KMB-IIT-GUW-230606-05
The subject plant is located in district of and falls under NIC Category-31. This assessment was carried out by the IEAC Center, IIT Guwahati, during the course of the year 2023.
General Info
Principal Product
Steel Furniture Manufacturing
Plant Area (Sq.ft)
1,30,000
No. of Employees
200
Production Hours
7,200
Annual Production
Annual Sales
₹10,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹64,57,568
Total Recommended Investment(one time)
₹7,75,000
Total Recommended Savings(per year)
₹18,60,118
Energy Costs Calculation
Electricity
Annual Usage
6,12,332
Unit
kWh
Unit Cost
₹10.5
Annual Cost
₹64,57,568
Total Energy Costs(per year)
₹64,57,568
Observations & Recommendations
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Maximum demand that has been reached in the previous year is 303 kVA. While the sanctioned demand is 588 kVA | Return the demand of 250 kVA to reduce the demand charges | ₹8,10,000 | ₹ |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Transformer Current harmonics (21.5%) is higher then the IEEE standard of 8% | Install harmonics filter to avoid distortion in harmonics | ₹ | ₹5,00,000 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall Power factor maintained is very low. In months ( July 2022, February & March 2023) power factor is maintained only at 0.77 and penalty has been paid | Improve the power factor above 0.97 to get rebate of 3% of total unit consumption | 33,908 | ₹2,28,879 | ₹15,000 | 0.8 | |
| APFC phase sensing is done on single phase | Take APFC Phase sensing from all 3 phases to maintain PF on all phases | ₹ | ₹ |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Compressor unloading hours is high (7 hours per day) | Install VFD to reduce the unloading losses | 67,200 | ₹4,53,600 | ₹1,25,000 | 3.31 | |
| Compressor current pressure setting is very high (12 bar) | Reduce the pressure setting to 7 bar | 17,700 | ₹1,19,475 | ₹ | ||
| Overall air leakages is found to be high ( 25 CFM) | Arrest all the identified air leakages | 10,800 | ₹72,900 | ₹15,000 | 2.47 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| In spray painting, due to the excess flow there has been the re-circulation at the output of the pump | The pump suction valve has been throttled and discharge valve has been opened completely | 21,165 | ₹142,864 | ₹ |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Totally, there are 40 conventional ceiling fans running in maximum working hours and consuming power of 70 W | Replace conventional Ceiling fan with BLDC fans which consumes 28 W | 4,800 | ₹32,400 | ₹120,000 | 44.4 |