Replace T8 lamps with LEDs for huge energy savings at JK Fenner plant

Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
Detailed Energy Audit

At
J K Fenner India Ltd
Patancheru
April 2014
CIISohrabji Godrej Green Business Centre
CONTENTS
Chapter
No.
Description
Page
No.
Executive Summary
Introduction
II
Acknowledgment
III
List of Energy Saving Proposals
IV
Energy Saving Proposals
Management Aspects And Conclusions
50
Annexure
53
Backup Calculations
75
Total No of Pages: 117
EXECUTIVE SUMMARY
J.K. Fenner (India) Limited is a member of the JK Organization which ranks
among the top Industrial houses in India for over 100 years. The name
Fenner has been synonymous with Mechanical Power Transmission and
Sealing Solutions. Fenner commenced operations in India in 1929 and put up
their first manufacturing unit at Madurai in Tamilnadu in the year 1956.
Currently there are 7 manufacturing units over 5 locations.
Their product lines cover V-Belts, Oil seals, Moulded Rubber Components and
Engineering Products for applications in both Industrial and Automotive
mechanical power transmissions.The Industrial segment would address major
sectors like Steel, Cement, Coal, Sugar, Power, Paper, Textiles, Food
processing, Agriculture and many other.
The plant team has done exceedingly well in incorporating certain energy
efficiency aspects in design stage. Further, plant team has taken many steps
towards the improvement in energy efficiency.
CII has conducted the Detailed Energy Audit at J.K. Fenner (India) Limited,
Patancheru Plant from 10th to 13th March, 2014. A detailed presentation was
made to the plant team covering various energy conservation opportunities on
13th March, 2014. The combined efforts of J.K. Fenner (India) Limited and
CII-Godrej GBC team have together identified, annual energy saving potential
of Rs. 90.22 Lakhs, based on present energy cost.:
No. of
Proposals
Annual
savings in
Lakhs
17
90.22
1.54
Annual savings with investment (Rs. Lakhs)
15
88.68
Investment Required
15
65.85
Months
Details
Total Annual savings (Rs. Lakhs)

Annual savings without investment
(Rs. Lakhs)
Average payback period for capital proposals
SPECIFIC ACTION PLAN

a) Specific target date for implementation of proposals should be made within
30 days from submission of this report.
b) The plant should prioritise the above proposals and implement them in a
phased manner.
c) In our opinion the following proposals can be implemented within next
three months straightaway and should be on top priority.
(ESP Nos. 3, 4, 5, 6, 8, 9, 10, 11, 12, 14, 15 & 16)
The above proposals do not require much investment and no detailed
verification.
As a second priority and after detailed verification the following proposals
should be implemented.
(ESP Nos. 1, 7 & 13)
As a third priority and after detailed verification the following proposals
should be implemented.
(ESP Nos. 2 & 17)
d) The plant had already done commendable jobs in Energy conservation. CII
strongly feels that, the plant team should form an energy management
committee which involves senior persons from all departments and the
committee should continue the work and progress towards World Class
Energy Efficient Unit.
CHAPTER - I
INTRODUCTION
J.K. Fenner (India) Limited, Patancheru evinced interest in availing the
services of Confederation of Indian Industry for conducting a detailed energy
audit in their factory.
This report on the detailed energy audit carried out at J.K. Fenner (India)
Limited, Patancheru, is in accordance with CIIs proposal, agreed by J.K.
Fenner (India) Limited, Patancheru vide their work order No. 1876980
dated 27th January 2014.
The detailed energy audit comprised of the following activities:
Detailed data collection of power consuming equipments, production
capacities of major equipment, operating parameters and section wise
specific power consumption.
Power measurements of major electrical energy consumers.
Measurement of efficiency of major power consuming equipment such as
fans etc.,
A detailed training programme on energy management was conducted to
seek more inputs from the plant personnel
Analysis of collected data and measurements to develop specific energy
saving proposals.
Discussion with the plant personnel on the identified proposals.
Presentation on the findings of detailed energy audit to plant personnel.
We are pleased to mention that all the identified energy savings proposals
have been discussed with plant executives concerned before finalising the
Projects.
The contents of the report are based on the data provided by J.K. Fenner
(India) Limited, Patancheru plant personnel during the detailed energy
audit.
The plant personnel should implement the suggestions made in the report
after verifying safety aspects. It is the responsibility of the plant personnel to
observe statutory regulations, if any, as applicable to the factory.
CHAPTER - II
ACKNOWLEDGMENT
CII acknowledges with thanks the co-operation and the hospitality extended to
the CII energy audit team during the detailed energy audit at J.K. Fenner
(India) Limited, Patancheru.
The interactions and deliberations with J.K. Fenner (India) Limited team
were exemplary and the whole exercise was thoroughly a rewarding
experience for CII.
The arrangements and support during the energy audit were excellent. We
deeply appreciate the interest, enthusiasm and commitment of J.K. Fenner
(India) Limited, Patancheru team towards the energy conservation.
We would also like to place on record our sincere thanks and appreciation for
all the senior plant executives.
CHAPTER - III
LIST OF ENERGY SAVING PROPOSALS
Sl.
No
Energy Saving Propsals
Annnual Savings
(Rs.Lakhs)
Investment
Required
(Rs.Lakhs)
Payback
Period
(Months)
Replace the 1x36W And 2x36W T8 Lamps with 1x20 W

LEDs
5.83
9.8
20
Replace the 1x28W And 2x28W T5 Lamps with 1x20 W

LEDs
0.24
0.66
33
Optimize the Lighting Voltage in the Plant
1.85
1.75
12
Switch of Lights in Canteen During Day Time
0.03
0.00
Install New Energy Efficient Pump in 100 T.R Cooling

Tower
2.21
0.8
Replace Inefficient Raw Water Transportation Pump with

Energy Efficient Pump
1.91
1.50
10
Replace Aluminum Blades with FRP Blades for Cooling

Tower Fans
Optimise the Operation of the Chilled Water System
0.06
0.10
20
11.05
7.00
Excess Air Optimization in 3 Ton Boiler
7.20
6.00
10
10
Excess Air Optimization in Thermic Fluid Heater
1.51
0.00
11
Avoid Idle Steam Flow Through VAM
10.45
3.0
12
Insulate Suction Pipeline of Feed Pump for 3-Ton Boiler
2.28
1.00
13
Avoid Heat Loss From Tanks in Shell Treatment Plant
0.53
0.70
16
14
Avoid Compressed Air Usage in Shell Treatment Plant
0.60
0.60
12
15
Replace Thermic Fluid Heater with Electric Heating

Process in Old Oil Seal Section
23.00
10.00
16
Replace FO Boiler with Wood/Briquette Fired Boiler
17
Optimize the Operation of the Pumps in the RO Plant
Total
20.44
20.00
12
0.98
3.0
37
90.22
65.85
Long Term Proposal
Install Solar Steam Generator to Supplement FO Boiler
93.5
800.00
104
Renewable Energy for Lighting
0.50
4.00
96
Replace CFLs with LEDs
0.35
1.62
55
Chapter IV
Energy Saving Proposals
CII Sohrabji Godrej Green Business Centre
ENERGY SAVING PROPOSAL No. 1
REPLACE THE 1X36W and 2X36W T8 LAMPS WITH

1X20 W LEDs
During the course of detailed energy audit at J K Fenner (India) Ltd.,
Patancheru, a detailed study of plant lighting load was carried out to
identify energy saving opportunities.
Present Status
174 Nos of 1X36 W and 316 Nos of 2X36 W T8 lamps were installed in the
plant in the following areas: V Belt, Old oil seal, Old & New STP, Grinding
room, Buffing sheds, MRPS, Eaton, RM stores, FG stores, Boiler house, air
compressor, Rig test room, Chilling plant, Rig test room, RMC lab,
Technical Lab, Canteen, time office. The location-wise break up of these
lamps is given below.
The calculated power consumption of all T8 lamps is around 29 kW.
1X36 W2X36W
Nos
Nos
S.No. Location
1
Heavy Plant
Power in Operating
kW
Hours per day
14
1.22
16
V Belt
21
115
9.04
16
Old Oil seal
20
61
5.11
16
New Oil seal
23
1.66
12
Old STP
0.36
10
Grinding room
0.65
12
Buffing sheds
0.72
22
MRPS
16
1.37
18
Eaton
12
0.94
10
10 RM stores
20
1.15
11 FG stores
75
2.84
10
0.22
12
11
0.40
12
12 Boiler house
Air
compressor,
13 chilling plant, rig
test room
14 RMC Lab
21
1.58
12
15 Generator shed
0.04
12
16 Technical lab
0.43
12
0.86
0.43
12
17 Canteen
18 Time office
It is recommended to replace these T8 lamps with 1X20 W LEDs. Light

Emitting Diode (LED) is the latest technology and offers the following
advantages:
Advantages of LED
Lower energy consumption: The energy consumption of LEDs is low
when compared to the other conventional sources for the same
amount of Lumen output.
Type of Lamp
Lumen/Watt
CRI
Life hours
Fluorescent lamps
50
Good (67-77)
5,000
LED lamps
120
Very Good (> 80)
50,000 1,00,000
A 1X18 W LED was installed in the plant (near calibration room). CII
commends the plant team for this excellent initiative taken. The lux levels
were measured at two locations: at 1X18 W LED and at 2X36 W T8 lamps.
Type of Lamp
Lux measured
2X36 W T8
590
1X18 W LED
495
High S/P ratio: LEDs have higher scotopic/photopic ratio (S/P ratio).
The eye has two primary light sensing cells called rods and cones
cones function in day light and process visual information whereas rods
function in night light. The cone dominated vision is called photopic
and the rod dominated vision is called scotopic. The S/P ratio indicates
the measure of light that excites rods compared to the light that
excites cones. In office environments, illumination is more effective if
the S/P ratio is high as it is under scotopic region. LEDs hence are
ideally suited for these applications as they have a high S/P ratio.
Longer life time: LEDs have longer life time of around 1,00,000
hours. This is equivalent to 11years of continuous operation or 22
years of 50% operation.
Faster switching: LED lights reach its brightness instantly upon

switching and can frequently be switched on/off without reducing the
operational life expectancy.
Greater durability and reliability: As LEDs are solid-state devices
and uses semi-conductor material; they are sturdier than conventional
sources that use filaments or glass. LEDs can also withstand shock,
extreme temperatures and vibration as they dont have fragile
materials as components.
Good Colour Rendering Index (CRI): The color rendering index,
i.e., measure of a light sources ability to show objects as perceived
under sunlight is high for LEDs. The CRI of natural sunlight is 100 and
LEDs offer CRI of 80 and above.
LED offers more focused light and reduced glare. Moreover, it does not
contain pollutants like mercury
LED technology is highly compatible for solar lighting as low-voltage
power supply is sufficient for LED illumination.
Recommendation
It is recommended to replace the existing 174 nos. of 1X36 W and 316
nos. of 2X36W T8 lamps with 1X20 W LEDs. The energy saving that can
be achieved by replacing the T8 lamps with LEDs is around 19 kW.
Benefits
The estimated annual savings that can be obtained by replacing T8 lamps
with LEDs is Rs. 5.83 lakhs. The investment required is Rs. 9.80 lakhs.
The payback period is 20 months.
REPLACE THE 1X28W and 2X28W T5 LAMPS WITH

