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Confederation of Indian IndustryConfederation of Indian IndustryCII-Sohrabji Godrej Green Business CentreCII-Sohrabji Godrej Green Business Centre
Detailed Energy Audit
At
K R Pulp Papers !i"itedShahjahanpur
#une $%&'
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C)*+E*+S
Chapter
*o,
DesriptionPage
*o,
Executive Summary 1
I Introduction 3
II Acknowledgment 4
III List of Energy Saving Proposals
I! Energy Saving Proposals "
! #anagement Aspects And $onclusions %
Annexure 3
&ackup $alculations '
Total No of Pages: 117
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E.EC/+I0E S/11AR2
K R Pulp Papers !i"ited is among India(s leading manufacturers of eco)friendly paper enric*ed wit* t*e expertise and experience of around twodecades in making paper from non conventional raw material i+e+ &agasse, aresidue of sugar cane+
Incorporated in 1--, t*e company *as two fully integrated pulp and papermanufacturing facilities situated in S*a*.a*anpur district in t*e state of /ttarPrades* in India+ 0*e /nit)1 is used to manufacture raft paper w*ile /nit)2 isused to manufacture *ite paper+
$II *as conducted t*e etailed Energy Audit at K R Pulp Papers !i"ited,S*a*.a*anpur Plant from 1%t*to 1't*April, 2%14+ A detailed presentation wasmade to t*e plant team covering various energy conservation opportunities on
1't*
April, 2%14+ 0*e com5ined efforts of K R Pulp Papers !i"ited and $II)6odre. 6&$ team *ave toget*er identified, annual energy saving potential ofRs, '3',&% !a4hs, 5ased on present energy cost+7
Details*o, of
Proposals
Annualsa5ings in
!a4hs
0otal Annual savings 89s+ Lak*s: $3 '3',&%
Annual savings wit*out investment89s+ Lak*s:
' &%6,3%
Annual savings wit* investment 89s+ Lak*s: &7 3$8,9%
Investment 9e;uired &7 &93,7%
Average pay5ack period for capital proposals 1onths 6
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SPECI:IC AC+I)* P!A*
a: Specific target date for implementation of proposals s*ould 5e made wit*in3% days from su5mission of t*is report+
5: 0*e plant s*ould prioritise t*e a5ove proposals and implement t*em in ap*ased manner+
c: In our opinion t*e following proposals can 5e implemented wit*in nextt*ree mont*s straig*taway and s*ould 5e on top priority+
8ESP :
0*e a5ove proposals do not re;uire any investment and no detailedverification+
As a second priority and after detailed verification t*e following proposalss*ould 5e implemented+
8ESP
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C;AP+ER - I
I*+R)D/C+I)*
K R Pulp Papers !i"ited< Shahjahanpurevinced interest in availing t*eservices of $onfederation of Indian Industry for conducting a detailed energyaudit in t*eir factory+
0*is report on t*e detailed energy audit carried out at K R Pulp Papers!i"ited< Shahjahanpur< is in accordance wit* $II(s proposal, agreed 5y K RPulp Papers !i"ited< Shahjahanpur vide t*eir work order
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C;AP+ER - II
ACK*)=!EDG1E*+
$II acknowledges wit* t*anks t*e co)operation and t*e *ospitality extended to
t*e $II energy audit team during t*e detailed energy audit at K R Pulp
Papers !i"ited< Shahjahanpur,
0*e interactions and deli5erations wit* K R Pulp Papers !i"ited teamwere exemplary and t*e w*ole exercise was t*oroug*ly a rewardingexperience for $II+
0*e arrangements and support during t*e energy audit were excellent+ edeeply appreciate t*e interest, ent*usiasm and commitment of K R Pulp Papers !i"ited< Shahjahanpur team towards t*e energy conservation+
e would also like to place on record our sincere t*anks and appreciation for
all t*e senior plant executives+
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C;AP+ER - III
!IS+ ): E*ERG2 SA0I*G PR)P)SA!S
Sl,*o
Energy Sa5ing PropsalsAnnnual Sa5ings
>Rs,!a4hs?
In5est"entRe@uired
>Rs,!a4hs?
Payba4Period
>1onths?
1 9educe t*e @re;uency of 0ur5o 6enerator 1 to 4- B 1%%+%% % %
2 9educe Cne 0ap Setting of 0ransformer 2+1% % %
3 CptimiBe t*e Lig*ting !oltage in t*e Plant +%% 2+%%
4Install !aria5le @re;uency rives in Identified Pumps InPulp #ill
>+"% 4'+4% 1%
Install !aria5le @re;uency rives in $entricleaner
Pumps in Pulp #ill "+"% "+% 11
>Install !aria5le @re;uency rives in Identified Pumps inPaper #ac*ine
"+4% 1%+%% 1
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'Install !aria5le @re;uency rives in $entricleanerPumps in Paper #ac*ine
43+%% 1-+% >
"Avoid t*e Pressure rop Across @eed $ontrol !alve &yCperating &fp it* !fd in /nit 1
4+%% 4+% 14
-Avoid Passing 0*roug* #inimum 9ecirculation Line &yInstalling #ultistage rag !alves @or &oiler @eed Pumpin /nit 1
-+%% +%% '
1%Avoid t*e Pressure rop Across @eed $ontrol !alve &yCperating &fp in Auto it* !fd in /nit 2
2'+%% 1+%% 1
11Avoid Passing 0*roug* #inimum 9ecirculation Line &yInstalling #ultistage rag !alves @or &oiler @eed Pumpin /nit 2
4+"% "+% 2%
12Avoid 9ecirculation of $ondensate &y Installing !fd And9educing Speed of $ondensate Extraction Pump
2+4% 1+%%
13 9educe Air Ingress in /nit)1 &oiler @lue 6as Pat* 2+% % %
14Cperate All t*e $ooling 0ower @ans And 9educe t*eSpeed &y Installing !fd @or All @ans in /nit)2 PowerPlant
4+%% 3+%% -
19educe Excess @low 0*roug* eat Exc*angers in /nit)2Power Plant
32+%% "+%% 3
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1>Switc* off Cne $ondensate Extraction Pump $ompletelyin /nit)2 Power Plant
3+2% % %
1'Avoid Pressure rop Across ot ell Level $ontrol!alve And #aintain ot ell Level irectly &y Installing!fd
2+%% 1+% -
1"Avoid Cperating Cne Pump &y Pumping m aterirectly to eaerator After Passing 0*roug* t*e @las*Steam eat Exc*anger in Paper #ill Section
3+2% 1+%% 4
1-CptimiBe t*e Cperation of Instrument Air $ompressorsin /nit )2
1>+4% 1%+%% '
2%CptimiBe t*e Cperation of Instrument Air $ompressorsin /nit )1
>+%% +%% 1
21 CptimiBe !acuum Pump Cperation in /nit)2 +2% 2+%% >
229eplace ! &elt it* $ogged @lat &elt in IdentifiedE;uipments
34+4% 2%+%% '
23CptimiBe t*e $ondensate 9ecovery $ircuit in Paper AndEvaporator Section
4+4% 4+%% 11
+otal '3',&% &93,7% '
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Chapter IV
Energy Saving Proposals
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E*ERG2 SA0I*G PR)P)SA! *), &
RED/CE +;E :RE/E*C2 ): +/RB) GE*ERA+)R &+) '7 ;
uring t*e detailed energy audit at K R Pulp and Papers !i"ited,energy conservation 5y reducing fre;uency of t*e tur5o generator wasexplored in detail as t*e alternator was isolated from t*e grid+
uring t*e detailed energy audit at K R Pulp and Papers !i"ited,energy conservation 5y reducing fre;uency was explored in detail+ Inorder to look at t*is possi5ility a detailed study was carried out for t*eloading of t*e motors along wit* t*e plant team+
Present Status
0*e rating of t*e 0ur5o generator is given 5elow for reference+
9ating of t*e alternator 1%%% k!A
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0*e current operatingCperated at a fre;uency of t*e 061 is % B+ Adetailed load study was carried out in t*e plant to explore t*e possi5ilityof reducing fre;uency of alternator+ 0*roug* motor study, it was foundt*at t*e motors in t*e plant are operating mostly in t*e range of >% D "%+
#a.ority of t*e process e;uipment will not 5e affected in production asmost of t*e process e;uipment *asveve a !@sinstalled and reducingt*eir speed will not *amper production+ +
#a.ority of t*e process e;uipment also *ad margin in e;uipmentre;uirement and operating conditions+ @or example t*e pumps in t*eplant were t*rottled wit* valves significantly to meet t*e operatingre;uirements+0*e pumps also delivers energy to cater t*e pressure lossacross t*e valve+9educing t*e fre;uency of t*e alternator will avoid t*ispressure loss across t*e valve and reduce t*e energy consumed 5ypumps+
Proposed syste"
ue to t*is availa5le margin 5etween operation and re;uirement, t*ere isa good potential to optimiBe t*e fre;uency of t*e plant+A detailed studywas carried out along wit* t*e plant team to understand t*e loading oft*e motors to explore opportunity of fre;uency rediuction+ As mentionedearlier in t*e proposal t*e loading of t*e motors in t*e plant are found to5e in t*e range of >% D "%+ &ased on t*e loading of t*e motors t*efre;uency can 5e reduced to 4- B safely wit*out overloading t*e motors.
