EAR/22-23/KISEM-12/IITI-05/02
The subject plant is located in district of and falls under NIC Category-25. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
Rust preventive coated spring washers, heat treated spring washers, soft spring washers, etc.
Plant Area (Sq.ft)
1,00,000
No. of Employees
25
Production Hours
4,768
Annual Production
37,000
Annual Sales
₹2,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹25,73,603
Total Recommended Investment(one time)
₹79,91,400
Total Recommended Savings(per year)
₹4,28,348
Energy Costs Calculation
Electricity
Annual Usage
2,89,182
Unit
kWh
Unit Cost
₹9
Annual Cost
₹25,73,603
Total Energy Costs(per year)
₹25,73,603
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Quantity of washers loaded per batch of Rotary Hardening Furnaces - 1 and 2 is low at 45kg | Reduce specific energy consumed per batch by optimizing loading per batch to 50kg | 6,144 | ₹55,300 | ₹ | 0 | |
| Heat lost through front cover and rear rotary area surfaces of Rotary Hardening Furnaces - 1 and 2 | Provide suitable thermal insulation at the high temperature surfaces | 10383 | ₹93448 | ₹150,000 | 20 | |
| Heat lost through top cover edge areas of Tempering Furnaces - 1 and 2 | Provide suitable thermal insulation at the high temperature surfaces | 1071 | ₹9635 | ₹20,000 | 25 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The Cooling tower is underloaded and effectiveness is found low | Improve range and L/G ratio by reducing waterflow rate by installing and operating the pump using VFD and intermediate operation of fan | 11552 | ₹103972 | ₹75000 | 9 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The quenching oil tanks are separate for each hardening furnace and two pumps are operated to circulate oil between the tanks | Interconnect the two tanks and one pump alone can be operated to maintain the oil circulation between the tanks | 2098 | ₹18882 | ₹15000 | 10 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Mechanical power transmission slip found to be slightly high in certain Coiling machines | Reduce slippage in belt and pulley system through replacement of conventional V-belts with Cogged V-belts and reduce motor speed using existing VFD | 280 | ₹2688 | ₹9000 | 41 | |
| Efficiency of Induction Motors used in Coiling Machines is low | Replace 7 Nos of 2HP and 2 Nos of 0.75 HP Induction motors with IE3 Efficiency class Induction Motors | 5392 | ₹48528 | ₹90000 | 23 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Efficiency of 200kVA Transformer is found low due to slightly high energy loss compared to standard equipment | Undergo maintenance of the transformer including oil filtration, breather renewal etc. | 5470 | ₹49230 | ₹50000 | 13 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ceiling fans used in the plant area and office are inefficient conventional type | Replace 22 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC ceiling fans | 3540 | ₹31860 | ₹70400 | 27 |
LT - Lighting
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Lighting used in the plant area and office are inefficient conventional type | Replace 3 Nos of (1x36W FTLs), 5 Nos of (1x40W FTL), 6 Nos of (2x36W FTLs) Conventional lighting with (1x20W LED TLs), (1x20W LED TLs), (2x20W LED TLs) respectively | 1645 | ₹14805 | ₹12000 | 10 |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Electricity is consumed from utility grid alone and there is no source of renewable energy in the plant | Install a Rooftop 150 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy | 180000 | ₹1620000 | ₹7500000 | 56 |