1X20 W LEDs
Present Status
11 Nos of 1 X28 W T5 lamps were installed in the power house and 22
Nos of 2 X 28W T5 lamps were installed in Heavy plant.
The power consumption of these T5 lamps is around 1.5 kW.
It is recommended to replace these T5 lamps with 1X20 W LEDs. Light
Emitting Diode (LED) is the latest technology. As discussed earlier, LEDs
offer the advantages of lower energy consumption, high S/P ratio, longer
life time, faster switching, greater durability and reliability and good CRI.
LED offers more focused light and reduced glare.
Recommendation
It is recommended to replace the existing 1X28 W and 2X28W T5 lamps
with 1X20 W LEDs. The energy saving that can be obtained by replacing
T5 lamps with LEDs is around 0.9 kW.
Benefits
The estimated annual savings that can be obtained by replacing T5 lamps
with LEDs is Rs. 0.24 lakhs. The investment required is Rs. 0.66 lakhs.
The payback period is 33 months.
OPTIMIZE THE LIGHTING VOLTAGE IN THE PLANT

Present Status
The lighting load is catered by a separate feeder. The lighting load was
measured during day time and night time.
Day time
Night time
Voltage
Current
kW
R-phase
239.0
53.3
11.2
Y-phase
238.3
60.1
13.55
B-phase
238.5
48.2
9.84
R-Phase
238.2
49.0
10.80
Y-Phase
240.6
76.1
17.85
B-Phase
241.1
51.0
12.41
A servo stabilizer was installed to maintain the output voltage. The

lighting voltage is maintained around 239 V, which is on higher side. The
disadvantage of the servo stabilizer is, there is no provision to change
the preset voltage value (the reference value with which feedback is
compared).
The disadvantages of operating the lamps with higher voltages are:
Increase in power consumption of the lamp
Reduction in life of lamp
The optimum voltage for lighting should be in the range of 210-220 V and
is being implemented by many plants. The advantages of reducing the
supply voltage from the present 239 V to 220 V are as follows:
Reduction in power consumption (1% reduction in voltage results in
1% reduction in power, as power is directly proportional to voltage)
Life span of lamps is maintained as specified by the manufacturer
There is no significant drop in the lux levels.
Thus there is good potential to install separate lighting transformer and

reduce the power consumption of the lighting circuit and maintain the tap
setting at 220 V.
It is recommended to
1. Install a lighting transformer
2. Maintain the output voltage at 220 V
Recommendation
It is recommended to install a lighting transformer and maintain the
output voltage at 220 V. The energy saving that can be obtained is around
3.2 kW.
Benefits
The estimated annual savings that can be obtained by installing a lighting
transformer is Rs. 1.85 lakhs. The investment required is Rs. 1.75
lakhs. The payback period is 12 months.
SWITCH OF LIGHTS IN CANTEEN DURING DAY TIME

Patancheru, it was observed that lights were on during day time in
canteen, at the dining area. 8 Nos of 2X36 W T8 lamps were on. As there
is adequate day lighting in the canteen, it is recommended to switch off
these lamps.
Recommendation
It is recommended to switch off these lamps, as there is adequate day
lighting.
Benefits
The estimated annual savings that can be obtained by switching off these
lamps is Rs. 0.03 lakhs.
INSTALL NEW ENERGY EFFICIENT PUMP IN 100TR

COOLING TOWER
Present Status
During the course of detailed energy audit of J K Fenner (India) Ltd.,
Patancheru, a detailed study of all the cooling water supply systems was
done for possible energy saving potential.
The cooling water supply system is explained by the following diagram:
31.2 m3/hr
CT Pump
Cooling
Tower
230C
1.2 bar
5.37 kW
60% open
16.5 m3/hr
1.4 m3/hr
Hot Well
Process Pump
25.60C
The cooling tower pump supplies water from the hot well to the cooling
tower. It was observed that 4 % of water was being re-circulated back
into the hot well at the outlet of the pump. The remaining water was
supplied to the cooling tower with the pipeline being throttled to a 60%
open position.
This process pump supplies water from the cooling tower to the plant.
The following are the measured operating values of the cooling water
pump:
Operating flow
: 32.6 m3/hr
Operating head
: 12 m
Operating power
: 5.37 kW
It was also observed that only 16 m 3/hr water was being pumped to the
plant by the process pump and the excess 14.7 m 3/hr (45 % of the water
being pumped) water is being re-circulated back to the hot well. This
shows that the water supplied to the cooling tower is more than that of
the water supplied to the plant.
Based on the above parameters, the efficiency of the water pump is
estimated as 22%, which is low. The lower operating efficiency of the
pump can be due to the following reasons.
Mismatch between design head and operating head
Low efficiency by design
At present new pumps are available with efficiencies in the range of 70%
to 75%. Hence, there is a good potential here to reduce the water flow to
the cooling tower and reduce the specific energy consumption
Recommendation
We recommend the following:
Step - 1
Trim the Impeller of the pump by 10 percent to reduce the flow output
of the pump
Due to the impeller trimming:
The flow is reduced by 8.5 m3/hr
Head is reduced by 2.5 m
Power consumed by the pump will be reduced by 2.2 kW
Step - 2
Install correct size pump with an operating efficiency more than 70%.
Contact the supplier and select a Cooling Tower pump which is
designed to run at the required operating parameters.
The recommended specifications of the new pump can be as follows:
Volumetric Flow
: 20m3/hr
Head
: 12 m
Efficiency
: >70%
Energy saving of 4 kW is possible

Benefits
Step - 1
Trimming the impeller would result in annual energy saving of about of
Rs. 1.11 Lakhs. This requires an investment of Rs. 0.2 Lakhs for the
new high energy efficient cooling tower pump with a simple payback
period of 2 months.
Step - 2
Installing a correct size energy efficient pump would result in an annual
energy savings of Rs. 2.21 Lakhs. This requires an investment of Rs.
0.8 Lakhs for the new high energy efficient cooling tower pump with a
simple payback period of 5 months.
REPLACE
INEFFICIENT
RAW
WATER
TRANSPORTATION PUMP WITH ENERGY EFFICIENT
PUMP
Present Status
It was observed that the cooling return water from the process is
collected into a return water sump. The water from this sump is being
pumped to the hot well of the cooling tower. This pump operates in closed
loop with the return water sump level sensor and also plant team reduced
the diameter of the impeller. CII Godrej GBC congratulates the plant
team for this excellent energy conservation initiative.
This process is represented with the help of the following diagram:
19.76 m3/hr
6.81 kW
10 m
Cooling Return Water Sump
Hot Well of Cooling Tower
The design specification of return water supply pump is:

Design flow
: 65 m3/hr
Design head
: 35 m
Design power
: 11 kW
The operating parameters of the pump are:

Operating flow
: 19.76 m3/hr
Operating head
: 15 m
Operating power
: 6.81 kW
Efficiency
: 13%
It is observed that the design head and capacity of the pump is much
higher than the actual requirement. Due to the deviation in the design
and operating parameters, the best efficiency point shifted to the lowest
efficiency zone.
Thus there is good potential to reduce the power consumption of the
return water pump by installing new high energy efficient pump.
Recommendation
Install correct size pump with a design efficiency of more than 70%.
Specification of the new high energy efficient pump are:
o Volumetric Flow
: 20 m3/hr
o Head
: 15 m
o Efficiency
: >70%
By implementing this proposal at least 5 kW reduction in power

consumption is possible.
Benefits
1.5 Lakhs for the new high energy efficient pump with a simple payback
period of 10 months.
REPLACE ALUMINUM BLADES WITH FRP BLADES FOR

COOLING TOWER FANS
Present Status
One cooling tower in the plant is running the CT fan with aluminium
blades which is consuming 3.18 kW.
The present trend is to install fibre reinforced plastic (FRP) blades. The
advantages with FRP blades are:
Better aerodynamic properties
Less in weight compared to fan with aluminium blades
Lesser starting current
Thus there is good potential to replace the aluminium blades with FRP
blades which will reduce the power consumption by atleast 3 - 5%. This
has been operating successfully in many industries including Engineering,
Process and Chemical etc.
Recommendation
We recommend replacing aluminium blades with FRP blades for cooling
tower fan.
Benefits
The annual energy saving potential by implementing this project is
Rs. 0.06 Lakhs. This requires an investment of Rs. 0.10 Lakhs for new
blades. This project has a simple pay back period of 20 months.
OPTIMISE THE OPERATION OF THE CHILLED WATER

SYSTEM
Present Status
Patancheru, a detailed study of the chiller system was studied in
detailed for possible energy saving oppurtunities.
Screw Chiller
Comp kW: 36.5
Chiller TR: 39.35
17.10C
Hot Well Pump
Cold Well Pump