Proposed syste"
e recommend to reduce t*e fre;uency and operate it at 4- B+ 0*ereduction in fre;uency will ma.orly reduce t*e power consumed 5ycentrifugal e;uipment+ 0*e power consumed 5y centrifugal e;uipment areis proportional to cu5e of speed and t*e power consumed 5y positivedisplacement e;uipment arepower consumed 5y positive displacemente;uipment isproportional to t*e speed+ it*Also, 5y reducing t*e t*e
reduction in fre;uency t*e power consumed 5y individual motors alsoreduce, due to t*e reduction in no load losses of t*e motor+ In order too5tain t*e savings on a conservative 5asis only 4% of centrifugale;uipment are considered for calculation of energy savings+
Since t*e alternator 061 is operating isolated from t*e grid and also dueto t*e margin availa5le in t*e e;uipment, t*ere is a good potential tooptimiBe t*e fre;uency of t*e plant to 4- B+
A small variation in speed will lead to apprecia5le reduction in t*e powerconsumption of t*e plant+ 0*e fre;uency reduction is only possi5le for t*e
situation w*en plant is running wit*out sync*roniBation wit* grid+
Steps involved in fre;uency reduction
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1
2
30*e fre;uency of t*e alternator can 5e reduced 5y reducing t*e tur5inespeed+ In 9 Pulp and Paper a trial was taken along wit* t*e plant teamand t*e fre;uency was reduced to 4-+ B+ $II congratulates t*e plantteam on t*e excellent effort+
=ith the redution in fre@ueny the poer onsu"ed by indi5idual"otors also redue< due to the redution in no load losses of the"otor , +he turbine rp" an be redued to &%' rp" to "aintainthe alternator fre@ueny as '7 ;,
Abstrat of +rial +a4en at site +rial to redu e alternator fre@uenyto '7, ;
A trial was taken wit* discussions from t*e plant team and t*e fre;uencywas reduced to 4-+ B from % B+ $II t*anks t*e plant team for *elpingextending all t*e support in taking t*e trial+ us take t*e trial+
0*e speed of t*e prime mover corresponding to % B of operation is1%'>% rpm, w*ic* in turn corresponds to 1%% rpm of t*e alternator+ 0*isrpm was reduced from 1%'>% rpm to 1%>3 rpm+ 0*e speed of t*e primemover and correspondingly t*e fre;uency of t*e alternator was reducedfrom % B from 4-+ B+
*en t*e fre;uency of t*e alternator was reduced from 1%'>% % to
1%>3 4-+ rpmB, t*e power produced 5y t*e alternator s*owed animmediate reduction of 1"% k+ 0*is reduction of 1"% k ofreductiono5servedis instantaneous,as t*e fre;uencies of !@s read.ustitself to t*e re;uired fre;uency of operation wit*in few cycles+ Also, duringt*is reduction in power produced 5y t*e alternator, a reduction of 1+0P of steam consumption was also o5served+
0*e immediate c*ange of values o5served during t*e trial arec*ange ofvalues?results o5served during t*e trial ismentioned in t*e ta5le 5elow7
Parameter Before +rial %;
After trial '7,;
@re;uency of t*eAlternator
% B 4-+ B
Cperating 9P# of t*etur5ine
1%'>% rpm 1%>3 rpm
6eneration # 1%+-' # 1%+'- #
$apacity 0P '-+42 ''+"'
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0*e value mentioned a5ove is an instantaneous value and cannot 5econsidered for energy savings directly+ In order to monitor t*e reductionin energy produced 5y t*e alternator t*e monitoring of powerconsumption *as to 5e monitored for a longer duration to realiBe t*eenergy savings ac*ieved+
0*e !@s will ad.ust t*e voltage and fre;uency to operate at t*e desiredvalues 5ased on t*e feed5ack given to t*e !@+ ue to t*is t*e effect offre;uency reduction will *ave no effect on t*e e;uipment w*ic* *ave!@s+ In t*e future t*e plant team may plan on installing !@s fore;uipment in t*e plant for energy savings+ Cverall t*e effect of fre;uencyreduction may 5e reduced 5y installing !@s and t*e margin of energysavings may reduce 5y installing more !@s+ Event*oug* t*e margin ofenergy savings reduces it is still recommended to reduce t*e fre;uency oft*e alternator and operate at 4- B+
Reo""endation
e recommend
to 0o reduce t*e fre;uency of 061 to 4- B from 4-+ B in steps of
%+2 B+ +
Cn a $conservatively 5asis4% of load is assumed as centrifugal+
Atleast 2% k can 5e saved 5y implementing t*is proposal+
Benefits
Annual energy savings of Rs &%%,%% !a4hscan 5e ac*ieved 5y reducingt*e energy savings+ 0*e investment re;uired for t*e pro.ect is
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E*ERG2 SA0I*G PR)P)SA! *), $
RED/CE )*E +AP SE++I*G ): +RA*S:)R1ER
uring t*e etailed Energy Audit conducted at KR Pulp and Papers!i"ited< Shahjahanpurt*e opportunity to optimiBe t*e voltage of plantwas studied+
Present Status
0*e induction motors in t*e plant are rated for 41!+ 0*e tap settingswere maintained to o5tain a voltage 42'! for 0ransformer + 0*e loadingof motors in t*e plant were ranging from '%)"+
0*e grap* s*own in @ig 5elow is drawn for an induction motor on a pu5asis+ It s*ows t*e effect of stator terminal voltage to total motor lossesfor various per unit loading for an induction motor+ 0*e no load curve ont*e grap* s*ows t*at t*e no load loss reduces as t*e stator terminalvoltage reduces+ 0*e pu? 5s total "otor losses
0*e grap* s*own a5ove is drawn for loading at F, G, H and full load+ @oreac* loading of t*e motor t*ere is an optimum voltage point w*ere t*e
total motor loss is at minimum for t*at condition of loading+ 9educing t*evoltage 5elow t*e optimum point, t*e motor capacity gets derated andt*e current flowing t*roug* t*e motor increases i+e+ voltage 5elow t*eoptimum point derates t*e motor+
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0*e motor *as to draw a fixed amount of power to satisfy t*e s*aft powerfor specific loading conditions+ Since, t*e terminal voltage of t*e motorreduces t*e current is increased to meet t*e s*aft power+ 0*is causes anincrease in current and *ence increases copper losses in t*e stator andt*e rotor and during t*is condition of low voltage t*e no load loss is lower
as compared to t*e *ig*er voltage applied to t*e motor+
0*e voltage drop at t*e motor terminals s*ould 5e seen 5ased on t*elengt* of t*e ca5le, siBe of t*e ca5le installed, 5ased on t*e power factorof t*e motor and also due to any loose connections in lugs or t*e wiring oft*e motor+ According to IE$ >%%3" a 41! motor can 5e safely operatedwit* a range 23%?4%%! 1% and )> at t*e #$$ and also 4 voltagedrop is allowed at t*e supply terminals+ 0*e motors are generallydesigned to *andle a voltage variation of J 1% from t*e rated value+
#otors consuming low power factor may *ave *ig*er voltage drop andcan 5e compensated 5y installing capacitor 5anks at t*e motor terminalsor motor &s+ $are s*ould 5e taken w*ile installing capacitor 5anks at t*emotor terminals, t*at t*e installed k!A9 of t*e capacitance s*ould notexceed t*e no load k!A9 of t*e motor+
Since t*e voltage maintained at t*e motor terminals may lie 5elow t*eoptimum voltage point as explained a5ove, t*e current consumed 5y t*emotors may increase, w*ic* may increase t*e copper losses in t*e motor+&ut t*e reduction of voltage reduces t*e magnetiBation losses of t*emotor and can 5e significantly reduce t*e energy consumed in t*e plant+0*e loading of t*e motors in t*e plant *as 5een o5served to 5e '% D ",t*e current consumed 5y t*e motors will not exceed t*e full load currentof t*e motor, due to t*e reduction in voltage and t*e motor can 5e safelyoperated+
Proposed syste"
In general for an A$ induction motor operating at a *ig*er voltage t*anrated, t*e no load losses can 5e reduced 5y reducing t*e voltage to t*erated value+ As a t*um5 rule t*ere is 1 reduction in power consumption
for every 4 reduction in voltage+ &ased on t*is t*e t*um5 rule of 1reduction in power consumption for every 4 reduction in voltage, powersavings of > k can 5e ac*ieved in t*e plant 5y reducing one tap settingof t*e distri5ution transformers811k!?433!:+
+aps setting of the +ransfor"ers and orresponding ;+ and !+0oltages
+ap Position ;+ 0oltage >0? !+ 0oltage >0?
1 11>%
$>Reo""ended? &&$6
3>Current? &&%%%
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433
4 1%'2
1%4%
> 1%1'
' --%%
Proposed syste"
In general for an A$ induction motor operating at a *ig*er voltage t*anrated, t*e no load losses can 5e reduced 5y reducing t*e voltage to t*erated value+ As a t*um5 rule t*ere is 1 reduction in power consumptionfor every 4 reduction in voltage+ &ased on t*is t*e t*um5 rule of 1reduction in power consumption for every 4 reduction in voltage, power
savings of > k can 5e ac*ieved in t*e plant 5y reducing one tap settingof t*e distri5ution transformers811k!?433!:+
0*e tap settings of 0ransformer are mentioned in t*e ta5le a5ove+ 0*ecurrent tap setting of t*e transformer is at 3 rd tap+ 0*e current tap settingmaintains a voltage of 42' !+ 0*is voltage can 5e reduced closer to 41 !,at w*ic* t*e motors in t*e plant are designed+ 0*is gives us a goodopportunity to reduce t*e plant voltage to 41 !+
0*e tap settings of 0ransformer are mentioned in t*e ta5le 5elow+ 0*ecurrent tap setting of t*e transformer is at 3 rdtap+ 0*e current tap settingmaintains a voltage of 42' !+ 0*is voltage can 5e reduced closer to 41 !,at w*ic* t*e motors in t*e plant are designed+ 0*is gives us a goodopportunity to reduce t*e plant voltage to 41 !+
Reo""endation
$urrently all t*e distri5ution transformers are rated for 11k!?433!+ 0*etap position is in t*e normal tap of 43+ It is recommended to reduce t*etap settings of 0ransformer 4t* to 3rd tap in order to7
#aintain 41 D 42% ! as t*e distri5ution transformer output voltage
9educes magnetiBation losses in t*e motors
Atleast > k can 5e saved 5y reducing one tap setting in t*e
transformers
Benefits
CptimiBing t*e voltage in distri5ution transformers will result in an annualenergy saving of Rs, $,&% !a4hs+ 0*ere is no investment re;uired fort*is proposal+
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E*ERG2 SA0I*G PR)P)SA! *), 3
I1PR)0E +;E P)=ER :AC+)R ): P)=ER
P/RC;ASED :R)1 E!EC+RICI+2 B)ARD
uring t*e etailed Energy Audit conducted at KR Pulp and Papers!i"ited< Shahjahanpurt*e opportunity to improve t*e E& power factorwas explored in detail+
Ba4ground
0*e grid power in 9 Pulp and Papers is used mainly for operating t*eplant during t*e failure of any power generation sources in t*e plant8Emergency conditions:+ 0*e power is used to c*arge t*e transformers forno load condition only+ 0*e 5illing system used is in terms of k!A* and t*eload utiliBed was very low maintaining a power factor of %+-' at t*e grid+0*e k!A* consumed in t*e grid was around 2, 4", %%% k!A*, t*e k*consumption is 2, 3>, %%% k*, leading t*e power factor of operation to5e %+-+
0*ere is a good potential to optimiBe t*e power factor of operation to 5e%+--+0*e power factor of E& can 5e improved 5y installing capacitor5anks+&ased on t*e E& consumption t*e re;uired amount of capacitor5anks re;uired to maintain %+-- pf is also calculated.
