KMB-IIT-MAD-26.12.22-04
The subject plant is located in district of and falls under NIC Category-13131. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2022.
General Info
Principal Product
Finished Textiles
Plant Area (Sq.ft)
45,000
No. of Employees
250
Production Hours
2,700
Annual Production
15,00,000
Annual Sales
₹6,78,00,000
Assessment Summary
Total Energy Costs(per year)
₹1,20,48,946
Total Recommended Investment(one time)
₹33,30,000
Total Recommended Savings(per year)
₹15,57,010
Energy Costs Calculation
Electricity
Annual Usage
10,41,675
Unit
kWh
Unit Cost
₹9.55
Annual Cost
₹99,47,996
Briquette
Annual Usage
219994.8
Unit
kg
Unit Cost
₹9.55
Annual Cost
₹21,00,950
Total Energy Costs(per year)
₹1,20,48,946
Observations & Recommendations
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Current Harmonics | Install Harmonic Filters | ₹0 | ₹10,00,000 | |||
| Absence of On load Tap Changer | Install/Repair On load Tap changer | 15,625 | ₹1,49,219 | ₹10,00,000 | 80.4 |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Demand Underutilization | Surrender unutilized sanctioned demand | ₹1,59,000 | ₹0 | 0 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| No 3 phase sensing | Install three phase sensing | ₹ | ₹100000 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 70200 | ₹6,70,410 | ₹100000 | 1.8 | |
| Low loading percentage | The actual plant CFM load should be calculated accurately and there should be one compressor meeting the base air load by running at full load and the other for meeting peak/fluctuating loads by operating it with a VFD; | 20,025 | ₹1,91,239 | ₹80,000 | 5.0 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Old Type Fans | Use BLDC Fan with equivalent velocity | 25,800 | ₹2,46,390 | ₹7,00,000 | 34.1 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ineffective Combustion | Optimize the Air-Fuel Ratio | 15,611 | ₹1,01,472 | ₹ 3,00,000.00 | 35.5 | |
| Poor Thermal Insulation | Locate and Repair Defective Insulation on All Heating Plant Equipment and Piping | 6,043 | ₹39,280 | ₹50,000 | 15.3 |