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


The subject plant is located in district of and falls under NIC Category-24319. This assessment was carried out by the IEAC Center, IIT Gandhinagar, during the course of the year 2023.

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

Annual Usage




Unit Cost


Annual Cost


Total Energy Costs(per year)


Observations & Recommendations
CPF - Capacitor & Power Factor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Frequent On & Off of Capacitor connected with APFCUse fixed capacitor of 25 kVAR₹92,726₹7,5001
TR - Transformer
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Average voltage at each phase is 440 V and machines are rated for 415 VChange the tapping of transformer
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Current harmonics present in the systemInstall passive harmonic filter95,834₹7,37,924₹1,00,0002
PP - Pumps
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Furnace pumps are running at low efficiencyUse VFD with one pump and take input from pressure transmitter for controlling the speed of pump with its head18000₹1,38,600₹60,0006
Panel Cooling Water pump running at high head due to heat exchanger choking issueUse VFD with one pump and take input from Pressure transmitter for controlling the speed of pump with head, this will improve the efficiency of operating pump14000₹1,07,800₹40,0005
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Effectiveness of Panel cooling heat exchanger are reducedClean the heat exchanger
High TDS at Cooling tower sump waterMaintain the TDS in range of 1000-1500 ppm-do proper blowdown
Approach, effectiveness and range of Cooling tower increase.Properly clean the nozzle and also check the layer formation on fills and also reduce the flow of cooling tower water.28,080₹2,16,216₹50,0003
Continuous operation of cooling tower fanUse VFD with cooling tower fan motor (vfd input is sump temperature)5,543₹5,543₹25,0007
Use CLCT for furnace cooling of capacity 100 TRInstall CLCT and remove one 7.5 kW pump and 5.5 kW pump93,180₹7,17,486₹15,00,00024
No insulation on cooling tower pipelineProper insulation of all the incoming pipe line required as sump temperature is 28deg C but at furnace heat exchanger it is 31.5 and at panel heat exchanger it is 37 deg C