KMB-IIT-BOM-160423-11
The subject plant is located in Kolhapur district of Maharashtra and falls under NIC Category-25. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2023.
General Info
Principal Product
Press and Fabrication (Welding Assembly)
Plant Area (Sq.ft)
4,00,000
No. of Employees
150
Production Hours
7,200
Annual Production
Annual Sales
₹30,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹1,46,45,406
Total Recommended Investment(one time)
₹9,70,000
Total Recommended Savings(per year)
₹17,53,641
Energy Costs Calculation
Electricity
Annual Usage
9,30,476
Unit
kWh
Unit Cost
₹10.2
Annual Cost
₹95,23,270
LPG
Annual Usage
60,481
Unit
Kg
Unit Cost
₹84.7
Annual Cost
₹51,22,136
Total Energy Costs(per year)
₹1,46,45,406
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| All APFC are contactor type and many derated capacitors were found. | Replace the derated capacitors and APFC operating mechanism should be corrected with thyristor based | 36,981 | ₹3,75,727 | ₹40,000 | 1 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Many Pressing machines are idle for most of the time. | Install VFD and for big machines cogged belt is preferred | 85,680 | ₹8,70,509 | ₹7,70,000 | 10.6 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Too much leakage in compressed air line. | Arrest Leakage frequently | 38,637 | ₹3,92,556 | ₹10,000 | 0.3 | |
| All compressors are normal screw type compressors | One of the compressors should be provided with VFD so as to meet the variable loads | 11,304 | ₹1,14,849 | ₹1,50,000 | 15.7 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Water flow is less | Install VFD and optimize the flow in such a way that the pressure/flow in plant is maintained. | ₹ | ₹ | |||
| Cooling Tower has no sprinkling | Sprinkling will increase the range of cooling tower and hence save energy | ₹ | ₹ |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| LPG burner is used and exhaust is going out | Regenerative burner can be used which will save around 10 % of LPG | ₹ | ₹ | |||
| Input and output lines to heaters are open | Reduce the space by using auto closure door | ₹ | ₹ |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| In phosphating section, Heating tanks are open | Close the tanks with some lead or install some kind of mechanism to close the lead while there is no intervention | ₹ | ₹ |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Soiling, degrading of glass surface which may result in moisture ingress | Install water drainer clip | ₹ | ₹ |