Reo""endation
It is recommended to improve t*e E& power factor to reduce t*e k!A*c*arges+ Approximately ->%% k!A* can 5e saved per mont*+erecommend
0o install capacitor 5anks and improve t*e E& power factor to %+--
Around ->%% k!A* can 5e saved
Benefits
Annual energy savings of Rs ,%% !a4hs can 5e ac*ieved+ 0*einvestment re;uired for t*e capacitor 5anks are Rs $,%% !a4hs, w*ic* ispaid 5ack in "onths+
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E*ERG2 SA0I*G PR)P)SA! *), '
I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I*IDE*+I:IED P/1PS I* P/!P 1I!!
uring t*e etailed Energy Audit conducted at K R Pulp Papers !td,% 11 44%
$ontinuous igester
ilution Pump
P/ '4 4" 3 14 '2+"
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et ilution Pump )&S1
P/ 11- >% 12 1" 4%%
&ack S*ower Pump )&S1
P/ 1%% 1' % 12%
et ilution Pump )&S 2
P/ -> >> 2 1-+ %%
&ack S*ower Pump )&S 2
P/ 1%1 1' % 13%
as*ed 0owerPump
P/ 11> '1 "% ' )
ilution Pump P/ 12> 4 % 1>
Secondary ScreenPump
P/ 132 21 3% >
Screened 0owerPump
P/ 14> 24 % '
L$ $*est Pump P/ 1% 24 1 '
Screened 0ower
ilution Pump
P/ 1> 4 2, 14 1>
ECP !A0 ilutionPump
P/ 1>- 1 2" 4+
ECP as*er ilutionPump
P/ 1'1 4 >% 1%+
0*us t*ere is excellent potential to save energy 5y installing !@(s for t*e
pumps and varying flow as per re;uirement+
Reo""endation
e recommend t*e following7
Install !aria5le @re;uency rives for t*e identified pumps
Cperate t*ese pumps wit* suggested !@ feed5ack
!ary speed of pump to maintain re;uired flowCptimiBe t*e power
consumption
Benefits
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0*e annual savings of Rs, 9,8% !a4hscan 5e ac*ieved 5y implementingt*is pro.ect+ 0*e investment re;uired is Rs, '6,'% !a4hs w*ic* is paid5ack in &% "onths+
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E*ERG2 SA0I*G PR)P)SA! *),
I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I*CE*+RIC!EA*ER P/1PS I* P/!P 1I!!
uring t*e etailed Energy Audit conducted at K R Pulp Papers !td, 2 21
#ac*ine $*est PumpP#1"
4 % 13+ )
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0*us t*ere is excellent potential to save energy 5y installing !@(s for t*epumps and varying flow as per re;uirement+
Reo""endation
e recommend t*e following7
Install !aria5le @re;uency rives for t*e identified pumps
!ary speed of pump to maintain re;uired flow as per t*e process
re;uirement
CptimiBe t*e power consumption of t*e pumping system
Benefits
0*e annual savings of Rs, 9,'% !a4hscan 5e ac*ieved 5y implementingt*is pro.ect+ 0*e investment re;uired is Rs, &%,%% !a4hs w*ic* is paid5ack in & "onths+
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E*ERG2 SA0I*G PR)P)SA! *), 6
I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I*CE*+RIC!EA*ER P/1PS I* PAPER 1AC;I*E
uring t*e etailed Energy Audit conducted at K R Pulp Papers !td,+ >+-% + 1+> 2"
Actual orking pressure re;uired for different applications
@or control valve operations, t*e instrument air re;uirement is in
5etween 1+ D 3+ 5ar
@or press roll mac*ine D t*e pressure re;uirement is > 5ar
0*ere exists a good saving potential to optimiBe t*e pressure settings oft*e instrument air compressors+
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E*ERG2 SA0I*G PR)P)SA! *), $%
)P+I1IE +;E )PERA+I)* ): I*S+R/1E*+ AIRC)1PRESS)RS I* /*I+ -&
uring t*e detailed energy audit at 9 Pulp and Paper t*e compressorswere studied in detail and t*e following o5servations *ave 5een made+
Installed apaity
2 x 3"% $@# screw compressor
o 2 nos wit* k rated motor
In operation ( Paper plant
1 nos of k compressor
0*e pressure setting of all t*e identified compressors is as follows7
$apacity
Actual
re;uirement
Pressure
Suggested
Pr
reduction
9eduction
k Savings
8Pr reduction =
/nloading:$@#
/nloading Loading /nloading
$ompressor)
13"%
24 2"-+2 >+3 " + 2%+2 1+%
Actual orking pressure re;uired for different applications
@or control valve operations, t*e instrument air re;uirement is in
5etween 1+ D 3+ 5ar
@or press roll mac*ine D t*e pressure re;uirement is > 5ar
0*ere exists a good saving potential to optimiBe t*e pressure settings oft*e instrument air compressors+
Reo""endation
Install !@ and reduce t*e operating pressure setpoint to + 5ar+
0*is would *ave two 5enefits
o It would reduce t*e operating pressure t*ere5y reducing t*e
operating power
o
It would completely avoid t*e loss due to unloading
Press roll user re;uires > 5ar pressure, *ence to cater its need, a
small 5ooster compressor needs to 5e installed near t*e user
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Benefits
0*e annual energy saving potential is 9s+ +%% Lak*s+ 0*is will re;uire aninvestment of 9s+ >+%% Lak*s, w*ic* will *ave a simple pay5ack period of1 mont*s+
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E*ERG2 SA0I*G PR)P)SA! *), $&
)P+I1IE 0AC//1 P/1P )PERA+I)* I* /*I+-$
0*e vacuum system in /nit)2 was studied in detail and t*e followingo5servations were made+
Current Syste"
0*ere are 11 num5ers of vacuum pumps installed in paper mac*ine tocater its needs+ All are connected to a common *eader 5ut are isolatedfrom eac* ot*er wit* t*e *elp of valves+ 0*e vacuum pump connected towire mes* user is t*rottled at t*e user ends 5ut all ot*er vacuum arecompletely open+
)bser5ations
0*e vacuum re;uirement of various sections of paper mac*ines are ass*own 5elow7
!acuumPump %
' Pickup 9oll %% 34% 1>%
" Suction Press 8low Bone: 3-%
-Pickup felt, 3 press felt, /*le5ox 3"% 32%
>%
1%1=4 press felt, u*le 5ox
44% 31% 13%
11 44% 31% 13%
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As seen in t*e ta5le a5ove, t*e pressure drop 5etween t*e user and t*epump in eac* area is *ugevery *ig*+ 0*e possi5le reason for t*e samecould 5e
Improper line siBing
#oisture carryover to t*e vacuum pump due to non)availa5ility of
separators
Improper water evacuation from separators leading to moisture
carryover
Reo""endation
As it is o5served t*at t*ere is a *uge *ig* pressure drop 5etween t*e userand t*e pump, it is evided t*at t*e line siBing in eac* user is not proper+ Itis *ig*ly recommended to call a t*ird party to conduct a detailedengineering study only for t*e pipe siBing so t*at it could 5e 5roug*tdown to accepta5le limits+ *ile conducting t*e study t*e following pointsneeds to 5e kept in mind
0*e pressure drop across t*e separator s*ould 5e a maximum of
%mmg
0*e pressure drop across t*e complete pipeline s*ould not 5e more
t*an 2% mmg
A detailed study on t*e pipe siBing alone s*ould 5e done and t*e
pressure drop s*ould 5e 5roug*t down to accepta5le limits
Also !@ needs to 5e installed for all vacuum pumps and vacuum needsto 5e maintained 5ased on t*e user re;uirement from $S+
Sa5ings
0*e saving potential is calculated only for t*ose pumps as s*own in t*eta5le 5elow w*ere t*e pressure drop 5etween t*e source and t*e user is
*ig*+
VacuumPump No
UserSource Pr in
mmHgUser Pr in
mmHgDelta P in
mmHg
1 Wire bivac 300 Max 180 50
5Suction Press (high zone)
580 420 90
580 420 90
! Pic"u# $o%% 500 340 90
101&4 #ress 'e%t uh%e box
440 310 0
11 440 310 0
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In t*e a5ove ta5le, t*e pressure drop 8elta)P: is inclusive of %mmgpressure drop across t*e separator and 2%mmg pressure drop in t*epiping+
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Savings calculation
Sample calculation for ire &ivac M 3%%D1"%)%8separator:)2%8piping:
M %mmg
M Pressure drop x Powerconsumption
ead developed
M %mmg x 1%2 k3%% mmg
M 1' k
Similarly, saving for ot*ers is s*own in t*e ta5le 5elow
VacuumPump
NoUser
SourcePr in
mmHg
User Prin
mmHg
DeltaP in
mmHg
Powerconsumption in
kW
savingsin kW
1 Wire bivac 300Max180 50 102 1!
5 Suction Press (highzone)
580 420 90 180 28
580 420 90 14! 23
! Pic"u# $o%% 500 340 90 141 25
10 1&4 #ress 'e%t uh%ebox 440 310 0 1!4 2411 440 310 0 153 21
ota% 138
Benefits
0*e annual energy saving potential is Rs, ,$% !a4hs+ 0*is will re;uirean investment of Rs, $,%% !a4hs, w*ic* will *ave a simple pay5ackperiod of 8 "onths+
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E*ERG2 SA0I*G PR)P)SA! *), $$
REP!ACE 0 BE!+ =I+; C)GGED :!A+ BE!+ I*IDE*+I:IED E/IP1E*+S
Ba4ground
uring t*e detailed Energy Audit conducted at +9+ Pulp and paper,various e;uipments were studied for possi5le energy saving opportunities+
Some of t*e auxiliary 5ag filter fans, pumps, compressors and 5lowersusesconventional !)5elt drives for power transmission+ /se of ! 5eltscauses some energy losses+ 0*ere is a power transmission loss of a5out' ) ", w*en t*e !)5elts NE6E I
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@rom t*e a5ove grap* it is clear indication t*at t*e flat 5elt is operating at-" efficiency w*en t*e drive is 1%% loaded, 5ut !)5elt is operating att*e -4 efficiency only+ 0*ere exists good potential to replace !)5elt wit*t*e flat 5elt drives+
0*ese drives are ideal for steady load applications, suc* as fans,compressors, and 5lowers+ owever, it s*ould 5e ensured t*at t*e areaaround t*e e;uipment is free from oil or water spillage+
Also, proper preventive care must 5e taken to ensure proper alignment5etween t*e drive and driven e;uipment+
Reo""endation
e recommend converting t*e identified !)5elt drives into flat 5elt drivesfor t*e ma.or auxiliary 5ag filter fans+ 0*e list of identified fans is given5elow+ Ensure t*at t*e area around t*e e;uipment is free from oil orwater spillage 8cover could 5e used for protection:
S*+o ,-ui#.ent /#erating "W Saving Potentia%
1 Mixing hest 33 1*32
2 Machine hest 15 0*
3 Pu%# u.# chest 33 1*32
4 gro #u%# chest 30 1*2
5 acuu. #u.# cautisizing #%ant 130 5*2
,P rain #u.# 45 1*8
! agass chest agitator 55 2*28 acuu. #u.#s 11 nos 1398 55*92
9 6nit1 oi%er !P7 an 28 1*12
10 6nit1 oi%er !P7 : an 23 0*92
11 acuu. #u.#s 5 nos 3 14*4
ota% 215 8*24
Sa5ings
Cn a conservative 5asis 4 saving is calculated for t*e identifiede;uipments
Benefits
0*e annual energy saving potential is Rs, 3','% !a4hs+ 0*is will re;uirean investment of Rs, $%,%% !a4hs, w*ic* will *ave a simple pay5ackperiod of 6 "onths+
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E*ERG2 SA0I*G PR)P)SA! *), $3
)P+I1IE +;E C)*DE*SA+E REC)0ER2 CIRC/I+ I*PAPER A*D E0AP)RA+)R SEC+I)*
uring t*e detailed energy audit at 9 Pulp and Paper, t*e sondensaterecovery circuit was studied in detail and t*e following o5servations weremade+
Present status
0*e following o5servations were made in t*e evaporator and papersection
Stea" onsu"ption in e5aporator setion
Average ) 13 0P
9ecovery ) , '0P
Stea" onsu"ption in paper "ahine
Average ) 22 0P
9ecovery ) ', 1> 0P
0*e condensate levels in flas* tank and vacuum tank at paper mac*inesection is maintained 5y individual pumps associated wit* eac* tank wit*t*e *elp of control valves+ 0*e condensate collected in eac* tank is
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pumped into a recovery tank t*roug* a common *eader, w*ic* is againpumped into t*e deaerator wit* t*e *elp of a pump as s*own in t*e figurea5ove+
0*e condensate from t*e recovery section is also sent to t*e recovery
tank w*ic* is at 1%" deg $+
)bser5ation
Paper 1ahineAt paper mac*ine section, t*e individual controls valvesare *eavily t*rottled to t*e tune of 2> and 4-, w*ic* is due tomismatc* 5etween t*e design and operating condition+
E5aporator SetionAs t*e condensate w*ic* is entering t*e recoverytank from t*e evaporator section is at 1%" deg $, some portion of t*econdensate flas*es into steam w*ic* is vented into t*e atmosp*ere
Reo""endation
It is recommended to connect t*e condensate line from 5ot* evaporatorsection as well as from paper mac*ine section directly into t*e deaeratoras indicated 5y dotted line in t*e figure 5elow+
Install !@ in pumps associated wit* @las* tank and vacuum tank and t*elogic to !@ would 5e to maintain t*e tank level+
Stop t*e pump t*at transfers condensate from t*e recovery tank to t*edeaerator
0*e savings wit* t*is modification is as follows
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0*e energy loss associated wit* t*e pressure drop across t*e control
valves in @las* tank and vacuum tank pumps can 5e completelyeliminated+
As t*e new operating parameters will 5e matc*ing wit* t*e design
values, t*e pump will 5e working wit* 5etter efficiency
Stopping of t*e recovery tank pump will 5e saving power to t*e
tune of 11 k 8operating power:
@las* steam generated from 1%0P of condensate would 5e
M 12 kg? *r
ence 12 kg? *r of flas* steam could 5e avoided if directly introduced todeaerator, t*is would inturn reducest*e extraction steam to t*e deaeratorfrom t*e tur5ine+
Install new pump at t*e evaporator section, t*e new pump will *ave aspecification w*ic* will aid t*e condensate to 5e sent directly into t*edeaerator+ 0*e new specification will 5e as follows
$apacity )2% m3? *r
ead ) % mtr
#otor ) kSa5ings
Stoppage of recovery tank pump M 11 k
Benefits
0*e annual energy saving potential is Rs, ','% !a4hs+ 0*is will re;uirean investment of Rs, ',%% !a4hs, w*ic* will *ave a simple pay5ackperiod of && "onths,
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)bser5ation
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)BSER0A+I)* *), &
REP!ACE +&$ A*D +9 !A1PS =I+; E*ERG2E::ICIE*+ + !A1PS
uring t*e detailed energy audit at KR Pulp and Papers=?
Effiay
>!u"ens=att?
!a"p !ife
>hours?
39"" dia+&$?
3" >" 12%%%
$8"" dia+9?3> ' 1%%%
&8"" dia+?2" 1%3 1>%%%
Reo""endation
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0*ere is a good potential to replace existing 012 and 0" lamps wit* 0lamps+ It is recommended to replace 012 and 0" lamps wit* energyefficient 0 lamps+ 0*e savings 5y replacing 0" and 012 lamps wit*electronic 5allasts wit* 0 will 5e around " and 12 respectively+
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)BSER0A+I)* *), $
REP!ACE E.IS+I*G ;PS0 A*D ;P10 !A1PS =I+;E*ERG2 E::ICIE*+ !ED !A1PS
!atest Design +rend in !ighting
0*e latest trend in lig*ting is to utiliBe t*e rig*t amount of pupil lumens+0*e pupil lumens also considerst*e variation in sensitivity of t*e eye inrelation to t*e environment+ 0*e sensitivity of t*e eye varies 5etweendaytime lig*ting and nig*t time lig*ting as s*own in t*e figure 5elow+
0*e scotopic curve and p*otopic curve mention t*e day D time lig*tingand nig*t time lig*ting respectively+ 0*e eye colour is more sensitivetowards t*e green colour for p*otopic curve and is correspondingly for5lue colour in t*e case of scotpic vision+ 0*is data of relative sensitivity ofeye *elps us in designing t*e correct colour of t*e lamp re;uired fordifferent lig*ting conditions+ 0*e scotopic vision is well suited for nig*tenvironment suc* as street lig*ts, 5asements, closed rooms w*eresunlig*t is not availa5le+ 0*e p*otopic on t*e ot*er *and will 5e closer today D time environment+
0*e earlier system of lig*ting w*erein t*e ;uantity of lig*t delivered wasmentioned in lumens and not in pupil lumens considered only t*e p*otopiccurve+
Co"parison of !a"ps
0*e ta5le 5elow s*ows a 5rief comparison of all t*e lamps+ 0*e latesttrend is to go for LE lamps+ 0*ese LE lamps *ave very *ig* scotopic top*otopic ratio of 2+4+ 0*is is very well suited for street lig*ting andlig*ting in dark surroundings+
S+
