IIT Madras

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Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras


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


Plant Area (Sq.ft)


No. of Employees


Production Hours


Annual Production

Annual Sales

Assessment Summary

Total Energy Costs(per year)


Total Recommended Investment(one time)


Total Recommended Savings(per year)


Energy Costs Calculation
Grid Electricity

Annual Usage




Unit Cost


Annual Cost


Total Energy Costs(per year)


Observations & Recommendations
TR - Transformer
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Auxiliary Transformers are under loadedAuxiliary supply of both plants can be interlinked and Plant 1 Auxiliary transformer can be put on standby8,760₹72,708₹10,0001.7
725/1200 kVar is only inline in which 425 kVar is deratedReplace the Faulty and derated Capacitor1,26,540₹1050282₹900001.0
Plant 1 Auxiliary Trfr shows negative reactive powerAPFC mechanism of Plant 1 should be tested and replaced.84,360₹700188₹200000.9
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Sand mixer motor of Plant 1 is running 24 × 6 even when there is no loadLoad sensor can be installed and the motor can be operated with the sensor control.11,760₹97,608₹50001.0
Sand blender motor of Plant 1 is running 24 × 6 even when there is no loadLoad sensor can be installed and the motor can be operated with the sensor control.7,200₹59,760₹50001.0
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
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 linking4,01,300₹3330790₹50000
PP - Pumps
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
The pumps in Plant 1 were not in good condition and the performance is poor.Replace the pumps with Energy Efficient pumps61,100₹507130₹2300005.4
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
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 blanket5,09,100₹4225530₹1000000.3
In an area of 7 m2 of the furnace wall, the temperature is above 2000C where it should be maintained at 600CThe insulation lining should be maintained.1,49,800₹1243340₹600000.6
BL - Blower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Fume collector fan is running 24X6. but the fume collection is required about 5-7 mins in 1 cycleProvide 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₹1000001.2
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
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₹1000001.4