2 bar
70 m3/hr
60% open
3.8 bar
49.8 m3/hr
Process
18.90C
180C
Hot Well
During the audit, detailed study on pump efficiencies, chiller compressor

and TR estimation based on chiller water flow was carried out.
The plant has adopted a hot well & cold well system for the chiller system.
The return water from the plant is collected into the hot well and a hot
well pump takes the hot water and reduces the temperature in the chiller.
The design and operating parameters of the hot well pump are as follows:
Hot Well Pump
Head (m)
Flow (m3/hr)
Power (kW)
Design
18.5
72
7.4
Operating
20
70
8.01
Efficiency()
50%
The design specifications and the operating conditions of the process

pump are:
Process Pump
Head (m)
Flow (m3/hr)
Power (kW)
Design
31
93
10.5
Operating
39
49.8
8.9
Efficiency()
61%
After the water gets chilled, it gets collected into the cold well. The
temperature of the chilled water coming out from the chiller is 17.1 0C. It
was observed that the hot well and cold well were connected internally to
facilitate the overflow of water in the wells. Because the amount of water
being supplied by the hot well pump is more than the cold water pumped
to the process, the chilled water in the cold well is getting mixed with the
hot water. This resulted in chilled water temperature rise to 18 0C.
The process pump then supplies the chilled water from the cold well to
the process equipments at 18 0C.
This indicates that the chilled water temperature requirement is 18 0C
instead of that we are producing chilled water at 17.1 0C. Thus there is
good potential to reduce the power consumption of the compressor by
increasing the set point by 1 0C.
Increase in set point should be done only after converting two well system
to single well system. So that mixing of hot water and cold water will be
completely avoided.
Proposed System
Screw Chiller
New Pump with

VFD Control
60 m3/hr
17.10C
5 bar
To Process
18.90C
Hot Well
In this proposed system, the return water from the process accumulates
in the hot well. From the hot well, the new VFD operated hotwell pump
will supply water to the chiller and then to the process. This new hotwell
pump will operate in closed loop with the pumps discharge pressure and
optimum flow throughout the process will be maintained.
complete chilling system by converting to single well system.
Recommendation
Replace the existing Hot well/Coldwell system with single well system
Install a single high capacity and high energy efficient pump which
would supply chiller water to the end users through the chilling unit
This high capacity energy efficient pump will have lesser fixed energy
losses than a two pump system. The higher design efficiency of the
new pump will also reduce the overall pumping power consumptio n.
As the present system is operating healthy at 18 0C chilled water

temperature, we request the plant team to increase the chilled water
temperature by 1 0C
Install VFD to the new pump and operate the pump in closed loop with
the discharge pressure of the pump so that optimum flow is always
maintained in the chilled water circuit
This minimizes the valve control operation completely
The recommended specifications of the new pump are as follows:
o Volumetric Flow
: 60 m3/hr
o Head
: 60 m
o Efficiency
: >70%
Thus by implementing this project at least 21kW reduction in power

consumption of the chiller operation system.
Benefits
The annual energy saving potential by implementing this project is
Rs. 11.05 Lakhs. This requires an investment of Rs. 7.00 Lakhs for
new energy efficient pump along with VFD. This project has a simple
payback period of 7 months.
EXCESS AIR OPTIMIZATION IN 3 TON BOILER

During the Detailed Energy Audit conducted at J K Fenner (India) Ltd.,
Patancheru, the boiler & steam system were studied for energy saving
potential.
Present Status
A 3 Ton Furnace oil fired boiler and a 2 Ton Furnace oil fired boiler are
installed for steam generation. The 3 ton boiler is currently used to
generate steam at 14 bar for various users in the plant. The details of the
pressure requirement in different areas are as given below:
MRPS section for V Belt Curing 7 bar
Heavy Rota Curing section for V Belt Curing 12 bar
Shell Treatment plant 5 bar
The furnace oil feed is controlled in an Auto-mode for low flame and high
flame. The combustion air is also controlled by an auto damper. There is a
significant pressure drop across the damper irrespective of the firing
scenarios. The blower has been designed for the higher head to circulate
the combustion air through air preheater and then to the burner.
During the energy audit we observed that the air preheater was
bypassed. The blower was found to be operating at an efficiency of 40%.
The pressure required for the boiler varies between 100 & 150 mm WC for
low flame and high flame scenarios. The operating parameters are given
in the below table:
Fan Head
Pressure
Damper
mm WC
514
After
Fan Power
Flow
Efficiency
mm WC
kW
M3/hr
150
8.1
2100
40
FO
O2: 2 %
Temp: 250 oC
514 mm WC
Boiler
3 TPH
150 mm WC
Ambient air:
High Flame Scenario
30oC
During the High flame scenario, the oxygen in the stack was found to be
at 1%. During the Low flame scenario, the oxygen in the stack was
increasing to 11%.
FO
O2: 11 %
Temp: 210 oC
514 mm WC
Boiler
3 TPH
100 mm WC
Ambient air:
Low Flame Scenario
30 0C
The measured excess air % during the low flame scenario is 111%. The
FD fan power consumption is high due to higher air supply during the low
flame scenario. A huge amount of energy is lost due to the operation of
the boiler with excess air. The heat generated by the boiler is partly lost to
the excess air, resulting in an increase in fuel consumption to generate
the same amount of steam.This leads to a drop in the efficiency of the
boiler.
Thus there is excellent potential to reduce fuel and power consumption by
installing VFD fitted energy efficient fan and operate in closed loop with
the O2 sensor.
Recommendation
Step 1:
Install an Online Flue gas Analyzer at the Boiler Outlet
Interlock the existing damper to maintain the O2% in the Boiler outlet
Step 2:
Install a new high energy efficient blower with VFD of the following
specification:
o
2500 m3/hr, 250 mm WC, >65 % efficiency
Interlock the VFD operation with the boiler outlet O2

Vary flow of fan to maintain the O2% of 2-3 % in Boiler outlet
Benefits
The annual savings of Rs. 7.20 Lakhs can be achieved by implementing
this project. The investment required is Rs. 6.00 Lakhs with a simple
EXCESS AIR OPTIMIZATION IN THERMIC FLUID

HEATER
Patancheru, the thermal systems were studied for energy saving
potential.
Present Status
A 2 Lakh kcal HSD-fired Thermic Fluid Heater is installed providing hot
therminol-55 to the Oil based heaters of the Old Oil Seal Section. It
operates in on/off mode interlocked with the thermic fluid outlet
temperature. The set points for the on/off operation are given below:
On at 206 0C
Off at 239 0C
HSD
O2: 11 %
Temp: 200 oC
TFH
Stack
Ambient air:
30oC
The measured excess air % in the TFH is 111%. A huge amount of energy
is lost due to the operation of the TFH with excess air. The heat generated
by the TFH is partly lost to the excess air, resulting in an increase in fuel
consumption to transfer the same amount of heat to the thermic fluid .This
leads to a drop in the efficiency of the TFH.
There is excellent potential to reduce fuel and power consumption by
decreasing the combustion air flow to decrease the O2% in the TFH outlet.
Recommendation
Take trial by reducing the supply air quantity by closing the blower
damper
Decrease flow of blower to maintain the O2% of 2-4 % in TFH outlet
Benefits
The annual savings of Rs. 1.51 Lakhs can be achieved by implementing
this project. There is no investment required for this project.
AVOID IDLE STEAM FLOW THROUGH VAM

Patancheru, the steam systems were studied for energy saving
potential.
Present status
There is a 90 TR Screw Chiller to meet the requirement of the chilled
water for the Cooling cycle of the curing process. Earlier, Vapour
Absorption Machine was operated utilizing the steam from the boiler to
generate the chilled water.
The plant has installed the Screw Chiller in place of VAM. Presently the
VAM is in standby mode, but the pipe line was found to be hot with a
surface temperature of 980C. Though the valve is partially closed, still the
steam is passing through the control valve and the condensate is collected
in the condensate tank.
This steam returns to the condensate flash tank without doing any useful
work.
60 %
7.5 Bar
VAM
0.05 - 0.09 TPH
By pass for VAM
The measured steam flow through the line was 0.09 TPH. This test was
carried out with the support of bucket test. This would translate to 6 % of
the total steam generation.
There is scope to reduce the idle steam consumption by stopping idle flow
of steam through the line. This can be done by installing a valve on the
line near the common Header.
Recommendation
Install a control valve in the line near the common Header and close
completely
Benefits
Annual savings of Rs. 10.45 Lakhs can be achieved by implementing this
project. The investment required is Rs. 3.00 Lakhs with a simple
INSULATE SUCTION PIPELINE OF FEED PUMP FOR 3TON BOILER

Patancheru, the boiler & steam systems were studied for energy saving
potential.
Present status
The pipeline from the feed water tank to the feed pump inlet is 20 m long
and not insulated. The temperature drop within this circuit is around 9
120C.
The radiation losses from the line can be avoided by insulating the line
completely. Every 10C drop in the Boiler feed temperature is equivalent to
a loss of 1480 kcal/hr.
800C
Feed Tank
700C
Boiler
1.45 TPH
1 running
There is good potential to reduce the fuel consumption by insulating the

entire line and the Boiler feed pump inlet header.
Recommendations
Insulate the boiler feed pump suction from the feed tank to the pump
Savings have been calculated only for a 50C drop
Benefits
Annual energy savings of Rs. 2.28 Lakhs can be obtained by
implementing this proposal. The investment required for insulating the
line would be Rs. 1.00 Lakhs with a simple payback period of 6 months.
AVOID HEAT LOSS

TREATMENT PLANT
FROM
TANKS
IN
SHELL
During the detailed energy audit conducted at J K Fenner (India) Ltd.,

Patancheru, the shell treatment plant was explored in detail for energy
saving opportunities.
Present Status
The shell treatment plant consists of 13 tanks which are used to clean and
coat shells. Out of these, 5 tanks use the process steam for heating
application.
1. Degreasing tanks 2 tanks
2. Phosphating tanks 2 tanks
3. Passivasing tanks 1 tank
The tanks surface temperature was measured with a Pyrometer and the
following were the observations:
Tank
Degreasing Degreasing Phosphating Phosphating Passivasing

