EAR/22-23/KISEM/IITR-05
The subject plant is located in district of and falls under NIC Category-22. This assessment was carried out by the IEAC Center, IIT Ropar, during the course of the year 2022.
General Info
Principal Product
Plastic products
Plant Area (Sq.ft)
1,30,000
No. of Employees
350
Production Hours
7,200
Annual Production
Annual Sales
₹1,50,00,000
Assessment Summary
Total Energy Costs(per year)
₹42,89,800
Total Recommended Investment(one time)
₹4,25,000
Total Recommended Savings(per year)
₹9,38,879
Energy Costs Calculation
Electricity
Annual Usage
6,07,116
Unit
kWh
Unit Cost
₹7
Annual Cost
₹42,89,800
Total Energy Costs(per year)
₹42,89,800
Observations & Recommendations
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Contract demand with PSPCL in unutilised | Surrender 50 kVA of unutilised excess demand | ₹88,800 | ₹ |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Average current harmonics in each phase (48.3%, 51.1%, 45.5%) is above standards. | Install harmonics filter for suppressing the harmonics | ₹ | ₹3,00,000 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| A few capacitor banks are derated | The existing capacitor banks are sufficient to maintain the unity power factor. | ₹ | ₹ | |||
| Faulty capacitor is connected in APFC | Uninstall the faulty capacitors from the APFC panel | ₹ | ₹ |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are high | Arrest air leakages regularly | 36,183 | ₹2,53,278 | ₹20,000 | 0.9 | |
| Screw compressor unloading time is high | Existing screw compressor can be operated with VFD drive | 30,660 | ₹2,14,620 | ₹50,000 | 2.8 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High surface temperature on Extrusion machines | Provide proper thermal insulation is to all Extrusion machines | 36,631 | ₹2,56,417 | ₹50,000 | 2.3 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Cold water is pumped from cold well to overhead tank and the excess water is discharged to the well itself | Existing pump can be operated with float switch in overhead tank | 17,966 | ₹1,25,764 | ₹5,000 | 0.5 |