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1 Life %%%%ours
1%,%%%)12,%%%ours
1,%%%)2%,%%%ours
>%%%)"%%%ours
12%%%)1%%%ours
"%%%%ours
2 Lamp
Efficacy
-%)1%% > to
-%
-%)14% >%)> '%)1%4 >%)"%
3 Lumenepreciation
3% O%,%%%ours
/pto4% O12%%%ours
/pto4% O1%%%ours
1)2%
till endof life
1)2% tillend of
life
1)2% tillend of life
4 $9I '%)-% >)-% 22) 2 >)" >%)- "%
$olor !ariety *ite Qellow *ite *ite w*ite
> colortemperature
21%%)1%%%%
4%%%k)%%%k
21%%)3%%%
3%%%)>%%%
3%%%)>%%
2'%%)>%%
' S?P 9atio upto2+4
1+> %+>2 1+3)2+2
1+3)2+2 1+"
" arm uptime -%Lumens
Instant minutes
4minutes
1minute
1%)%Seconds
Instant
- @licker free yes
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Advantages of LEs
Lower energy consumption
1?LE Longer lifetime 8%,%%% to 1%%,%%% *rs:
ig* Scotopic to p*otopic ratio
Smaller siBe
@aster switc*ing
6reater dura5ility and relia5ility
6ood $9I "%
0*e PS! lamps used for lig*ting *ave very low scotopic to p*otopic ratioof %+>2 and even t*oug* t*e lamp efficacy is *ig*, -% D 14% lumens?watt,
considering only lumen levels and not pupil lumens+ #ultiplying t*isefficacy wit* t*e scotopic to p*otopic ratio from t*e ta5le will give us t*epupil lumens?watt w*ic* is > D "' pupil lumens?watt+ $omparing wit*LE t*e actual pupil lumen?watt will 5e around 21> D 24% pupillumens?watt, w*ic* gives us a good opportunity to replace t*e existingPS! lamps wit* LEs+ In order to ac*ieve t*e same amount of pupillumens t*e power consumed 5y LE is atleast % lesser in comparisonto PS! lamps+
Similarly P#! lamps can also 5e replaced wit* LEs+ 9eplacement of
sodium vapour and mercury vapour lamps wit* LEs are mentioned in t*eta5le 5elow+
Sodiu" 0apour 1erury 0apour !ED
' 12 33
1% 2% '%
2% 4%% 12%
Reo""endation
It is recommended to replace PS! and P#! lamps wit* LEs+ 0*erecommended values for standard lamp siBes are mentioned in t*e ta5lea5ove+
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)BSER0A+I)* *), 3
;AR1)*ICS 1EAS/RE1E*+S
Ba4ground
As a part of t*euring t*e detailed energy audit detailed energy audit ata*armonic survey was conducted at K R Pulp and Papers !i"ited
#ercury &lended lamps Power input ecreases 5y 2%
#etal alide lamps Power input ecreases 5y 2%
PS! lamps Power input ecreases 5y 2%
LPS! lamps Power input ecreases 5y "
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#o57 --1')%3%>, -41'%)33-4"
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infoOmuskaanengineers+com
8, Poer Engineers
Consultants
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Cpp+ ero cycle Ltd,
Lud*iana)1%
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5usinessOpowerengineer+5iB
Energy Effiient !ighting
GE !ightingPlot %1%%P*7 -1)"%)2"2"3')"% 8&oard'
@ax7 -1)1123314332Email7 s+k+dangiOp*ilips+com
Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre
mailto:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://www.gelighting.com/india/email.html?0mailto:[email protected]:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://www.gelighting.com/india/email.html?0mailto:[email protected] -
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Asian Eletronis !td,
)11, 9oad >
;a5ellMs India !td,3%4, 3%", 3rd @loor, 1-t*&rigade 6arden$*urc* Street, &angalore)>%%%1P*7 %"%)2-43-')-"@ax7 %"%)2-%13%
E)mail7 5angaloreO*avells+com
!ED !A1PS
1+ Binay )pto Eletronis P5t
!td,
44, Armenian Street
$alcutta D '%% %%1
P*7 %33 D 221%3"%', 2242-%"2,
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Email7 5inayOvsnl+com
infoO5inayLE+com
2+ Kan"ur Eletronis >P? !td,
8LE = #otor $ontrol:
44, Puramprakasa road
&ala.i %% %14
0el7 -1)44)2"13%33?-1)44)
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3, Kality Eletrials P5t, !td,
#fg+ Solar #odules = LE
Lig*ting
3)>)14?-, imayatnagar
ydera5ad D %% %2-
P*7 %4% D 2322 >""-
@ax7 %4% D 2344 %'1
Email7 gupta%1Okwalityindia+com kwalityOkwalityindia+com
', CK)* 0ISI)*S P0+, !+D,
C5eroi $*am5ers D I
4t* @loor, CPP+ SA& 0!
'333-", 2>'334'2,
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E)mail7 ckonimpexOvsnl+net,ckonimpexOgmail+com
, )SRA1 India P5t, !td,
Signature 0owers, 11t* @loor
0ower &, Sout* $ity)I
6urgaon 122%%1
aryana, India+
0el7 -1)124)4%"1"1,
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8, IC *ASA ( !ED !ights$*andmor Agencies 1%?'>, CldAnand 1%241-Contat Person *a"e#ona D % D -"2%1 22>2
Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected] -
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I*D/C+I)* !A1PS
Bajaj Eletrials !td
+ )3)1%-%?2, 3rd @loor!it*al as $*am5ers,
9a.5*avan 9oad, Soma.i guda,
ydera5ad ) %% %"2
P*one 7 %4%)23442-32, 23442-33,
23442-34
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gv+reddyO5a.a.electricals+com
naveenkO5a.a.electricals+com
EHess >EHellene In EnergySa5ing Solutions?
2nd Street, ot*ari Layout, 41 %%, 0amil>24CAPACI+)RS
&, 1o"aya Capaitors4%1, #ad*av ApartmentsRawa*ar 9oad, Cpp+ 9ly+ Stn+6*atkopar 8East:#um5ai ) 4%% %''0el7 %22 ) 21>"2"1?"2,>'4%%1?%2@ax7 %22 ) 21> %'"
$, Baron Poer 3"
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#r+ Cmer aiser8&usiness evelopment#anager:1eher Capaitors >P? !td,T2?1, &asappa 9d+,&angalorearnataka, India ) >%%2'P*7 %"%)''%4->2#o57 %-"4%1-2%%@ax7 %"%)222232
', EPC)S India Pri5ate !td,14?2, &runton 9oad&angalore >% %20el 7 -1 "% 4%3-%>1,4%3-%>4%@ax 7 -1 "% 4%3-%>%3sales+inOepcos+com
, EPC)S India Pri5ate !td,#e*ta Industrial Estate#at*uradas !asan.i 9oad$*akala, An*eri 8East:#um5ai 4%%%-30el7 -1 22 2> "3 2> % -1 22 2> "3 2> 1@ax7 -1 22 2> "3 2> 4
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Cogged flat Belts
K, K, Rubber Co"pany >India? P5t, !td,1, 9ani R*ansi 9oad1--42, 233121 23>12%'2, 23>'-%4@ax7 -1 11 23>21">2Email7 [email protected]
:enner India !td*ivra. $omplex II! @loor, 4"%, Anna Salai%% %3India
0el7 -1)44)243124% to '@ax7 -1)44)2434-%1>, 2432%1-3ptdVm*;Ofennermail+com
Agitators
1+ :luidy"e +ehnologiesE)2?4, Popular Prestige,India? P5t, !td,Cld 3"
Cffice #o5ile7 -3"1% 4'2348#arketing:, -3"2" 2114380ec*nical:Email7 5aronpowerOvsnl+net
5aronpowerOsatyam+net+incorporateO5aronpower+com
Cro"pton Grea5es !i"ited,$6 ouse, >t* @loorr+ Annie &esant 9oadorli, #um5ai ) 4%% %3%
India0el7 -1 %22 2423 ''''@ax7 -1 %22 2423 ''""
Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre
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Cu""ins India !i"itedPower 6eneration &usiness /nit3 A?1?2 ErandawanaPune D 411 %3"P*7 %2% D >>%2 '2
@ax7 %2% D >>%2 "%-%Contat Person
1r, S Ra5ihandran6eneral #anager#o57 %-"22% -3'"Email7su5ramaniam+ravic*andranOcummins+com
*eel ControlsT112, #inerva Industrial EstateP 9oad, , 9ow ouse, 6oyal Inter $ity&e*ind rive in cinema, 0*alte.9oad, 0*alte.A*meda5ad, 6u.arat 3"% %4IndiaP*7 8%'-: 2>"4 %124? 324
APCT , Lake Avenue,%, 24--"21%Email7npsl+corporateOnumericups+com
E"erson *etor4 PoerPlot '2%"%%%?"%%2?'"%%@ax7 %22 ) 2"2"3", 2"%%"2-,2"242">
Consul Consolidated Pri5ate !i"ited
-?>, Ist Street, !enkates*wara %% %2%, 0amil
@ax7 8-1:)844:)244%34'%
E)mail7 consulOvsnl+com, npkris*nanOconsulindia+com
Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre
mailto:[email protected]:[email protected]:[email protected]:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected]:[email protected]:[email protected]:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.com -
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=aste ;eat Reo5ery
+her"aH !td,*anra. #a*al, 2nd @loor$*atrapati S*iva.i #a*ara. #arg
)3)>4-,
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infoOt*ermalindia+com
1egather" DNteh P5t !td
Plot 1%, Perungudi Industrial Estate
Perungudi, $*ennai ) >%%%->+ I4'-2 ? 42>2-%%"
Email I 7 govinmegaOsify+com?
govinmegaOgmail+com
)I! :IRED +;ER1)PACA/A+;ER1 S2S+E1
+her"aH Babo4 =iloH
!i"ited
Energy &uilding, 1 &lock, Plot 14?3"?"