-1
2
-1
-2
Bigger
Side
length
Temp.
(0C)
81
48
90
90
65
Smaller
Side
length
Temp.
(0C)
48
48
66
67
40
The tanks, being at a higher temperature than the ambient temperature

emit infrared radiations. This heat transfer is directly proportional to the
temperature of the body to the power of four. Hence the losses increase
exponentially with any difference in temperature.
The collective surface area of all the tanks together is 7.9
radiation losses are 1270 kcal/hr.
2 and the total
Thus there is scope to reduce steam consumption by either insulating the

tanks or applying the nansulate paint to decrease the radiation losses.
Recommendations
Option-1:
Install glass wool insulation for all the 5 tanks
Option-2:
Apply Nansulate Paint for reducing the radiation losses
Benefits
Annual energy savings of Rs. 0.53 Lakhs can be obtained by
implementing either Option-1 or Option-2. The investment required for
installing glass wool insulation for all 5 tanks is Rs. 0.64 Lakhs with a
simple payback period of 15 months. The investment required for
applying nansulate paint for all 5 tanks is Rs. 0.7 Lakhs with a simple
AVOID
COMPRESSED
TREATMENT PLANT
AIR
USAGE
IN
SHELL

Patancheru, the shell treatment plant was explored in detail for energy
Present status
Currently Compressed air is used for aeration in the treating tanks in the
Shell treatment plant. The diameter of the compressed air supply pipe is
2.5 cm and the estimated velocity is 5 m/s. The compressed air was
estimated at 31 CFM.
Usage of compressed air is not needed for the purposes of aeration in the
tanks and can be replaced with blowers instead . Aeration as a process
requires flow of air at a pressure to overcome the pressure of the liquid.
In this scenario, quantity of air is more important than the pressure. 0.10.2 bar pressure would be sufficient for aeration but currently air at
pressure of 6 bar is being used. The comparison between the specific
energy consumption for compressed air and blower air is given below:
SEC of the Compressor 0.19 kW/CFM
SEC of Blower 0.05 kW/CFM
By replacing the compressed air with blower air will reduce in the
operating specific energy consumption by 0.14 kW/CFM
Thus there is good potential to save energy by installing blowers for the
aeration in place of compressed air usage.
Recommendations
Install blowers to replace compressed air usage
Specification of the blowers should be:
o
53 m3/hr, 0.1 kg/cm2
Benefits
project. The investment required for the Blowers is Rs. 0.60 Lakhs, with
a simple payback period of 12 months.
REPLACE THERMIC FLUID HEATER WITH ELECTRIC

HEATING PROCESS IN OLD OIL SEAL SECTION
Patancheru, the Old Oil Seal Section was explored in detail for energy
Present status
A Thermic Fluid Heater installed in the Old Oil Seal Section to provide hot
thermic fluid (Therminol - 55) to 20 oil seal moulding machines. The rated
capacity of the TFH is 2,00,000 kcal/hr.
The TFH operates in on/off mode interlocked with the thermic fluid outlet
temperature. The set points for the on/off operation are given below:
On at 206 0C
Off at 239 0C
The daily consumption of diesel for the TFH is 390 litres/day at the cost
of Rs. 59.7/litre. This accounts to an operating cost of Rs. 23,283 per day
and Rs. 69.84 Lakhs per year.
There were originally 23 oil seal moulding machines utilizing hot thermic
fluid, but plant has taken a trial of retrofitting three machines with electric
heaters to replace the thermic fluid requirement. CII congratulates
plant team for this excellent step in energy conservation.
The power consumption of the electric heater retrofitted machines was
measured and found to be 4.5 kWh per hour. This accounts to an
operating cost of Rs. 15,595 per day and Rs.46.78 Lakhs per year.
From the discussions with the plant team, it was understood that the
plant has been planning to discard the old oil seal section. The payback
period of this proposal is only 5 months. If decision to discard old oil
section takes more than 5 months, there is good potential to reduce
energy consumption by retrofitting with electric heaters.
A secondary option is to replace the thermic fluid heater with a
wood/briquette fired TFH of same capacity. Due to the relatively less cost
of wood, there is potential to install and operate a Wood fired TFH to
provide hot thermic fluid to the Moulding machines.
Recommendations
We recommend the following
Option 1:
Retrofit Moulding Machines with Electric Heaters and eliminate thermal
heaters
Option 2:
Replace existing TFH with new Wood fired Boiler of the following
specifications:
o 2 lakh kcal, 65 % Efficiency
Benefits
Option 1
project. The investment required for retrofitting electric heaters is around
Rs. 10.00 Lakhs with a simple payback period of 5 months.
Option 2
project. The investment required for new wood fired TFH is around Rs.
10.00 Lakhs with a simple payback period of 3 months.
REPLACE FO BOILER WITH WOOD/BRIQUETTE FIRED

BOILER
Patancheru, the boiler & steam system were studied for energy saving
potential.
Present Status
A 3 Ton Furnace oil-fired boiler and a 2 Ton Furnace oil fired boiler are
generate of around 1.6 TPH of steam at 14 bar for various users in the
plant. The parameters required by the different areas are as given below:
HRC section for V Belt Curing 12 bar
Due to relatively inexpensive nature of wood, there is potential to reduce
operating cost by installing and operating a wood/briquette fired boiler of
similar capacity instead of the Furnace oil fired boiler. The comparison of
operating costs of 3 T FO Boiler and Wood Fired Boiler is given below:
Parameters
Fuel Consumption per
day
Furnace Oil Boiler
Wood Fired Boiler
2,200 litres
14,521 kg
Fuel Unit cost
Rs. 42.7/litre
Rs. 6/kg
Cost per Mkcal

(Rs/Mkcal)
Rs. 4420
Rs. 1715
Fuel Cost per day
Rs. 93,940
Rs. 87,126
Annual Fuel Cost
Rs. 281.82 Lakhs
Rs. 261.38 Lakhs
Only one user HRC section is using 12 bar pressure steam. From the
discussions with the plant team, it was understood that the plant is
planning reduction in roller diameter to reduce required pressure to 7.5
bar. After this modification, the maximum pressure of steam required
would be 8 bar. Then there would be scope to go for a 10 bar boiler.
Recommendations
Install and operate Wood/Briquette fired Boiler instead of 3T Furnace
Oil Boiler
o 3 TPH, 85 % Efficiency
The savings were calculated for 3 TPH steam generation while the
actual generation is only 1.4-1.6 TPH.
Benefits
project. The investment required for installing a wood fired boiler is
around Rs. 20.00 Lakhs. The simple payback period is 12 months.
OPTIMIZE THE OPERATION OF THE PUMPS IN THE

RO PLANT
Present status
During the detailed energy audit study at JK Fenner (India) Ltd.,
Patancheru detailed study was carried out on pumps of the reverse
osmosis circuit for identifying possible energy saving opportunities.
There are two HP pumps in the reverse osmosis plant. Pump 1, supplies
raw water from the tank to NGMF and ion exchange units and pump 2
supplies water into the reverse osmosis membrane. The water after
treatment is collected in the RO water storage tank.
Raw
Wat
er
RO Rejects
0.8 m3/hr
Recirculat
ion
0.8 m3/hr
45%
Ion
Exchan
ge
NGM
F
0.9
bar
40%
1.96
Pump
m3/hr
2
RO Water
Outlet
0.35 m3/hr
1.96
3
m
/hr
Pump
1
The design parameters of Pump 1 are:

Head
: 32 m
Speed
: 2760 rpm
Power
: 1.1 kW
Volumetric flow
: 3.96 m3/hr
The operating parameters of Pump 1 are:

Volumetric flow
: 1.96 m3/hr
Head
: 30 m
Power
: 1.5 kW
RO
Wat
er
Efficiency,
: 11.76%
Throttling
: 40% open
Pump 1 is operating with 40% valve throttling. Valve throttling indicates

that the pump was designed for higher rating but used for lower
capacities. Due to mismatch between the design and operating
parameters, the operating efficiency of pump 1 shifted to lower efficiency
zone.
The design parameters of Pump 2 are:
Pressure
: 22 bar
Power
: 3 kW
The operating parameters of Pump 2 are:

Throttling
: 45% open
Operating pressure
: 8 bar
Recirculation
: 41%
From the discussions had with the plant team during the audit, we
understood that the pump 2 has to operate with wide range of pressures
due to the membrane condition. The operating pressure range varies from
7.0 kg/cm2 (fresh membrane) to 15 kg/cm2 (membrane in chocked
condition).
Due to this the pump was design for higher head for meeting the
maximum operating head. Due to this the pump 2 should operate with the
valve throttling to meet the requirement at a given point of time. Valve
throttling increases the pressure drop across the control valve. This
pressure drop intern increases the excess power consumption of the
pump 2.
It is also observed that there is 41% water recirculation back to the pump
2 inlet.
pump 2 by installing VFD and operating the pump 2 in closed loop with
the header pressure. With the support of VFD we can reduce recirculation.
Recommendation
Case 1: We recommend the following for Pump 1
Install correct size pump with a design efficiency of more than 60%.
The recommended specifications of the new pump are:
Volumetric Flow
: 1.2 m3/hr
Head
: 3 bar
Efficiency
: >60%
Case 2: We recommend the following for Pump 2

Install correct size pump with a variable frequency drive (VFD) for the RO
high pressure pump (Pump 2) and operate the pump 2 in closed loop with
the header pressure.
The recommended specifications of the new pump are:
Volumetric Flow
: 1.2 m3/hr
Head
: 15 bar
Efficiency
: >60%
Benefits
Case 1:
1.0 Lakhs for the new high energy efficient pump with a simple payback
period of 44 months.
Case 2:
Installing a correct size energy efficient pump with a VFD would result in
an annual energy savings of Rs. 0.71 Lakhs. This requires an investment
of Rs. 2.0 Lakhs for the new high energy efficient pump along with a
VFD with a simple payback period of 34 months.
Total annual savings of Rs. 0.98 Lakhs can be achieved by implementing
this project. The investment required is around Rs. 3.00 Lakhs. The
simple payback period is 37 months.
LONG TERM ENERGY SAVING PROPOSAL No. 1
INSTALL SOLAR STEAM GENERATOR TO SUPPLEMENT

