approx.) Annual Energy Savings in kWh
Annual Cost Savings in Rs. (Rs.5.29/kWh)

Energy saving calculations: Rated Power : 9.3 kW Motor loading = 46%

5,000
1493 7465

Estimated Annual Energy Saving by converting to star connection = 1148 kWh/year


Estimated Annual Energy Saving by converting to star connection = 344 kWh/year Total annual saving = 1493 kWh
33

Payback Period

9 months

Training Centre
Optimize Use of Cooling Tower System
Description : Avoid use of cooling tower when not required by using temperature switch. Thus avoid use of 3.7 kW pump Energy saving calculations: Existing Energy Consumption = 3.7 x 5 hrs/day x 26 days x 12 months = 5772 kWh Proposed system energy consumption =3.7 x 5 hrs/day x 26 days x 6 months = 2886 kWh Estimated Annual Energy Saving = 2886 kWh Estimated Annual Cost Saving = Rs. 14,430/-

Total Investment in Rs. (approx.) Annual Energy Savings in kWh


Annual Cost Savings in Rs.

5,000
2, 886 14, 430

Payback Period

4 months
34

Training Centre
Optimize Use of Cooling Tower System

Water Tank

Engine

T E

Water Sump

35

IT
Cooling Load Calculations:
Objective 1. Provide information for equipment selection, 2. System sizing and system design Space Heat Gain Solar radiation through transparent surfaces such as windows Heat conduction through exterior walls and roofs Heat conduction through interior partitions, ceilings and floors Heat generated within the space by occupants, lights, appliances, equipment and processes Loads as a result of ventilation and infiltration of outdoor air Other miscellaneous heat gains Sensible heat a. Heat transmitted thru floors, ceilings, walls b. Occupants body heat c. Appliance & Light heat d. Solar Heat gain thru glass e. Infiltration of outside air f. Air introduced by Ventilation 36

IT
Cooling Load Calculations:
Latent Heat Loads a. Moisture-laden outside air form Infiltration & Ventilation b. Occupant Respiration & Activities c. Moisture from Equipment & Appliances External Cooling Load Roof Walls Solar Heat Load through glass Partitions, ceiling & floors Internal Cooling Load Infiltration Air People Equipments Lights
37

IT

38

IT
Use of VRV/ VRF HVAC system
Existing system Specific Energy Consumption : 1.4 kW/TR Proposed system Specific Energy Consumption : 0.8 kW/TR Reduction in Specific Energy Consumption : 42 %

Energy savings Calculations Existing Energy Consumption : 25 TR x 1.4 kW/TR x 8 hrs x 26 days x 12 months = 87,360 kWh/year Proposed system energy consumption: 25 TR x 0.8 kW/TR x 8 hrs x 26 days x 12 months = 49920 kWh/year Estimated Annual Energy Saving = 37440 kWh/year Estimated Annual Cost Saving = Rs. 1.98 lakhs
39

Dv Shop
Avoid idle running of Spiral Conveyor
Description : In the existing CNC machines, it is observed that spiral conveyor operates idle even when job is not loaded on the machines. By doing modification in programming, idle running cab be avoided.
Total Investment in Rs. (approx.) Annual Energy Savings in kWh
Annual Cost Savings in Rs. (Rs.5.29/kWh)

Energy saving calculations: Estimated Annual Energy Saving = 0.4 kW x 2 x 8 nos x 2 hrs x 26 days x 12 months = 4000kWh/year Estimated Annual Cost Saving = Rs. 21,126/-

Nil
18.870 99, 821

Payback Period
40

DV Shop
Use of Fanless Cooling Tower
Description : In the existing system induced draft type cooling tower is used. It requires 2.24W of power is needed to drive the fan. By installing fanless natural draft cooling tower leads to conserve the energy Energy saving calculations: Energy savings Calculations Existing Energy Consumption : 2.24 kW x 2 nos x 22 hrs x 26 days x 12 months = 32,148 kWh Proposed system energy consumption = 0 kWh Estimated Annual Energy Saving = 32,148 kWh Estimated Annual Cost Saving = Rs. 1.70 lakhs

Total Investment in Rs. (approx.) Annual Energy Savings in kWh


Annual Cost Savings in Rs. (Rs.5.29/kWh)

2 lakhs 32, 148 1. 7 lakhs

Payback Period

14 months
41

Technical Centre
Conversion of motor connection from delta to star
Description : In the existing CNC machines, motors are used for many purposes included conveyor, hydraulic motors etc. In some of motors loading found lower than the capacity. By converting motors from delta to star energy saving can be achieved.