@ax7 %44 D 24-" '>3"
Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre
mailto:[email protected]:[email protected]:%C2%[email protected]:[email protected]:[email protected]:[email protected]:%C2%[email protected]:[email protected] -
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:urnae
+her"al Syste"sPlot 2'>2, 2>2'-%@ax7 %44 ) 4214%-''Email7 t*ermalsystemsOya*oo+com t*ermalsystemsOairtel5road5and+in
Radiant Reuperati5e ;eaters
+her"aH Babo4 =iloH !i"ited
Energy &uilding, 1 &lock, Plot '"
@ax7 -1 22 2431 %--2 ? 2432 1-2-Email7 enconindiaOvsnl+comEmail7 akraiOencongroups+com
A"alga"ated Indl, Co"posites P, !td,
/nit -'
Atlas Copo Co"pressor Sales>)3)11-1, 2nd @loor, &ri. 0arang6reenlands, &egumpetydera5ad ) %%%1>
0el7 -1 4% 32-4-%-%@ax7 -1 4% 2341'-23
8#r+ *anan.ay esai9egional #anager:Atlas Copo Co"pressor Sales2nd @loor, 0ellus 0ec*nologies PvtLtd, 2%-?1&?1A, 9ange ill, Pune411%2%, P*7 -1 2% 32-4-%-%@ax7 -1 2% 2'14''"#o57 -1 -"23%141"Email7 d+desaiOin+atlascopco
Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre
mailto:[email protected]:[email protected]:[email protected][email protected]&subject=Inquiry%20from%20www.encongroups.commailto:[email protected][email protected]&subject=Inquiry%20from%20www.encongroups.commailto:[email protected]:[email protected]:[email protected]:[email protected][email protected]&subject=Inquiry%20from%20www.encongroups.commailto:[email protected][email protected]&subject=Inquiry%20from%20www.encongroups.commailto:[email protected] -
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Ingersoll-Rand >India? !td)Air $enterSolitaire $orporate Park I!/nit 411)412, 1st @loorAnd*eri)6*atkopar Link 9oad
#um5ai 4%%%-3$*akala, And*eri 8East:P*7 %22)>>-')@ax7 %22)>>-' >>
Godrej Group ( EE ser5ies#r < aruwala6odre. = &oyce #fg+ $o+ Ltd+Piro.s*anagar, !ik*roli,#um5ai ) 4%%%'-,
#a*aras*tra,India+P*7 -1)22)>'-> >> ? >'->--@ax '-> 11"
Den5i4 +ehnology Pri5ate !i"ited 11?, Arundale &eac* 9oadalaks*etra $olony&esant %%%-%*ttp7??www+denvik+in
Contat Person!i.ay ris*na, irector, &usiness evelopmentP*7 %-"4%"1"%% Email7 vi.ayOdenvik+in
;)C Dryers
Gaso Energy Syste"s >I? P5t, !i"ited0)122 , #+I++$+, &*osari, Pune ) 411 %2>0el+ 7 -1 2% 2'12 ""23 ? 3%>" 2>@ax7 %2% ) 2'11-'3
Email7kgiramOgasoenergysystems+com
Dryteh EngineersS*+ %1@ax 7 -1)2%)243'>'"-Email7 drytec*engineersOet*+net, v5kVdrytec*Oya*oo+co+in,.mdVdrytec*Oya*oo+co+in, responseOdrytec*engineers+com
Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre
mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory. -
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Energy Effiient Pu"ps
Suler Pu"ps India !td,- #I$, 0*ane &elapur 9oadig*a, % >"14E)mail7 spisalesOsulBer+com
Grundfos Pu"ps India Pri5ate!td,11" Cld #a*a5alipuram 9oad0*oraipakkam, $*ennai >%% %-'0el7 -1 44 24-> >"%%@ax7 -1 44 24-> >->-
@ax7 -12% 2444)%"24,2444)
41-",2444)%1>Email7 k5linOk5l+co+in
Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre
Kirlos4ar Brothers !td,/dyog &*avan, 0ilak 9oad,Pune 411 %%2 8India:P*7 -1 2% 2444%''%
mailto:[email protected]:[email protected]%20mailto:[email protected]:[email protected]%20 -
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Energy effiient fans
Dusteh Engineers P5t !td$ontact Person 7 #r 9 6upta WirXAddress 7 P)2' 2nd @lr malviya ?4321
@ax7 -1)44)2434'""'email7 salesOswitBerinstrument+com
Chanda4 Instru"ents P5t, !td,6)%%4, Smruti, Cpp+ *anwatey
-
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Air onditioning syste"
/nited Engineering Corporation14', 9 P 9oad, Secundera5ad)%% %%30elefax7 2'4)%1, 1113, 3-, 2'3)"->
Email7 ueca.ayOgmail+com= *yd2Vueca.ayOsanc*arnet+in!isit7 www+smartcool+co+in
Stea" +urbines >1ini "iro?
+ri5eni Engineering Industries !i"ited12 D A, Peenya Industrial Area &angalore >% %",0el7 %"%)2"3-4'21@ax7 %"%)2"--211)-4-1r S * Prasad24#o57 -"41"-4'2Email7 snprasadOt5g+trivenigroup+com
+urbo+eh Preision Engineering >P? !td,
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Insulations
1egha Insulations P5t !td,A)11?>t*@loor, ada Sa*e5 @latsalanala, &*avnagar D 3>4%%1
P*7 %2'")3%%423?2>@ax7 %2'")3%%4'2"Email7 miplOmeg*ainsulation+com
Contat Person#r ! S*a* )-"22)%''23 = -42>2)12"23#rs+ #ad*u7 -"'-)4>23
Energy 1anage"ent Softare
1anoj +elrandhe
#anager D nowledge &ased &usinesses = I0esSEE-+eh Solutions P5t, !td,11?, Lets $onserve, #I$ Info0ec* Park'-> 1'%% ? 1"%%@ax7 -1 22 >'-> 12
Contat Details#r+ omi+ '-> 22%1Email7 *ndOgodre.+com
1r, /"esh 0, Shah8$*ief 6eneral #anager:Industrial Electronics = Automation0el+7 -1 22 >'-> 2211Email7 uvsOgodre.+com
Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre
mailto:[email protected]://www.letsconserve.org/mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://www.letsconserve.org/mailto:[email protected]:[email protected]:[email protected]:[email protected] -
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$, Ingersoll-Rand >India? !i"ited,Plot 2 1%-0el7 -1 "% 221> >%%%@ax7 -1 "% 221> >%22
3 )rhid Industrial E@ui"ents Energy /tility Ser5ies 14' ) A, Cld Ani.rwadi, #aBgaon#um5ai ) 4%% %1%0el7 -1 ) 22 ) 23'3 '4 4
-1 ) 22 ) 23'4 23 4@ax7 -1 ) 22 ) 23'1 -4 4>
P! Engineering !i"ited8A Pun. Lloyd 6roup $ompany:'> Institutional Area, Sector 326urgaon ) 122%%1, India
Contat Person
#r Priya 9an.an umar6# ) &usiness evelopment1ob %6'&&%$&7$%< Bangalore
Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre
mailto:[email protected]:[email protected]:[email protected]:[email protected] -
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Supplier for Paddle 1iHers
B;S-Sonthofen >India? P5t, !td,>)3)22?1?'?&, 3rd floorCpp+ IIP#, ErramanBil
&an.ara ills, ydera5ad) %% %340el7 -1)4%)2331341 ?4@ax7 -1)4%)233134>
Contat Person
1r *eelesh Desai"%
Sangha5i Engineering121, $+I+E, 5alanagar Expansion
6and*inagar, ydera5ad )%% %3'And*ra Prades*P* %4%)23%">>31?33E mail seOsang*avigroup+com
Con5eyor Belts
1r 0ijay Ku"ar K9egional #anager)Sout*PhoeniH 2ule >P? !i"ited1st @loor, P # #odi, $ommercial $omplex
ar5ala #aidan, )4)1"'?>#a*atma 6and*i 9oadSecundera5ad D %% %%3P*7 %4%)>>32442, >>31442#o57 %)-3-32 23112Email7 pyl*ydOya*oo+co+in kandukurivi.ayOya*oo+com
Dislai"er
=hile e5ery are has been ta4en in o"piling this list< Confederation
of Indian Industry does not aepts any lai" for o"pensation< if anyentry is found to be rong< abbre5iated< o"itted or insertedinorretly either as to the ording spae or position in the list, =hileatte"pts are being "ade ontinuously to "a4e the list as elaborateRs,!a4hs?
Payba4Period
>1onths?
PersonDepart"entResponsible
+argetDate
Re"ar4s
19educe t*e @re;uency of 0ur5o 6enerator1 to 4- B
1%%+%% % %
2 9educe Cne 0ap Setting of 0ransformer 2+1% % %
3 CptimiBe t*e Lig*ting !oltage in t*e Plant +%% 2+%%
4Install !aria5le @re;uency rives inIdentified Pumps In Pulp #ill
>+"% 4'+4% 1%
Install !aria5le @re;uency rives in$entricleaner Pumps in Pulp #ill
"+"% "+% 11
>Install !aria5le @re;uency rives inIdentified Pumps in Paper #ac*ine
"+4% 1%+%% 1
'Install !aria5le @re;uency rives in$entricleaner Pumps in Paper #ac*ine
43+%% 1-+% >
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"Avoid t*e Pressure rop Across @eed$ontrol !alve &y Cperating &fp it* !fd in/nit 1
4+%% 4+% 14
-
Avoid Passing 0*roug* #inimum9ecirculation Line &y Installing #ultistagerag !alves @or &oiler @eed Pump in /nit1
-+%% +%% '
1%Avoid t*e Pressure rop Across @eed$ontrol !alve &y Cperating &fp in Auto
it* !fd in /nit 2
2'+%% 1+%% 1
11
Avoid Passing 0*roug* #inimum9ecirculation Line &y Installing #ultistagerag !alves @or &oiler @eed Pump in /nit2
4+"% "+% 2%
12Avoid 9ecirculation of $ondensate &yInstalling !fd And 9educing Speed of$ondensate Extraction Pump
2+4% 1+%%
139educe Air Ingress in /nit)1 &oiler @lue6as Pat*
2+% % %
14Cperate All t*e $ooling 0ower @ans And9educe t*e Speed &y Installing !fd @or All
@ans in /nit)2 Power Plant
4+%% 3+%% -
19educe Excess @low 0*roug* eatExc*angers in /nit)2 Power Plant
32+%% "+%% 3
1>Switc* off Cne $ondensate ExtractionPump $ompletely in /nit)2 Power Plant
3+2% % %
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1'Avoid Pressure rop Across ot ell Level$ontrol !alve And #aintain ot ell Levelirectly &y Installing !fd
2+%% 1+% -
1"
Avoid Cperating Cne Pump &y Pumpingm ater irectly to eaerator AfterPassing 0*roug* t*e @las* Steam eatExc*anger in Paper #ill Section
3+2% 1+%% 4
1-CptimiBe t*e Cperation of Instrument Air$ompressors in /nit )2
1>+4% 1%+%% '
2%CptimiBe t*e Cperation of Instrument Air$ompressors in /nit )1
>+%% +%% 1
21CptimiBe !acuum Pump Cperation in /nit)2
+2% 2+%% >
229eplace ! &elt it* $ogged @lat &elt inIdentified E;uipments
34+4% 2%+%% '
23CptimiBe t*e $ondensate 9ecovery $ircuitin Paper And Evaporator Section
4+4% 4+%% 11
+otal '3',&% &93,7% '
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a!"up Cal!ulations
Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre
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E*ERG2 SA0I*G PR)P)SA! *), &
RED/CE +;E :RE/E*C2 ): +/RB) GE*ERA+)R & +)'7 ;
0*e power produced 5y /nit 061 isM 1%+-' # at %+% B
Cn a conservative 5asis it is assumed t*at around 4% of load is assumedcentrifugal in nature
As per t*e loading of motors t*ere is a good potential to reduce t*e fre;uencyof t*e alternator 061 to 4- B+
Power consumed 5y centrifugal e;uipment 8Speed3
:
3
Power consumed 5y centrifugal e;uipmentM 4% of 1%+- #M 4+3> #
Power consumed 5y t*e centrifugal e;uipment after reduction in fre;uency to4- B M 84-:3 x 4+3>
8%:3
M 4+1% #
9eduction in power consumption M 4+3> D 4+1%Y 2% k
Annual energy savings M 2% k x 9s x "%%% *oursM Rs, &%%,%% !a4hs
0*ere is no investment re;uired for t*is proposal+
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E*ERG2 SA0I*G PR)P)SA! *), $
RED/CE )*E +AP SE++I*G ): +RA*S:)R1ER
0ransformer t*e L0 voltage maintained is 42' !+ 0*ere is a good potential toreduce t*e tap setting of t*e transformer and maintain Z 41!for transformer+
+ap Position ;+ 0oltage >0? !+ 0oltage>0?