FO BOILER
Patancheru, the opportunity to harness solar energy was explored.
Present Status
A 3 Ton Furnace oil-fired boiler and a 2 Ton Furnace oil fired boiler are
generate of around 1.6 TPH of steam at 14 bar for various users in the
plant. The parameters required by the different areas are as given below:
HRC section for V Belt Curing 12 bar
The average daily consumption of Furnace oil for the Boiler is 2200
litres/day at a cost of Rs. 42.7 per litre. This accounts to an operating
cost of Rs. 93,940 per day and Rs. 281.82 Lakhs per year.
On a long term basis, there is potential to install a solar
to supplement the Furnace oil boiler. The solar steam
supply steam to plant during the day and reduce
consumption. The steam generator supplies steam
pressure of 10 bar.
steam generator
generator would
the furnace oil
at a maximum
discussions with the plant team, it was understood that the plant is
planning reduction in roller diameter to reduce required pressure to 7.5
bar. After this modification, the maximum pressure of steam required
would be 8 bar. Then there would be scope to go for a 10 bar solar steam
generator.
Recommendations
Install and operate Solar Steam Generator instead of 3T Furnace Oil
Boiler during day time
The Furnace oil boiler is to be operated in on/off mode with an
interlock to the Header pressure
Benefits
project. The investment required for installing a solar steam generator is
around Rs. 800.00 Lakhs (Not Considering Govt. Subsidies). The simple
payback period is 8.6 years.
RENEWABLE ENERGY FOR LIGHTING

identify energy saving opportunities. The option of using renewable
energy for lighting was explored.
Present Status
The total lighting load at present was around 41 kW in the plant.
It is recommended to shift to renewable energy to cater to lighting load
requirement of the plant, in a phased manner.
The use of renewable energy for lighting reduces dependency on
conventional power. It contributed towards green energy and offers long
term benefits. Moreover, it helps in meeting requirements like RPO
(Renewable Purchase Obligation). J K Fenner team can further depict its
commitment towards energy efficiency and sustainability by opting to
renewable energy, setting an excellent example for other plants to follow.
The following approach can be followed to shift to renewable energy for
lighting:
Step 1: Installation of LED lamps in place of T8, T5, CFLs and other
conventional lamps, in accordance with the energy saving proposals
indicated earlier in the report. This reduces the lighting load significantly,
to around 15 kW from the present 41 kW.
Step 2: Solar powered street lighting: At present, 14 Nos of 65W LEDs
and 10 Nos of 90W LEDs are installed for street lighting. LED is the latest
energy efficient technology in lighting and CII congratulates the plant
team for taking up this excellent initiative as a futher energy conservation
opportunity, it is recommended to install a 2 kW capacity solar panel and
the requirements of street lighting can be met through renewable energy.
The following options can be explored:
Option 1 : Solar PV and Battery
A 2 kW roof top solar panel can be installed at the plant. The street
lighting requirement can be met through this.
Option 2 : Solar Mill
A Solar Mill is a hybrid system and taps solar and wind energy. It is
suitable for operation at 2 m/s to 17 m/s of wind speed. As it is a hybrid
system, the capacity utilization is also high.
Recommendation
It is recommended to opt for renewable energy for street lighting. A 2 kW
capacity solar panel/ solar mill can be installed and the requirements of
street lighting can be met through renewable energy.
Benefits
The estimated annual savings that can be obtained by shifting to solar
powered street lighting is Rs. 0.50 lakhs. The investment required is Rs.
4.00 lakhs.
Observation:
After the implementation of the above two steps, the use of renewable
energy can be further expanded, as detailed in the step 3:
Step 3: It is recommended to use renewable energy to meet the entire
requirement of plants lighting load (which should be around 15 kW after
the implementation of Step 1 of the proposal). A 15 kW solar PV/ solar
mill can be installed to cater to the entire lighting load requirement. The
investment required is around Rs. 40 lakhs and annual savings achieved
is around Rs. 5 lakhs.
REPLACE CFLS WITH LEDS

Present Status
CFL lamps were installed in the following locations:
FG Stores
: 28 Nos of 1 X 36 W lamps
Technical production office
EDC
The power consumption of these CFL lamps is around 2.9 kW.

It is recommended to replace these CFL lamps with 1X18 W LEDs. Light
Emitting Diode (LED) is the latest technology and offers the following
advantages:
Advantages of LED
Lower energy consumption: The energy consumption of LEDs is low
when compared to the other conventional sources for the same
amount of Lumen output.
Type of Lamp
Lumen/Watt
CRI
Life hours
Fluorescent lamps
50
Good (67-77)
5,000
LED lamps
120
Very Good (> 80)
50,000 1,00,000
High S/P ratio: LEDs have higher scotopic/photopic ratio (S/P ratio).
The eye has two primary light sensing cells called rods and cones
cones function in day light and process visual information whereas rods
function in night light. The cone dominated vision is called photopic
and the rod dominated vision is called scotopic. The S/P ratio indicates
the measure of light that excites rods compared to the light that
excites cones. In office environments, illumination is more effective if
the S/P ratio is high as it is under scotopic region. LEDs hence are
ideally suited for these applications as they have a high S/P ratio.
Longer life time: LEDs have longer life time of around 1,00,000
hours. This is equivalent to 11years of continuous operation or 22
years of 50% operation.
Faster switching: LED lights reach its brightness instantly upon

switching and can frequently be switched on/off without reducing the
operational life expectancy.
Greater durability and reliability: As LEDs are solid-state devices
and uses semi-conductor material; they are sturdier than conventional
sources that use filaments or glass. LEDs can also withstand shock,
extreme temperatures and vibration as they dont have fragile
materials as components.
Good Colour Rendering Index (CRI): The color rendering index,
i.e., measure of a light sources ability to show objects as perceived
under sunlight is high for LEDs. The CRI of natural sunlight is 100 and
LEDs offer CRI of 80 and above.
LED offers more focused light and reduced glare. Moreover, it does not
contain pollutants like mercury
LED technology is highly compatible for solar lighting as low-voltage
power supply is sufficient for LED illumination.
Recommendation
It is recommended to replace the existing 1X36 W and 2X36W CFL lamps
with 1X20 W LEDs. The energy saving that can be obtained by replacing
CFL lamps with LEDs is around 1.8 kW.
Benefits
The estimated annual savings that can be obtained by replacing CFL
lamps with LEDs is Rs. 0.35 lakhs. The investment required is Rs. 1.62
lakhs. The payback period is 55 months.
CHAPTER - V
MANAGEMENT ASPECTS & CONCLUSIONS

7.0
THE OBJECTIVES OF J.K.

PATANCHERU SHOULD BE
FENNER
(INDIA)
LIMITED,
Make Energy conservation a permanent activity at J.K. Fenner

(India) Limited, Patancheru.
To achieve lowest energy cost per unit of production.
The emphasis should be on production with quality and energy
efficiency rather than production with quality alone.
To achieve this objective, a firm top management commitment is
required at the highest level that the company wants to conserve
energy on a time bound basis.
The top priority is to implement the recommended proposals and
reap benefits.
7.1
Approach to An Energy Conservation Idea

Each energy conservation idea should be seen as an opportunity for
improvement. The approach must be on how to implement each
proposal and overcome the problems, if any. It is easier to say a
proposal is not possible or not implementable but the benefit comes
from the actual implementation, which needs lot of courage,
conviction and will power to implement.
7.2
Specific Recommendation
The J.K. Fenner (India) Limited, Patancheru team had already
done commendable jobs in Energy conservation. CII strongly feels
that Plant team should form an energy management committee
which involves senior persons from all departments and the
committee should continue the work and progress towards World
Class Energy Efficient Unit.
The main responsibility of implementing the proposals and
achievement of savings should be with the concerned operating and
maintenance personnel and not with the energy manager.
The immediate task of J.K. Fenner (India) Limited, Patancheru
should be to implement the identified proposals and get the
savings.
We would recommend, J.K. Fenner (India) Limited, Patancheru
to introduce a suggestion scheme for energy conservation. The
energy conservation committee should review all suggestions and

good proposals should be implemented. The originator for the good
suggestion, which has been successfully implemented, has to be
rewarded.
7.3
Assign Specific Responsibility

While the overall responsibility for energy conservation rests with
the top management, the concerned plants operating /
maintenance personnel should implement and report progress on
energy saving proposals.
Therefore, each energy saving proposal should be assigned to a
specific operating / maintenance personnel for implementation and
monitoring. The suggested format is enclosed as Annexure B.
Specific time bound action plan is required for implementation and
monitoring of energy saving proposals.
7.4
Monitoring Of Proposals
All the implemented proposals are to be monitored on a proposalby-proposal basis for actual achievement of savings on a monthly
basis.
7.5
Motivational Aspects
The successful management of energy depends on motivation of
technical personnel and their commitment. For this reason, J K
Fenner should carry out the following motivational aspects to
sustain energy conservation activities.
Send operating / Maintenance personnel for training programmes
in specific areas like
Fans & Blowers
Compressors
Heat Treatment system
Motors
Conduct in-house training programme on energy management.
Organise visits for executives to similar units to know the energy
conservation / process development, etc.
Present papers on energy conservation activities at the plant, in
other seminars.
7.6
Conclusions
J.K. Fenner (India) Limited, Patancheru team and CII

energy audit team together have identified 17 proposals for
implementation.
An annual savings potential of Rs. 90.22 Lakhs can be realised
by implementing the recommended proposals
Out of the total savings identified Rs. 1.54 Lakhs can be
achieved without any significant investment.
The remaining savings of Rs. 88.68 Lakhs can be achieved with
an investment of Rs. 65.85 Lakhs which will be paid back in 9
Months.
Implementation of identified proposals should be given top
priority and should be done step by step.
The major supplier address is enclosed as Annexure A
J.K. FENNER (INDIA) LIMITED, PATANCHERU
Assign specific responsibility for implementation of proposals
Monitor savings achieved on a proposal by proposal basis.
J.K. Fenner (India) Limited, Patancheru should have the
goal of sustaining the status of the best energy efficient plant in
the world.
Annexure
AnnexureA
SUPPLIER ADDRESS
VFD and other drives
1. Rockwell Automation India
Pvt. Ltd. (Allen-Bradley India
Ltd.)
C - 11, Industrial Area
Site - 4, Sahibabad
Ghaziabad - 201 010
Tel: +91 120 2895245, 2895252
Fax: +91 120 2895226
4. Danfoss Industries Pvt. Ltd.

