EAR/22-23/KISEM-12/IITI-06/01
The subject plant is located in district of and falls under NIC Category-27. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
LED street lights and LED flood lights
Plant Area (Sq.ft)
50,000
No. of Employees
32
Production Hours
3,576
Annual Production
6,000
Annual Sales
₹2,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹29,40,000
Total Recommended Investment(one time)
₹16,91,400
Total Recommended Savings(per year)
₹12,92,102
Energy Costs Calculation
Electricity
Annual Usage
2,45,000
Unit
kWh
Unit Cost
₹12
Annual Cost
₹29,40,000
Total Energy Costs(per year)
₹29,40,000
Observations & Recommendations
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are found to be high at different points of the circuit | Arrest air leakages regularly by conducting maintenance of compressed air system consisting of the plant, circuit and fittings. | 21,270 | ₹2,55,242 | ₹1,29,000 | 7 | |
| Screw compressor - unloading time is high due to varying pressure demand | Existing screw compressors could be retrofitted with a VFD drive and optimize power consumption according to actual pressure demand | 58700 | ₹704400 | ₹300000 | 6 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The Cooling tower is underloaded and effectiveness is found low | Improve range by reducing waterflow rate by installing and operating the pump using VFD and intermediate operation of fan | 8125 | ₹73123 | ₹50000 | 9 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Heat lost through air gaps near front door edges, rear door edges and bottom railings. | Seal the air gaps and Provide thermal insulation at the high temperature surfaces | 1846 | ₹16616 | ₹30000 | 22 | |
| 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 | 1126 | ₹10134 | ₹22400 | 27 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Average Power factor maintained is poor at the range of 0.83 Lag, due to which PF surcharge is imposed at 40% of Annual Electricity Bill. AFPC panel is not in working condition. | Do adequate maintenance and repairs of the APFC panel including replacement of damaged capacitors and auxiliaries and improve power factor to near unity to reduce contract demand and avoid PF surcharge | ₹131802 | ₹50000 | 5 |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| MCH Furnace is operated in ON/OFF control mode, even though smooth ramp PID controlled Thyristor Converter based heater modulating system is available | Operate using PID controlled Thyristor Converter and reduce Maximum Demand by 14 kVA and save demand charges | ₹100785 | ₹10000 | 2 |
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 22 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy | 26400 | ₹316800 | ₹1100000 | 42 |