1 11>%
433
$>Reo""ended? &&$6
3>Current? &&%%%
4 1%'2
1%4%
> 1%1'
' --%%
9educe t*e tap setting for t*e transformer to tap position 2 from tap position
0otal load of transformers M -' k
Power savings M %+%%>2 x -' k
M > k
Annual Savings M > k x "%%% *rs x 9s+ +%?k*M 9s+2,4%,%%%?)M Rs,$,'% !a4hs
0*ere is no investment re;uired for t*is proposal+
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E*ERG2 SA0I*G PR)P)SA! *), 3
)P+I1IE E!EC+RICI+2 B)ARD P)=ER :AC+)R
0*e mont*ly average power factor is maintained at %+-' lag+ 0*e E& 5illing isin k!A* so for 5y increasing t*e power factor towards unity t*e consumedk!A* units will decrease resulting in lower 5illing amount+
9ecommend to install auto P@ controller and maintain %+-- P@
0otal average k!A*?mont* M 24"%%% k!A*0otal average k*?mont* M 23>%%% k*Power factor M %+-
Improved Power factor M %+--
Average k!A*?mont* after E%%%?%+--M 23"3"3 k!A*
Savings k!A*?mont* M 24"%%%) 23"3"3M -,>1' k!A*
Annual savings M ->1'k!A* x 9s +%?k!A*x 12 mont*s
M 9s+,'',%2%?)Say Rs,,66 !a4hs
!A9 re;uired7#aximum instantaneous k M >>%k!A x %+-"
M >4' k$apacitor re;uired M 8tan[1D tan[2:
M >4' 8%+2%3:M 12-+4 k!Ar
Say &$% 40Ar
9ecommend to install 12% k!Ar 0 capacitor 5ank
Investment for AP@$ M 12% k!Ar \ 9s+1%%?k!ArM Rs, &
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E*ERG2 SA0I*G PR)P)SA! *), '
I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I* IDE*+I:IEDP/1P S I* P/!P 1I!!
Present Status
#any of t*e pumps in t*e pulp mill in /nit)II were found to 5e controlledt*roug* control valves+ 0*e flow re;uirement in t*e 5elow mentioned pumpsvaries on t*e 5asis of production levels and t*e consistency to 5e maintainedin t*e respective c*ests+
$losing of t*e valve creates an artificial resistance to t*e flow, additional to t*esystem resistance+ 0*is pressure drop across t*e valve is a mec*anical energyloss w*ic* is also included in t*e work done 5y t*e pump+ It is estimated t*at
a5out 1%)4% of t*e pump power consumption is lost across t*e valve+
Sa5ings
*a"e of Pu"p+ag
*a"ePoer
4=
0al5e)pening
F
4=Sa5ing
:lo"3hr
Screw Press $*estPump
P/ '> ' 3)>% 11 44%
$ontinuous igesterilution Pump
P/ '4 4" 3 14 '2+"
et ilution Pump )&S1
P/ 11- >% 12 1" 4%%
&ack S*ower Pump )&S1
P/ 1%% 1' % 12%
et ilution Pump )
&S 2
P/ -> >> 2 1-+ %%
&ack S*ower Pump )&S 2
P/ 1%1 1' % 13%
as*ed 0owerPump
P/ 11> '1 "% ' )
ilution Pump P/ 12> 4 % 1>
Secondary Screen
PumpP/ 132 21 3% >
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Screened 0owerPump
P/ 14> 24 % '
L$ $*est Pump P/ 1% 24 1 '
Screened 0owerilution Pump
P/ 1> 4 2, 14 1>
ECP !A0 ilutionPump
P/ 1>- 1 2" 4+
ECP as*er ilutionPump
P/ 1'1 4 >% 1%+
@or Savings, considering 1% savings for 'D1%% open valve considering2% savings for >%D' open valve 3% savings for 1%D>% open valve
@or Example, consider $ontinuous igester ilution Pump P/ '4
Saving Potential M %+2 x 4" kM 14+4 kSay 14 k
0otal Saving Potential M 14>+ k
Annual Savings M 14>+ k x "%%% *rs?yr x 9s+ ?k*M 9s+ >,"%,%%%
Investment for !@ O Rs, '6,' !a4hs
Pay5ack period M 9s+ 4'+4% Lak*s x 12 mont*s9s+ >+"% Lak*s
M &% "onths
Benefits
0*e annual savings of Rs, 9,8% !a4hscan 5e ac*ieved 5y implementing t*ispro.ect+ 0*e investment re;uired is Rs, '6,'% !a4hs w*ic* is paid 5ack in &%"onths+
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E*ERG2 SA0I*G PR)P)SA! *),
I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I*CE*+RI C!EA*ER P/1PS I* P/!P 1I!!
Present Status
0*e $entricleaner pump in t*e pulp mill in /nit)II was found to 5e controlledt*roug* a control valve+ 0*e flow re;uirement in t*e pump varies on t*e 5asisof production level+
$losing of t*e valve creates an artificial resistance to t*e flow, additional to t*e
system resistance+ 0*is pressure drop across t*e valve is a mec*anical energyloss w*ic* is also included in t*e work done 5y t*e pump+ 0*e necessity forcontrolling t*e valve is due to *ig*er design *ead or design flow+
0*ere is pressure loss of %+" 5ar across t*e valve for primary $etricleanerpump w*ic* accounts to more t*an 3% of t*e pump *ead+ As pump power isdirectly proportional to t*e operating *ead of t*e pump, t*ere is good potentialto save energy+
Sa5ings
Pump isc*arge Pressure M 3+4 5ar
Pump ead M 3+4 D %+4 5arM 3 5ar
Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre
+o Sreen =asher
9' 4=P/ &$9
'%F open
Pri"ary Centrileaner
Standpipe
3,' bar
$,8 bar%,8 bar
Pri"ary Centrileaner
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Pressure rop across !alve M 3+4 D 2+> 5arM %+" 5ar
Pump Power M "4 k
As pump power is directly proportional to t*e operating *ead of t*e pump
Saving Potential M %+" 5ar x "4 k3 5ar
M 22+4 kSay 22 k
Annual Savings M 22 k x "%%% *rs?yr x 9s+ ?k*M 9s+ ","%,%%%
Investment for !@ O Rs, 9 !a4hs
Pay5ack period M 9s+ "+% Lak*s x 12 mont*s9s+ "+" Lak*s
M && "onths
Benefits
0*e annual savings of Rs, 9,9% !a4hscan 5e ac*ieved 5y implementing t*ispro.ect+ 0*e investment re;uired is Rs, 9,% !a4hs w*ic* is paid 5ack in &&"onths+
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E*ERG2 SA0I*G PR)P)SA! *), 8
I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I* IDE*+I:IEDP/1PS I* PAPER 1AC;I*E
Present Status
#any of t*e pumps in t*e paper mill in /nit)II were found to 5e controlledt*roug* control valves+ 0*e flow re;uirement in t*e 5elow mentioned pumpsvaries on t*e 5asis of production levels and t*e consistency to 5e maintainedin t*e respective c*ests+ 0*e pumps would *ave 5een designed for maximumproduction and *ence t*e flows are generally controlled t*roug* valves+
$losing of t*e valve creates an artificial resistance to t*e flow, additional to t*esystem resistance+ 0*is pressure drop across t*e valve is a mec*anical energy
loss w*ic* is also included in t*e work done 5y t*e pump+ It is estimated t*ata5out 1%)4% of t*e pump power consumption is lost across t*e valve+
Sa5ings
*a"e of Pu"p +ag*a"e
Poer4=
0al5e)pening
F
4=Sa5ing
:lo"3hr
9efined S $*est PumpP#1"1
1% 2" ) 22
&roke $*est PumpP#1-%
1- 4" + ''
&agasse Pulp $*estPump
P#1-4
24 '> 2 21
#ac*ine $*est PumpP#1"
4 % 13+ )
@or Savings, considering 1% savings for 'D1%% open valve considering2% savings for >%D' open valve 3% savings for 1%D>% open valve
@or Example, consider &roke $*est Pump P# 1-%
Saving Potential M %+3 x 1- kM +' kSay + k
0otal Saving Potential M 21 k
Annual Savings M 21 k x "%%% *rs?yr x 9s+ ?k*M 9s+ ",4%,%%%
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Investment for !@ O Rs, &% !a4hs
Pay5ack period M 9s+ 1%+% Lak*s x 12 mont*s9s+ "+4% Lak*s
M &% "onths
Benefits
0*e annual savings of Rs, 9,'% !a4hscan 5e ac*ieved 5y implementing t*ispro.ect+ 0*e investment re;uired is Rs, &%,%% !a4hs w*ic* is paid 5ack in &"onths+
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E*ERG2 SA0I*G PR)P)SA! *), 6
I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I*CE*+RIC!EA *ER P/1PS I* PAPER 1AC;I*E
Present Status
0*e $entricleaner pumps in t*e paper mill in /nit)II were found to 5econtrolled t*roug* control valves+ 0*e flow re;uirement in t*e pumps varies ont*e 5asis of production levels+
$losing of t*e valve creates an artificial resistance to t*e flow, additional to t*esystem resistance+ 0*is pressure drop across t*e valve is a mec*anical energyloss w*ic* is also included in t*e work done 5y t*e pump+ 0*e necessity forcontrolling t*e valve could 5e due to *ig*er design *ead or design flow+