296, Old Mahabalipuram Road
Sholinganallur
Chennai - 600 119
Tel : 044- 24503511-16
Fax: 044-24503521,18
E-mail:
danfoss.india@danfoss.com
2. Asea Brown Boveri (ABB) Ltd.

Plot No. 5 & 6, II Phase
Peenya Industrial Area
P B No. 5806, Peenya
Bangalore - 560 058
Tel: +91 80 2294 9585
Fax: +91 80 2294 9389
5. Larsen & Toubro Ltd

Headquarters
Mount Poonamallee Road
Manapakkam
P.B.No.979, Chennai 600 089
Tel: 044-22526000, 22528000
Fax: 044-2249 3317
3. Control Techniques India Ltd.

117/B, Developed Plot
Industrial Estate, Perungudi
Chennai - 600 096
Tel : 044 - 2496 1123/1130/1083
044 - 42152091
Fax: 044 2496 1602
Email:
ct.india@controltechniques.com
6. Eurotherm DEL India Limited

152, Developed plots Estate
Perungudi
Chennai 600096
Ph: 044 24961129, 24961186,
24961230
Fax: 044 24961831
E-Mail: info.in@eurotherm.com
7. Siemens Ltd., Bangalore -A&D

3rd Floor, Jyoti Mahal.No.49
St. Marks Road
Bangalore - 560 001
Ph: 080 - 22042000, 22219450,
22219460, 22042000
Fax: 080 22224131, 22489320
8. Schneider Electric India Ltd.

(Corporate Office)
A-29, Mohan Co-operative
Industrial Estate, Mathura Road
New Delhi, Delhi
India - 110 044
Tel: 011- 41590000, 42590000;
Fax: 011-41678010/11/12
Email: in-care@in.schneiderelectric.com
ENERGY EFFICIENT MOTORS

1.
2.
3.
6.
Kirloskar Electric Co.

Limited
Post Box No. 5555
Malleshwaram West
Bangalore 560 055
Tel : +91-80-23572111,
23371771
Fax : +91-80-23372488
Siemens Limited
Kalwe Works
Belapur Road
Thane 400 601
Tel: +91 22 27600001-04
Fax: +91 22 2762 3730
ABB Global Services Ltd.
#49, 2nd Floor,
E-Wing Khanija Bhavan Race
Course Road
Bangalore - 560 001
Tel: +91 80 22949150-53

Fax: +91 80 2353245
4.
Crompton Greaves Limited.

CG House, 6th Floor,
Dr. Annie Besant Road.
Worli, Mumbai - 400 030
INDIA.
Tel : +91 022 2423 7777
Fax : +91 022 24382288
5.
Bharat Bijilee Limited

37, Lady Curzon Road
II floor, Ramanashree Chambers
Bangalore 560 001
Tel: 080-25595547/ 25592646
Fax: 080-5592823
Email:
bblbangalore@blr.bharatbijlee.co
m
bblbangalore@gnblr.global.net.in
Baldor Electric India Pvt Ltd

19, Commerce Avenue
Mahaganesh Colony
Paud Road
Pune 411 038
Ph: 020 2545 2717 / 18
AUTOMATIC STAR-DELTA-STAR CONVERTOR

1. Vijay Energy Products Pvt.
Ltd.
Sagar Apartmenst G F
No 23 Gopalakrishna Road
T Nagar
Chennai 600017
Tel: 044 28156540, 28152906
Fax: 044 - 28152906
Email: vijayenergy@eth.net
2. Excellent Industrial
Instruments
1/63, E Type, SIDCO Nagar
Villivakkam, Chennai 600 049
Tel : 044 26172977
Fax : 044 26172531
Email: xlenergy@vsnl.net
Web: www.xlntenergy.com
LIGHTING ENERGY SAVER / LIGHTING TRANSFORMER

1. BEBLEC (INDIA) PVT. LTD.,
P.O. # 3411, 711, 6th " B" CROSS
3RD BLOCK, KORAMANGALA
BANGALORE - 560 034.
(KARNATAKA) INDIA
Phone: 91 - 080
25520831/25530831/25531752/
25535734
Fax: 91 - 080 25530807
e mail: info@beblec.com
2. Beblec (India) Pvt. Ltd.,
126, Sipcot Indl. Complex
Hosur - 635 126 (TN)
Tel : 91-4344276358/278658/276958/276959
Fax: 91-4344-276358/59
3. Beblec India Pvt. Ltd.
III, Anand Estates
J M C Compound
189/A, S G Marg
Mumbai - 400 011
Tel: 022 - 23080078/23073321
Fax: 022 - 23071494
Email: mumbai@beblec.com
4. ES Electronics (India) Pvt.

Ltd.
No. 438, 4th Main Road,
Nagendra Block,
B.S.K. Ist Stage, Bangalore 560050
Karnataka, India
Ph: 91-8026420623/624/26728761/26727
836
Fax: 91-8026420623/624/26728761/26727
836
Key Personnel
Mr. R. Sekar (Managing Director)
Mobile: +91 - 9448491548,
9844136209, 919448354504
5. Jindal Electricals
390 A, Industrial Area-A,
Ludhiana-141003
Phone : 0091-161-2607271,
2220035, 2600051
Fax : 0091-161- 2600385
E-Mail :je@jindalelectricals.com
6. Servomax India Limited
No 38 E.C.Extn, ECIL (post)

Hyderabad-500062. INDIA
Ph: 91 40 27123927, 27123279
www.servomax.net
7. Consul Consolidated Private Limited

9/6, Ist Street, Venkateshwara Nagar, Adyar
Chennai -600 020, Tamil Nadu, India.
Phone : +(91)-(44) 24403473/24403476
Fax : +(91)-(44)-24403470
E-mail : consul@vsnl.com, npkrishnan@consulindia.com
AUTOMATIC VOLTAGE CONTROLLER/STABILIZER
1. Consul Consolidated Private
Limited
9/6, Ist Street, Venkateshwara
Nagar, Adyar
Chennai -600 020, Tamil Nadu,
India.
Phone : +(91)-(44)
24403473/24403476
Fax : +(91)-(44)-24403470
E-mail : consul@vsnl.com,
npkrishnan@consulindia.com
2. Neel Controls
# 112, Minerva Industrial Estate
P K Road, Near Hercules Hoist
Mulund (W)
Mumbai 400 080
Ph: 022 2560 3371 / 2569
5047
Fax: 022 2568 3211
Email: harit@neel.in
3. Jindal Electric & Machinery
Corp.
C-57, Focal point, Ludhiana
141010
Ph: +91-161-2670250, 2676890,
2676968
Fax: 0161-2670252
E-mail: jemc@jindalelectric.com
4. Globe Rectifiers
Plot no. 211, sector-24
Faridabad-05, Haryana
Ph: +91-129-2237896/97,
4060708
Fax: 0129-2442072
E-mail:
globerectifiers@rediffmail.com,
gr@globerectifiers.com
5. Muskaan Engineers
423, Industrial area A
Ludhiana 03
Ph: +91-161-5088381
Fax: 5022381
Mob: 99157-03056, 94170-33948
E-mail:
info@muskaanengineers.com
6. Power Engineers &
Consultants
E-731, Phase-VIII, focal point,
Opp. Hero cycle Ltd,
Ludhiana-10
Ph: +91-161-3294989
Fax: 0161-2303021
Mob: 9317562989, 9872862989
E-mail:
business@powerengineer.biz
Energy Efficient Lighting

GE Lighting
Plot No. 42/1 & 45/14,
Electronic City - Phase II
Bangalore - 560100
Ph: +91-80-28528375-80 (Board
Numbers)
Lighting division Extn: 3128
Fax: +91-80-28528552
gelighting@geind.ge.com
Philips India Limited
Ashoka Estate, 9th Floor,
24, Barakhamba Road, Connaught
Place
New Delhi 110001
Ph: +91-1123353280
Ph: +91-1123321167
Fax: +91-1123314332
Email: s.k.dangi@philips.com
Asian Electronics Ltd.

D-11, Road No. 28
Wagle Ind. Estate
Thane - 400 604, India
Ph: 022 - 2583 5504 - 09
Fax: 022 - 2582 7636
Havells India Ltd. (Corporate

office)
E-1, Sector 59, Noida-201307
(U.P.), India
Ph: +91-120 - 2477777
Fax: +91-120 - 2583904 /
2588182 / 2477666
OSRAM India Pvt. Ltd.

Signature Towers, 11th Floor
Tower B, South City-I
Gurgaon 122001,
Haryana, India.
Tel: +91-124-4081581,
+91-124-4150100
Fax: +91-124-4081577
Havells India Ltd.

304, 308, 3rd Floor, 19th
Brigade Garden
Church Street, Bangalore-560001
Ph: 080-25594397-98
Fax: 080-25590130
E-mail: bangalore@havells.com
LED LAMPS
1. Binay Opto Electronics Pvt
Ltd.
44, Armenian Street
Calcutta 700 001
Ph: 033 22103807, 22429082,
22102039
Fax : 033 22421493
Email: binay@vsnl.com
info@binayLED.com
2. Kanmur Electronics (P) Ltd.

(LED & Motor Control)
44, Puramprakasa road
Balaji Nagar, Royapettah
Chennai-600 014
Tel: 91-44-28130353/91-4428131982
Fax: 91-44-28131982
Email: kanmur@vsnl.com
3. Kwality Electricals Pvt. Ltd.

Mfg. Solar Modules & LED
Lighting
3-6-145/9, Himayatnagar
Hyderabad 500 029
Ph: 040 2322 6889
Fax: 040 2344 0571
Email: gupta01@kwalityindia.com
kwality@kwalityindia.com
5. OSRAM India Pvt. Ltd.

Signature Towers, 11th Floor
Tower B, South City-I
Gurgaon 122001
Haryana, India.
Tel: +91-124-4081581,
+91-124-4150100
Fax: +91-124-4081577
4. CKON VISIONS PVT. LTD.

