KMB-IIT-BOM-160423-10
The subject plant is located in district of 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)
3,00,000
No. of Employees
150
Production Hours
7,200
Annual Production
Annual Sales
₹10,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹81,97,540
Total Recommended Investment(one time)
₹11,60,000
Total Recommended Savings(per year)
₹35,20,049
Energy Costs Calculation
Electricity
Annual Usage
7,43,915
Unit
kWh
Unit Cost
₹11
Annual Cost
₹81,97,540
Total Energy Costs(per year)
₹81,97,540
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| All APFC are contactor type and one capacitor Y phase was found disconnected | APFC operating mechanism should be corrected with thyristor based | ₹ | ₹ |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Many Pressing machines are idle for most of the time | Install VFD for big machines | 1,41,271 | ₹15,53,981 | ₹8,80,000 | 6.8 | |
| Pulleys are broken. | Don’t over tight the belts. If slippage is more replace with cogged belts | ₹ | ₹ |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Too much leakage in compressed air line. | Arrest Leakage frequently | 1,25,654 | ₹13,82,194 | ₹10,000 | 0.1 | |
| All compressors are normal screw type compressors | One of the compressor should be provided with VFD so as to meet the variable loads | 41,949 | ₹4,61,439 | ₹1,50,000 | 3.9 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Water flow is bypass to maintain the flow inside the plant | Install VFD and optimize the flow in such a way that the pressure/flow in plant is maintained | 11,130 | ₹1,22,435 | ₹1,20,000 | 11.8 | |
| Cooling Tower has no sprinkling. | Sprinkling will increase the range of cooling tower and hence save energy | ₹ | ₹ |
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 | ₹ | ₹ |