KMB-IIT-GUW-230524-02
The subject plant is located in Guwahati district of Assam and falls under NIC Category-22209. This assessment was carried out by the IEAC Center, IIT Guwahati, during the course of the year 2023.
General Info
Principal Product
Thermoware, Plastics
Plant Area (Sq.ft)
1,50,000
No. of Employees
300
Production Hours
7,200
Annual Production
Annual Sales
₹25,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹3,83,09,500
Total Recommended Investment(one time)
₹11,50,000
Total Recommended Savings(per year)
₹83,40,216
Energy Costs Calculation
Electricity
Annual Usage
47,56,440
Unit
kWh
Unit Cost
₹8
Annual Cost
₹3,83,09,500
Total Energy Costs(per year)
₹3,83,09,500
Observations & Recommendations
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Maximum Demand that has been reached in the previous year is 1149 kVA while the sanctioned demand is 2000 kVA | Surrender the excess demand of 600 kVA | ₹25,92,000 | ₹ |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| In previous year, from the month November 2022 to April 2023, PF is below 0.97 | Improve the power factor above 0.97 to get rebate of 3% of total unit consumption | 42,005 | ₹3,44,441 | ₹50,000 | 1.7 | |
| Only 128 kVAR connected in 500 kVAR APFC in old panel. Only Single phase sensing in APFC panel | Replace the derated capacity of 300 kVAR and also install three phase sensing | ₹ | ₹ | |||
| PF correction is based on feedback from single phase only | Install three phase sensing to bring PF to unity. | ₹ | ₹ |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Already, there is an onload tap changer in the transformer. So the function of AVR is minimized | Bypass the AVR from transformer line to MV Panel ACB | 71347 | ₹5,85,045 | ₹7,00,000 | 14.4 | |
| Transformer current harmonics (16%) is higher than the IEEE Standard of 8% | Install Harmonics filter to avoid distortion in harmonics | ₹ | ₹ |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall Air leakage is high (39 cfm) in Low pressure compressors. | Arrest all the identified air leakages | 51,450 | ₹4,21,890 | ₹50,000 | 1.4 | |
| Low pressure Compressor's current pressure setting is very high (9.3 bar) | Reduce the pressure setting to 6.5 - 7 bar | 1,51,900 | ₹12,45,580 | ₹ | ||
| Overall Leakages in the High pressure compressor is very high. one compressor is running only for air leakages | Arrest all the identified air leakages | 2,14,200 | ₹17,56,440 | ₹50,000 | 0.3 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| In Cooling tower for Injection moulding section, nearly, 31.5 m3/hr of water is flowing through bypass from hot water tank to cold water tank | VFD can be installed to minimize and balance the excess water flow. | 44,100 | ₹3,61,620 | ₹1,50,000 | 5 | |
| In Cooling tower for ASB machine section, nearly, 29 m3/hr of water is flowing through bypass and there is not much deviation in the flow when the third cold water pump is turned off | Third cold water pump can be completely turned OFF and VFD has to be installed so that the excess water flow can be balanced. | 1,26,000 | ₹10,33,200 | ₹1,50,000 | 1.7 |