Total Investment in Rs. (approx.) Annual Energy Savings in kWh Annual Cost Savings in Rs. (Rs.5.29/kWh) Payback Period

Nil 4425 22, 145 Nil


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Transformer
Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Transformer No. Transformer No. 1 Transformer No. 2 Transformer No. 3 Transformer No. 4 Location A Shop A shop 1 Comp MSEB B Shop Trans. 1 I/C B Shop Trans. 2 I/C Rated kVA 500 750 750 750 400 1000 750 500 750 750 750 750 1000 750 750 AVERAGE Measured % kVA Loading 82 329 176 115 234 239 209 92 225 125 28 67 185 156 142 16 44 23 15 58 24 28 18 30 17 4 9 19 21 19 PEAK HOUR Measured % kVA Loading 183 447 334 211 275 313 397 144 391 154 66 165 334 272 256 37 60 44 28 69 31 53 29 52 20.6 9 22 33 36 34 582 406 424 406 369 477 213 472 161 193 235 353 367 291 78 54 57 102 37 64 43 63 21.4 26 31 35.3 49 39 Max Peak KVA Max Peak loading

Transformer No. 5 B shop 4 R SL 90, 380 V Transformer No. 7 Bearing Panel Incomer Transformer No. 8 Transformer No. 9 Transformer No. 10 Transformer No. 11 Transformer No. 12 Transformer No. 13 Transformer No. 15 Transformer No. 17 HT1 & 2 HT Canteen, lab, IT F1 MSEB F2 MSEB F7 MSEB F4 MSEB F3 MSEB F5 MSEB Tech. Center

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Transformer
Sr. No. Transformer No. Location Rating NL Loss (kW) 1.4 1.225 1.225 1.225 1.4 1.15 1.225 1.4 1.225 1.225 1.225 1.225 1.15 1.225 1.225 Load Loss Losses (kW) (kWh) 7 9.5 9.5 9.5 7 12 9.5 7 9.5 9.5 9.5 9.5 12 9.5 9.5 1.41 1.26 1.23 1.23 1.55 1.16 1.24 1.41 1.24 1.23 1.23 1.23 1.15 1.23 1.23 Total Annual Loss Annual Loss in Rs. (Rs. (kWh) 5.29/kWh) 11148.2 9960.1 9775.8 9733.5 12270.6 9162.3 9806.2 11162.9 9821.9 9738.9 9703.9 9712.6 9140.5 9759.8 9750.2 150647.5 58,974.01 52,688.82 51,714.17 51,490.47 64,911.59 48,468.66 51,874.84 59,051.70 51,958.05 51,518.67 51,333.50 51,379.50 48,353.45 51,629.21 51,578.60 7,96,925.23

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Transformer No. 1 Transformer No. 2 Transformer No. 3 Transformer No. 4

A Shop A shop 1 Comp MSEB B Shop Trans. 1 I/C B Shop Trans. 2 I/C

500 750 750 750 400 1000 750 500 750 750 750 750 1000 750 750

Transformer No. 5 B shop 4 R SL 90, 380 V Transformer No. 7 Bearing Panel Incomer Transformer No. 8 Transformer No. 9 Transformer No. 10 Transformer No. 11 Transformer No. 12 Transformer No. 13 Transformer No. 15 Transformer No. 17 HT1 & 2 HT Canteen, lab, IT F1 MSEB F2 MSEB F7 MSEB F4 MSEB F3 MSEB F5 MSEB Tech. Center

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