EAR/23-24/KISEM/IITI-10/01
The subject plant is located in district of and falls under NIC Category-29301. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
Engines for Trucks, Buses and Marine applications
Plant Area (Sq.ft)
1,00,000
No. of Employees
350
Production Hours
8,760
Annual Production
73,000
Annual Sales
₹10,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹2,66,00,000
Total Recommended Investment(one time)
₹20,36,000
Total Recommended Savings(per year)
₹49,67,301
Energy Costs Calculation
Electricity
Annual Usage
33,00,000
Unit
kWh
Unit Cost
₹8
Annual Cost
₹2,63,00,000
Diesel
Annual Usage
2700
Unit
kg
Unit Cost
₹112
Annual Cost
₹3,00,000
Total Energy Costs(per year)
₹2,66,00,000
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. | 1,30,701 | ₹9,93,327 | ₹3,08,000 | 4 | |
| Common distribution line used for all applications | Separate distribution line for low pressure applications such as cleaning | 42361 | ₹321944 | ₹300000 | 12 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Conventional Electric Resistance heaters are used to heat coolant used for Engine Cylinder head washing unit | Install Energy Efficient Air to Water Heat Pump combined with Plate Heat exchanger and keep existing Electric Resistance heaters as standby | 82134 | ₹1716596 | ₹560000 | 4 | |
| Conventional Electric Resistance heaters are used for drying painted parts in the drying oven | Recover waste heat from compressor exhausts and feed to paint the drying oven with proper air inlet and discharge ducting and existing Electric Resistance heaters as standby. | 54750 | ₹416100 | ₹200000 | 6 | |
| Conventional Ceiling fans are used | Replace with Energy Efficient BLDC Ceiling fans | 4860 | ₹39936 | ₹48000 | 15 | |
| Conventional Wall fans are used in the Office Spaces | Replace with Energy Efficient BLDC Ceiling fans | 4500 | ₹39200 | ₹80000 | 25 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Cooling Tower fan operate 24x7 irrespective to load | Install VFD for Cooling tower fan and operate as per the approach temperature. | 3504 | ₹26630 | ₹40000 | 19 | |
| Pressurised water return line from the Engine Test cell is discharge to common sump tank In the existing system, dynamometer cooling water is delivered to Heat Exchanger CT pump operate irrespective to load | Avoid discharging in common sump tank. Provide dedicated pump above the test cell and deliver water directly to HE. Required pump of 2 bar pressure and 95 m3/ hr water flow rate. Avoid delivering Dyno cooling water to HE and reduce the load on HE and Cooling Tower. Required pump of 2 bar and 30 m3/ hr with sump tank. Provide VFD controlled to CT pump with feedback of range and provide proportionate flow with respect to RO Water | 38196 | ₹290290 | ₹100000 | 5 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Losses are found to be higher than standard limits | Undergo routine maintenance, oil filtration, breather replacement, overall check-up etc. | 109609 | ₹833033 | ₹100000 | 2 |
LT - Lighting
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Conventional CFL Lighting is used in certain areas of the office space | Replace with Energy Efficient LED Lighting | 14191 | ₹107852 | ₹144000 | 17 | |
| Common area and corridor lights are always switched ON | Install IR Occupancy sensors and automatically manage lighting in common areas | 5729 | ₹43450 | ₹100000 | 28 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| In hydropneumatics pump faulty NRV is available. When pump 2 is in operation, pump 1 is rotate in opposite direction | Replace faulty NRV at suction and discharge side of both the pump | 4691 | ₹35651 | ₹5000 | 2 | |
| In RO Plant 3 pump is used to deliver the water from RAW water tank to OHT. Pump 1 and 2 used in the RO system and deliver the water in PVC tank and pump 3 is used to deliver water from PVC to OHT. The Efficiency of the pump is placed between 5% to 13%. | Replace all pump with single correct rated and efficient pump. Deliver direct water from raw tank to OHT | 3574 | ₹27163 | ₹10000 | 4 | |
| In the existing stage the TDS from RO Plant is 6 ppm. But the required TDS is in between 40 to 45 ppm | Proposed to install TDS meter at the main output line and maintain the TDS within the range of 40 to 45 ppm by direct mixing of raw water into the RO water. Direct mixing reduced the pump working hours and obtained the required ppm. In addition, the life cycle of RO Plant is also increased. | ₹ | ₹ | |||
| In Hydropneumatics pump VFD is bypassed | Provide VFD in the Electrical circuit and reduce the power and loading percentage of the pump. | 5063 | ₹38481 | ₹6000 | 2 | |
| Inefficient pump is used in the pumping circuit | Proposed to use corrected rated and efficient pumps in the system. | 2063 | ₹15679 | ₹25000 | 19 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Bypass of pressurised air is observed from blower discharge line | Provide VFD for the blower and operate as per the require pressure, flow and DO level | 2891 | ₹21970 | ₹10000 | 5 |