EAR/22-23/KISEM-IITB-03
The subject plant is located in district of and falls under NIC Category-24319. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2022.
General Info
Principal Product
Foundry
Plant Area (Sq.ft)
8,000
No. of Employees
200
Production Hours
8,400
Annual Production
Annual Sales
₹
Assessment Summary
Total Energy Costs(per year)
₹20,58,00,890
Total Recommended Investment(one time)
₹7,25,000
Total Recommended Savings(per year)
₹1,31,58,986
Energy Costs Calculation
Grid Electricity
Annual Usage
2,48,55,180
Unit
kVAh
Unit Cost
₹8.28
Annual Cost
₹20,58,00,890
Total Energy Costs(per year)
₹20,58,00,890
Observations & Recommendations
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Auxiliary Transformers are under loaded | Auxiliary supply of both plants can be interlinked and Plant 1 Auxiliary transformer can be put on standby | 8,760 | ₹72,708 | ₹10,000 | 1.7 | |
| 725/1200 kVar is only inline in which 425 kVar is derated | Replace the Faulty and derated Capacitor | 1,26,540 | ₹1050282 | ₹90000 | 1.0 | |
| Plant 1 Auxiliary Trfr shows negative reactive power | APFC mechanism of Plant 1 should be tested and replaced. | 84,360 | ₹700188 | ₹20000 | 0.9 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Sand mixer motor of Plant 1 is running 24 × 6 even when there is no load | Load sensor can be installed and the motor can be operated with the sensor control. | 11,760 | ₹97,608 | ₹5000 | 1.0 | |
| Sand blender motor of Plant 1 is running 24 × 6 even when there is no load | Load sensor can be installed and the motor can be operated with the sensor control. | 7,200 | ₹59,760 | ₹5000 | 1.0 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are high / Set pressure of both the compressors are different and they are interlinked. | Arrest air leakages periodically / Maintain both Plant 1 & 2 compressors on same set pressure while both are inter linking | 4,01,300 | ₹3330790 | ₹5000 | 0 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The pumps in Plant 1 were not in good condition and the performance is poor. | Replace the pumps with Energy Efficient pumps | 61,100 | ₹507130 | ₹230000 | 5.4 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| A minimum of 10 mins idle period which has no manual intervention in a cycle with span of 35 mins. | Radiation losses in this time can be reduced by putting ceramic blanket | 5,09,100 | ₹4225530 | ₹100000 | 0.3 | |
| In an area of 7 m2 of the furnace wall, the temperature is above 2000C where it should be maintained at 600C | The insulation lining should be maintained. | 1,49,800 | ₹1243340 | ₹60000 | 0.6 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Fume collector fan is running 24X6. but the fume collection is required about 5-7 mins in 1 cycle | Provide individual dampers to all fume sucking mouths and install VFD. The VFD is to be programmed in such a way that the dampers and suction blower speed should be incorporated. | 1,24,200 | ₹10,30,860 | ₹100000 | 1.2 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 1.Approach of Cooling Tower-2 is high and outlet water temperature is also high. 2. The range of the cooling towers were less than designed values. | 1.Change the fins which were not good in condition and maintain the cooling tower frequently. 2.Range should be increased so that the pump power can be decreased. | 1,01,300 | ₹8,40,790 | ₹100000 | 1.4 |