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

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)

₹20,48,348

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
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Quantity of washers loaded per batch of Rotary Hardening Furnaces - 1 and 2 is low at 45kgReduce specific energy consumed per batch by optimizing loading per batch to 50kg6,144₹55,3000
Heat lost through front cover and rear rotary area surfaces of Rotary Hardening Furnaces - 1 and 2Provide suitable thermal insulation at the high temperature surfaces10383₹93448₹150,00020
Heat lost through top cover edge areas of Tempering Furnaces - 1 and 2Provide suitable thermal insulation at the high temperature surfaces1071₹9635₹20,00025
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
The Cooling tower is underloaded and effectiveness is found lowImprove range and L/G ratio by reducing waterflow rate by installing and operating the pump using VFD and intermediate operation of fan11552₹103972₹750009
PP - Pumps
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
The quenching oil tanks are separate for each hardening furnace and two pumps are operated to circulate oil between the tanksInterconnect the two tanks and one pump alone can be operated to maintain the oil circulation between the tanks2098₹18882₹1500010
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Mechanical power transmission slip found to be slightly high in certain Coiling machinesReduce slippage in belt and pulley system through replacement of conventional V-belts with Cogged V-belts and reduce motor speed using existing VFD280₹2688₹900041
Efficiency of Induction Motors used in Coiling Machines is lowReplace 7 Nos of 2HP and 2 Nos of 0.75 HP Induction motors with IE3 Efficiency class Induction Motors5392₹48528₹9000023
TR - Transformer
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Efficiency of 200kVA Transformer is found low due to slightly high energy loss compared to standard equipmentUndergo maintenance of the transformer including oil filtration, breather renewal etc.5470₹49230₹5000013
HVC - Heating Ventilation & Cooling
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Ceiling fans used in the plant area and office are inefficient conventional typeReplace 22 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC ceiling fans3540₹31860₹7040027
LT - Lighting
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Lighting used in the plant area and office are inefficient conventional typeReplace 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) respectively1645₹14805₹1200010
ALS - Alternate Source of Power
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Electricity is consumed from utility grid alone and there is no source of renewable energy in the plantInstall 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 energy180000₹1620000₹750000056