IIT Madras

IIT Hyderabad

IIT Bombay

IIT Indore

IIT Gandhinagar

IIT Guwahati

IIT Ropar

Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras

KMB-IIT-GUW-230605-04

The subject plant is located in Guwahati district of Assam and falls under NIC Category-17014. This assessment was carried out by the IEAC Center, IIT Guwahati, during the course of the year 2023.

General Info

Principal Product

Packaging

Plant Area (Sq.ft)

30,000

No. of Employees

45

Production Hours

7,200

Annual Production

Annual Sales

₹5,00,00,000

Assessment Summary

Total Energy Costs(per year)

₹81,54,895

Total Recommended Investment(one time)

₹10,08,000

Total Recommended Savings(per year)

₹22,41,775

Energy Costs Calculation
Electricity

Annual Usage

9,58,190

Unit

kWh

Unit Cost

₹8.51

Annual Cost

₹81,54,895

Total Energy Costs(per year)

₹81,54,895

Observations & Recommendations
DM - Demand Management
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
The Sanctioned demand of the plant is 402.35 KVA but the max. Demand that has been reached in the previous year is 203 KVASurrender the demand of 200 KVA₹8,64,000
TR - Transformer
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
The overall transformer and stabilizer loss is highReplace the off load transformer and stabilizer with energy efficient transformer with on load tap changer54,617₹4,75,168₹6,00,00015.2
CPF - Capacitor & Power Factor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
the overall power factor has been maintained is (0.95-0.96) below 0.97Improve the power factor to 0.97 to get rebate of 3% of total unit consumption10,386₹90,358₹20,0002.7
In APFC, feedback signal is taken from single phaseinstall three phase sensing in the APFC
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Overall air leakage is high (10 cfm). Nearly, 14 points were identified.Arrest all the identified air leakages14,256₹1,24,027₹10,0002.7
CHR - Chiller
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Chilled water flow from the secondary pump process is high (39 m3/hr) and VFD in the secondary pump is not workingOptimize the flow and repair the VFD59400₹516780₹1000002.3
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
the difference in the temperature between the hot and cold water is very low because of mixing of water in the tankFlow should be optimized and automated with closed loop feed back system12420₹108054₹20000022.2
CT fan is not working and the water distribution in the cooling tower is not even due to the damaged fillsRepair the CT fan and install new fills and maintenance should be done regularly
FN - Fans
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
The power consumption by the individual exhaust fan (2 nos) is higher compared with the other fanRepair and modify the exhaust fans4752₹41342₹5000014.5
FN - Fans
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Totally, there are 8 conventional ceiling fans running in max. working hours and consuming power of 70 WReplace conventional ceiling fan with BLDC fans which consumes 28 W2534₹22046₹2800015.2