Oberoi Chambers I
4th Floor, OPP. SAB TV
New Link Road, Andheri (West)
Mumbai - 400053
Ph : 022 - 26733398, 26733472,
73
Fax : 022 26742965
E-mail: ckonimpex@vsnl.net,
ckonimpex@gmail.com
6. IC NASA LED Lights

Chandmor Agencies 10/76, Old
Anand Nagar
Next toReliance Energy,
Santacruz (E), Mumbai 400
055
Ph: 022 26101930 / 31 / 32,
Fax: 26102419
Contact Person Name
Mona 0 98201 22652
INDUCTION LAMPS
Bajaj Electricals Ltd
H. No. 6-3-1090/2, 3rd Floor
Vithal Das Chambers,
Rajbhavan Road, Somaji guda,
Hyderabad - 500 082
Phone : 040-23442932, 23442933,
23442934
Fax : 040-23302745
Email :
gv.reddy@bajajelectricals.com
naveenk@bajajelectricals.com
Excess (Excellence In Energy

Saving Solutions)
2nd Street, Kothari Layout, No.
11, Opposite Stock Exchange,
Singanallur
Coimbatore - 641 005, Tamil
Nadu, India
Mr. P V Venkatesh
Mob- 08376806624
CAPACITORS
1. Momaya Capacitors
401, Madhav Apartments
Jawahar Road, Opp. Rly. Stn.
Ghatkopar (East)
Mumbai - 400 077
Tel: 022 - 25168281/82,
65754001/02
Fax: 022 - 2516 0758
4. EPCOS India Private Ltd.
2. Baron Power
No. 3, Karpagambal Nagar,
Mylapore, Tamil Nadu, India
Ph: +91-44-24356383/84/86,
42131849/50
Fax: +91-44-24356385
3. Meher Capacitors
Mr. Omer Kaiser

(Business Development
Manager)
Meher Capacitors (P) Ltd.
#52/1, Basappa Rd.,
Bangalore
Karnataka, India - 560027
Ph: 080-57704962
Mob: 09845019200
Fax: 080-22225325
14/2, Brunton Road

Bangalore 560 025
Tel : +91 80 40390615,
40390640
Fax : +91 80 40390603
sales.in@epcos.com
Mehta Industrial Estate
Mathuradas Vasanji Road
Chakala, Anheri (East)
Mumbai 400093
Tel: +91 22 26 83 26 50
+91 22 26 83 26 51
Fax: +91 22 26 83 26 45
11th Floor
28 Dr. Gopal Das Towers
Barakhamba Road
New Delhi- 110 001
Tel: + 91 11 23 70 41 43
+ 91 11 23 70 41 44
Fax: + 91 11 23 70 41 46
ENERGY MANAGEMENT SYSTEMS

1. Enercon Systems Pvt Ltd.
23, KHB Light Industries Area
P B No.6418, Yelahanka
Bangalore
Tel : 080 8460666 / 8460555
Fax : 080 8460667
Email : marketing@enercon.co.in
2. Conzerv Systems Pvt. Ltd.

44P Electronic City East Phase
Hosur Road, Bangalore - 560 100
INDIA
Ph: 91 80 4118 9700
Fax: 91 80 4118 9729
91 80 41102659
email: contact@conzerv.com
3. KLG Systel
Plot No. 70A,
Sector - 34, Gurgaon - 122 004
Haryana (India)
Telephone: +91 (0) 124-4129900
Fax: +91 (0) 124-4129999
e-mail : klg.ho@klgsystel.com
Product Infra red sensor for lighting energy saving

Blue Technologies
61, shreepal chambers, 481/c shaniwar peth,
opp shaniwarwada, Pune - 411030, India.
Tel : +91 20 65209611 T/ F : 24468058,
Cell : +91 9371042444, 9326042444
bluesachin@gmail.com
Fixed Speed Drive (Power Boss)
ASR ASSOCIATES,
Street No.71/2, 21st A Main
Marenahalli,
JP Nagar 2nd Phase
Bangalore 560 078
Ph: 91 80 26493204
Fax: 91 80 2665 1157
Email: info@asrgroup.net
Flat belts
1. Elgi Ultra Industries Ltd.
India House, Trichy Road
Coimbatore - 641 018. India.
Phone: 91 (422) 2304141
Fax: 91 (422) 2301377
Email: info@elgiultra.com
2. Habasit-Iakoka Pvt. Ltd.

Goldwins
Civil Aerodrome Post
IND-Coimbatore, 641 014
Tel.: +91-(0)422-262 78 79, 262
84 20/21
Fax: +91-(0)422-262 72 14
Email:habasit.iakoka@habasit.com
Cogged flat Belts

K. K. Rubber Company (India) Pvt. Ltd.
51, Rani Jhansi Road
New Delhi 110055
India
Telephone: +91 11 23619942, 23531215
23612072, 23679045
Fax: +91 11 23621862
Email: sales@kkrubber.com
Fenner India Ltd
Khivraj Complex II
V Floor, 480, Anna Salai
Nandanam, Chennai - 600 035
India
Tel: +91-44-24312450 to 57
Fax: +91-44-24349016, 24320193
ptd_mhq@fennermail.com
Agitators
1. Fluidyme Technologies
E-2/4, Popular Prestige,
Near Highway Bridge, Warje,
Pune-411058
Maharashtra, INDIA
TeleFax : +91-20-25293397
Mobile : 09422009479
E-mail :fluidyme@sanchaernet.in
fluidyme@yahoo.co.in
2. Pinnacle Equipments
Gat No - 103, Jyotiba Nagar
Talawade Road, Pune
Maharashtra - 412 114
Ph: 020-27690413/27690890 /
32661602
Fax: 020-27690413/32661602
3. Indofab Industries
Street Address: C/3, Hatkesh
Udyog Nagar
City: Thane
Maharashtra 400 606
Ph: + (91)-9820077092
4. Elof Hansson (India) Pvt. Ltd.
Old No 11, New No. 23
2nd Main Road
Raja Annamalai Puram
Chennai - 600 028
India
Ph: +91-44 461 7901/ 7905
Fax: +91-44 461 7907 / 790
Automatic Power Factor Controllers / Harmonic Filters

Baron Power Ltd
1, Second Cross Street
Seethamma Colony Extension
Teynampet, Chennai - 600018
TamilNadu, India.
Office: 044-24356383/84&86 /
42131849/50, Fax: 044-24356385
Office Mobile: 93810 47234
(Marketing), 93828 21143
(Technical)
Email: baronpower@vsnl.net
baronpower@satyam.net.in
corporate@baronpower.com
Crompton Greaves Limited.
CG House, 6th Floor
Dr. Annie Besant Road
Worli, Mumbai - 400 030
India
Tel: +91 022 2423 7777
Fax: +91 022 2423 7788
Cummins India Limited

Power Generation Business Unit
35 A/1/2 Erandawana
Pune 411 038
Ph: 020 6602 7525
Fax: 020 6602 8090
Neel Controls
#112, Minerva Industrial Estate
P K Road, Near Hercules Hoist
Mulund (W), Mumbai 400 080
Ph: 022 2560 3371 / 2569 5047
Fax: 022 2568 3211
Contact Person
ABB Limited
Khanija Bhavan, 2nd Floor
East Wing, No. 49, Race Course Road
Bangalore - 560 001
Ph: 080 - 22949150 to 54
Fax: 080 - 22949148
Mr. S Ravichandran
General Manager
Mob: 098220 93785
Email:
subramaniam.ravichandran@cummin
s.com
UPS
APC
# 16, Row House, Goyal Inter City
Behind Drive in cinema, Thaltej
Road, Thaltej
Ahmedabad, Gujarat 380 054
India
Ph: (079) 2684 0124/ 324
APC
# 5, Lake Avenue,
Near Mudiali Bus Stop
Kolkata, West Bengal 700 026
India
Ph: (033)2465 5519, 2463 0064
Numeric Power Systems Ltd

"Numeric House"
No 5, Sir P.S Sivasami Salai
Mylapore, Chennai - 600 004, India.
Phone: 91-44-2499 3266 (10 Lines)
Fax: 91-44-2499 5760, 24998210
Email:
npsl.corporate@numericups.com
Emerson Network Power

Plot No. C - 20, Road No.19
Wagle Industrial Estate
Thane (West), PIN - 400604
Maharashtra
Tel: 022 67208000/8002/7800
Fax: 022 - 25828358, 25800829,
25824286
Consul Consolidated Private Limited

9/6, Ist Street, Venkateshwara Nagar, Adyar
Chennai -600 020, Tamil Nadu, India.
Phone: + (91)-(44) 24403473/24403476
Fax: + (91)-(44)-24403470
E-mail: consul@vsnl.com, npkrishnan@consulindia.com
Waste Heat Recovery

Thermax Ltd.
Dhanraj Mahal, 2nd Floor
Chatrapati Shivaji Maharaj Marg
Nr. Gateway of India
Mumbai - 400 039
Ph: 022 - 22045391, 22045324
Fax: 022 22040859
Chennai - 600 018

Tel: 04424303400, 24353831-4
Fax: 04424353841
Thermax Limited
6-3-649, Nalanda Complex
2nd Floor, Somajiguda, Behind
Medinova
Hyderabad - 500 482
Ph: 040-23310254, 23312013
Fax: 040-23312335
Thermax Limited
Process Heat Division
Fathima Akhtar Court
3rd Floor, 453, Anna Salai
Thermal Systems (Hyd) Pvt. Ltd.
Plot No.1, Apuroopa Township
IDA, Jeedimetla
Hyderabad - 500 055
Tel: 91-040-23091801-06
Fax(s): 91-040-23097433
info@thermalindia.com
Megatherm D'tech Pvt Ltd

Plot 150, Perungudi Industrial Estate
Perungudi, Chennai - 600096. INDIA
Phone: 91-44-65479255 / 42629008
Email ID : govinmega@sify.com /
govinmega@gmail.com
OIL FIRED THERMOPAC/AQUATHERM SYSTEM
Thermax Babcock & Wilcox