0*ere is pressure loss of 1+1 5ar across t*e valve for primary $etricleaner
pump w*ic* accounts to more t*an 2 of t*e pump *ead+ Similarly, t*ere isa 1+ 5ar pressure loss across t*e valve for t*e secondary centricleaner pumpw*ic* is more t*an 4% of t*e pump *ead+ As pump power is directlyproportional to t*e operating *ead of t*e pump, t*ere is good potential to saveenergy+
Sa5ings Calulations
$onsidering Primary $entricleaner pump
Pump isc*arge Pressure M 4 5ar
Pump ead M 4 D %+4 5arM 3+> 5ar
Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre
+o Pri"ary Sreen
through P1 $3'
$3' 4=P1 &%%
'%F open
:ro" C! BoH
' bar
$,7 bar %,9 bar
Pri"ary Centrileaner
6 4=P1 '$
3, bar
$ bar %, bar
'%F open
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Pressure rop across !alve M 4 D 2+- 5arM 1+1 5ar
Pump Power M 234 k
As pump power is directly proportional to t*e operating *ead of t*e pump
Saving Potential for P# 1%% M 1+1 5ar x 234 k3+> 5ar
M '1+ k
Saving Potential for P# 42 M 1+ 5ar x ' k3+1 5ar
M 3> k
0otal Saving Potential M 1%'+ k
Annual Savings M 1%'+ k x "%%% *rs?yr x 9s+ ?k*M 9s+ 43,%%,%%%
Investment for !@ O Rs, &7, !a4hs
Pay5ack period M 9s+ 1-+ Lak*s x 12 mont*s9s+ 43 Lak*s
M 8 "onths
Benefits
0*e annual savings of Rs, '3,% !a4hscan 5e ac*ieved 5y implementing t*ispro.ect+ 0*e investment re;uired is Rs, &7, !a4hs w*ic* is paid 5ack in 8"onths+
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E*ERG2 SA0I*G PR)P)SA! *), 9
A0)ID +;E PRESS/RE DR)P ACR)SS :EED C)*+R)!0A!0E B2 )PERA+I*G B:P =I+; 0:D I* /*I+ &
uring t*e detailed energy audit at KR Pulp Papers !i"ited%% m
9ated Power 7 -% k
% kg?cm2and t*e drum pressure is around4 kg?cm2+ &ecause of t*e severe t*rottling t*ere is *uge pressure drop acrosst*e feed control valve+ Approximately, 1% kg?cm2is t*e pressure drop is takingplace across t*e control valve+
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&oiler drum level is 5eing controlled 5y t*ree element control valve+ 0*isautomatic flow 5ased control valve operates 5ased on t*e level of t*e 5oilerdrum+ As per t*e drum level t*e open of t*e control valve varies+
@low controlling wit* t*e control valve is not an energy efficient mec*anism+
0*e loss *appening across t*e control valve can 5e minimised ? reduced 5yreducing t*e speed of t*e pump+
As t*e pump is already installed wit* !@ and running in manual mode+ Powerconsumption of t*e pump can 5e optimiBed 5y operating t*e !@ in automode+
Reo""endation
e recommend to
Cperate t*e pump wit* a closed loop feed5ack to t*e !@
o )ption & @eed5ack can 5e same t*at of to t*e valve 83 element
signal:
o )ption $ @eed5ack can 5e pressure difference of 2 kg?cm2across
t*e control valve
Saving $aculations
At least pressure drop of " kg?cm
2
can 5e reduced
reduction in pressure drop M " kg?cm2x 1%%>% kg?cm2
M 13+3
Power consumption of &@P M -% k
9eduction in power consumption M -% k x 13+3M 12 k
$onsidering 1%k savings,Annual Savings M 1% kx "%%%*rs x 9s+?k*M 9s+ 4,%%,%%%?)M Rs, ',% !a4hs
Investment for !@ M Rs ',% !a4hs
Pay5ack Period M 9s+ 4+ % Lak*s x 12 mont*s9s+ 4+% Lak*s
M &' "onths
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E*ERG2 SA0I*G PR)P)SA! *), 7
A0)ID PASSI*G +;R)/G; 1I*I1/1 RECIRC/!A+I)*!I*E B2 I*S+A!!I*G 1/!+IS+AGE DRAG 0A!0ES :)R
B)I!ER :EED P/1P I* /*I+ &
uring t*e detailed energy audit at KR Pulp Papers !i"ited+"M >" k
Annual Savings M >" kx "%%%*rs x 9s+?k*M 9s+ 2',2%,%%%?)
M Rs, $6,% !a4hs
Investment for automation M Rs &,% !a4hs
Pay5ack Period M 9s+ 1+% Lak*s x 12 mont*s9s+ 2'+% Lak*s
M & "onth
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E*ERG2 SA0I*G PR)P)SA! *), &&
A0)ID PASSI*G +;R)/G; 1I*I1/1 RECIRC/!A+I)*!I*E B2 I*S+A!!I*G 1/!+IS+AGE DRAG 0A!0ES :)R
B)I!ER :EED P/1P I* /*I+ $
uring t*e detailed energy audit at KR Pulp Papers !i"ited+ >+-% + 1+> 2"
Actual orking pressure re;uired for different applications
@or control valve operations, t*e instrument air re;uirement is in 5etween
1+ D 3+ 5ar
@or press roll mac*ine D t*e pressure re;uirement is > 5ar
0*ere exists a good saving potential to optimiBe t*e pressure settings of t*einstrument air compressors+
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Reo""endation
Interconnect t*e compressed air pipe lines of 5ot* paper plant and
power plant and stop t*e compressor in power plant
As we can see from t*e a5ove ta5le t*at t*e unloading percentage ofcompressor)3 is very *ig*, it would easily accommodate t*e compressedair re;uirement from power plant+
Install !@ in $ompressor)3 and reduce t*e operating pressure setpoint
to + 5ar+ 0*is would *ave two 5enefits
o It would reduce t*e operating pressure t*ere5y reducing t*e
operating power
o It would completely avoid t*e loss due to unloading
Press roll user re;uires > 5ar pressure, *ence to cater its need, a small
5ooster compressor needs to 5e installed near t*e user
Sa5ings alulation
As a first step, it is recommended to reduce t*e pressure settings and maintaint*e average pressure at + 5ar
Loading pressure 7 >+ 5ar
/nloading pressure 7 >+- 5ar
Average Pressure 7 >+' 5ar
Power saving in t*e compressor 5y reducing t*e operating pressure,
Power saving8IA$ T 1,2 = 3: M >+' D +>+' 1
M 1+"
Poer sa5ing in IAC &< $ 3 by reduing pressure
Average loading of compressor M 1%%
Loading Power of compressor M k
Power saving M k x 1+%% x %+1"M "+>k
@or 3 $ompressors M 3 x "+> k
M 2+>" k
M say 2 k
Poer sa5ing in IAC 3 by a5oiding unloading
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E*ERG2 SA0I*G PR)P)SA! *), $%
)P+I1IE +;E )PERA+I)* ): I*S+R/1E*+ AIRC)1PRESS)RS I* /*I+ -&
uring t*e detailed energy audit at 9 Pulp and Paper t*e compressors werestudied in detail and t*e following o5servations *ave 5een made+
Installed apaity
2 x 3"% $@# screw compressor
o 2 nos wit* k rated motor
In operation ( Paper plant
1 nos of k compressor
0*e pressure setting of all t*e identified compressors is as follows7
$apacity
Actual
re;uirement
Pressure
Suggested
Pr
reduction
9eduction
k Savings
8Pr reduction =
/nloading:$@#
/nloading Loading /nloading
$ompressor)
13"%
24 2"-+2 >+3 " + 2%+2 1+%
Actual orking pressure re;uired for different applications
@or control valve operations, t*e instrument air re;uirement is in 5etween
1+ D 3+ 5ar
@or press roll mac*ine D t*e pressure re;uirement is > 5ar
0*ere exists a good saving potential to optimiBe t*e pressure settings of t*einstrument air compressors+
Reo""endation
Install !@ and reduce t*e operating pressure setpoint to + 5ar+ 0*is
would *ave two 5enefits
o It would reduce t*e operating pressure t*ere5y reducing t*e
operating power
o
It would completely avoid t*e loss due to unloading
Press roll user re;uires > 5ar pressure, *ence to cater its need, a small
5ooster compressor needs to 5e installed near t*e user
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Sa5ings alulation
As a first step, it is recommended to reduce t*e pressure settings and maintaint*e average pressure at + 5ar
Loading pressure 7 >+3 5ar
/nloading pressure 7 " 5ar
Average Pressure 7 '+1 5ar
Power saving in t*e compressor 5y reducing t*e operating pressure,
Power saving8IA$: M '+1 D +'+1 1
M 2%+24