Limited
Energy Building, D1 Block, Plot No.
7/2
RD Aga Road, MIDC, Chinchwad,
Pune 411019,
Tel: 020 6612 6464, 66126411
Fax: 020 6612 6612
Aquatherm Engineering
Consultants
St. Thomas Building
Luz Church Road
Chennai
Tamil Nadu
India.
Ph: 91-44-24660462, 24994032,
24660464, 91-44-24996085
Email: auather@vsnl.com
aquather@eth.net
ECONOMISERS
Megatherm Engineers & Consultants Pvt. Ltd.
33, Oliver Road, Mylapore
Chennai - 600 004
Tel: 044 2498 7614/38/58
Fax: 044 2498 7638
Furnace
Thermal Systems
Plot No.150, SIDCO Industrial Estate (NP)
Ambattur, Chennai - 600 098
Tamil Nadu, India
Ph: 044 - 42140877, 26257625, 26255790
Fax: 044 - 42140977
Email: thermalsystems@yahoo.com
thermalsystems@airtelbroadband.in
Radiant Recuperative Heaters
Thermax Babcock & Wilcox Limited
Energy Building, D1 Block, Plot No. 7/2
RD Aga Road, MIDC, Chinchwad,
Pune 411019,
Tel: 020 6612 6464, 6612 6411
Fax: 020 6612 6612
Frp Blades For Mancoolers & Air Washers
ENCON (INDIA)
2B/06, Shivkripa,
N. C. Kelkar Road, Dadar (West)
Mumbai - 400 028, India.
Ph: +91 22 2437 2949 / 2430 6578
Fax: +91 22 2431 0992 / 2432 1929
Email: enconindia@vsnl.com
Email: akrai@encongroups.com
Amalgamated Indl. Composites P. Ltd.
Unit No.111 /112, Ashok Service Industrial Estate
L.B.S. Marg, Bhandup (West)
Mumbai - 400 078. India
Tel: 022-25964566, Tele Fax: 022-25346920 / 25963611
Email: info@aicomposites.com
Compressors & compressed air systems

Elgi Industrial Complex
Trichy Road, Singanallur
Coimbatore - 641 005
India. Tel: 0422 - 2589555
Fax: 0422 2573697
Atlas Copco Compressor Sales
6-3-1191, 2nd Floor, Brij Tarang
Greenlands, Begumpet
Hyderabad - 500016
Tel: +91 40 32949090
Fax: +91 40 23417923
(Mr. Dhananjay Desai

Regional Manager)
Atlas Copco Compressor Sales
2nd Floor, Tellus Technologies Pvt
Ltd, 209/1B/1A, Range Hill, Pune
411020, Ph: +91 20 32949090
Fax: +91 20 27145778
Mob: +91 9823014158
Email: d.desai@in.atlascopco
Ingersoll-Rand (India) Ltd Air Center

Solitaire Corporate Park IV
Unit 411-412, 1st Floor
Andheri-Ghatkopar Link Road
Mumbai 400093
Chakala, Andheri (East)
Ph: 022-6697-5555
Fax: 022-6697 5566
Godrej Group EE services

Mr H N Daruwala
Godrej & Boyce Mfg. Co. Ltd.
Pirojshanagar, Vikhroli,
Mumbai - 400079,
Maharashtra,
India.
Ph: +91-22-6796 5656 / 67965959
Fax No. : 91-22-6796 1518
Denvik Technology Private Limited

H 11/5, Arundale Beach Road
Kalakshetra Colony
Besant Nagar, Chennai 600090
http://www.denvik.in
Contact Person
Vijay Krishna, Director, Business Development
Ph: 09840851800 Email: vijay@denvik.in
HOC Dryers
Gaso Energy Systems (I) Pvt. Limited
T-122 , M.I.D.C., Bhosari, Pune - 411 026
Tel. : + 91 20 2712 8823 / 3068 5256
Fax: 020 - 27119573
Email:kgiram@gasoenergysystems.com
Drytech Engineers
Sh. No. 12-15, Sapana Co.op. Hsg. Soc.,
Opp. Konark Vihar, Off. Pune-Satara Road
Dhankawadi, Pune - 411043.
Maharashtra, INDIA
Tel : +91-20-24371445, 24376601
Fax : +91-20-24376789
Email: drytechengineers@eth.net, vbk_drytech@yahoo.co.in,
jmd_drytech@yahoo.co.in, response@drytechengineers.com
Energy Efficient Pumps

Sulzer Pumps India Ltd.
9 MIDC, Thane Belapur Road
Digha, Navi Mumbai 400 708
Ph: + 91-22-65134321-28,
39130500
Fax: + 91-22-2760 6814
E-mail: spisales@sulzer.com
Grundfos Pumps India Private
Ltd.
118 Old Mahabalipuram Road
Thoraipakkam, Chennai 600 097
Tel: +91 44 2496 6800
Fax: +91 44 2496 6969
Kirloskar Brothers Ltd.
Udyog Bhavan, Tilak Road,
Pune 411 002 (India)
Ph: +91 20 24440770
4198,2444-0156
Email: kblin@kbl.co.in
Fax: +91
20 24440824,
2444-
Energy efficienct fans

Dustech Engineers Pvt Ltd
Contact Person : Mr R K Gupta [Dir]
Address : P-27 2nd Flr malviya Ngr Mkt
New Delhi - 110017,
Delhi,
India.
Telephone No. : 91-011-6686085
Aerotech Equipments & Projects (p) Ltd.
101-a, Ansal Sumedha, Raj Nagar Distt. Centre, Ghaziabad - 201001, Uttar Pradesh,
India.
91-120-2710513 / 2711513
TCF-NADI Industrial Fans Pvt. Ltd.
Ponniammanmedu
No. 34, G.N.T. Road
Madhavaram, Chennai, 600 110 Phone: 91-44-2553-2206
Fax: 91-44-2553-2205
Email: nadiair@vsnl.net
Website: www.nadiindia.com
Low pressure drop flow meters
Emerson Process Management (India) Private Ltd.
D-Wing, 2nd Floor, Modern Mills Compound
Sane Guruji Marg, Jacob Circle, Mahalaxmi
Mumbai 400011
India
Tel +91 22 5662-0566
Fax +91 22 5662-0500
Email : Marcom@EmersonProcess.co.in
Switzer Instrument Limited
9, South Boag Rd. T.Nagar,
CHENNAI (Madras) - 600 017 India
Phone : +91-44-2434 0999/3956/4321
Fax: +91-44-24347887
email: sales@switzerinstrument.com
Chandak Instruments Pvt. Ltd.
G-004, Smruti, Opp. Dhanwatey
National College, Congress Nagar,
Nagpur-440012 (India)
Phone : +91-712-2420025
Fax
: +91-712-2420026
info@chandakinstruments.com
www.chandakinstruments.com
Air conditioning system

United Engineering Corporation
147, R P Road, Secunderabad-500 003
Telefax: 2754-5501, 1113, 3559, 2753-8956
Email: uecajay@gmail.com & hyd2_uecajay@sancharnet.in
Visit: www.smartcool.co.in
Steam Turbines (Mini & micro)
Triveni Engineering & Industries Limited
12 A, Peenya Industrial Area Bangalore 560 058,
Tel: 080-28394721
Fax: 080-28995211-5949
Mr S N Prasad,
GM - Mktg & Sales
Ph: 080 28391624
Mob: 9845189472
Email: snprasad@tbg.trivenigroup.com
TurboTech Precision Engineering (P) Ltd.
No.28/29,2nd Main Road
Rajaji Nagar Industrial Town
Bangalore 560 044
Fax: 080 23404341, 23200789, 23307227
Email:turbo1@vsnl.com
Visit: www.turbotechindia.com
Transvector Nozzle
General Imsubs Pvt. Ltd.
3711/A, GIDC, Phase-IV, Vatva
Ahmedabad 382445, India
www.giplindia.com,info@giplindia.com
Ph: +91-79-2584 0845;
25842503; (M) 0 99984 20601
Computational Fluid Dynamics Study
Mech-Well Industries Ltd
7-A, Old Anjirwadi
Mazgaon, Mumbai 400 010
Contact No.:022-66200314 (Direct Line)
Fax No. 022-66200380
E-mail: mechwell@vsnl.com
Mr. Sanaka Prasad
CFD team leader
Satyam Intergrated Engineering Solutions - IES
Satyam Technology Center
Bahadurpally, Hyderabad
Mob: 9849273302
IES_Marketing@satyam.com
Insulations
Megha Insulations Pvt Ltd.
A-11/6th Floor, Dada Saheb Flats
Kalanala, Bhavnagar 364001
Ph: 0278-3004523/26
Fax: 0278-3004728
Email: mipl@meghainsulation.com
Contact Person
Mr H V Shah -98252-07723 & 94262-12823
Mrs. Madhu: 98795-46523
Energy Management Software

Manoj Telrandhe
Manager Knowledge Based Businesses & ITes
SEE-Tech Solutions Pvt. Ltd.
11/5, Lets Conserve, MIDC InfoTech Park
Near VRCE Telephone Exchange
South Ambazari Road, Nagpur-440 022
Mobile: +91-9975325831
Ph: 0712-2222177
Fax: 0712-2225293
Web: www.letsconserve.org
Email: utisave@gmail.com
seemil_ngp@sancharnet.in
Compressed Air Audit and Control Systems
1.
Godrej & Boyce Manufacturing Company Limited.

Godrej Electricals & Electronics, Plant - 1
Pirojshanagar, Vikhroli
Mumbai - 400 079, India.
Tel.: +91 22 6796 1700 / 1800
Fax: +91 22 6796 1525
Contact Details
Mr. Homi. N. Daruwalla
(Vice-President)
Godrej Electricals & Electronics
Tel.: +91 22 6796 2201
Email: hnd@godrej.com
Mr. Umesh V. Shah
(Chief General Manager)
Industrial Electronics & Automation
Tel.: +91 22 6796 2211
Email: uvs@godrej.com;
2.
Ingersoll-Rand (India) Limited.

Plot No. 35, KIADB Industrial Area
Bidadi, Bangalore - 562 109
Tel: +91 80 2216 6000
Fax: +91 80 2216 6022
Orchid Industrial Equiments & Energy Utility Services

New no 86, Velmurugan Complex
Arya Gowda Road, West Mamabalam
Chennai 600 033
Tele fax: 044 23712834
Email: orchidie@eth.net; orchidies@eth.net;
Mr S Baskaran
Mobile: 94440 10371
Suppliers for Computational Fluid Dynamics (CFD) Study and Analysis
Mahindra Satyam Technology Centre

Bahadurpally Village
R R Dist, Hyderabad 500 043
Telephone: +91 40 3063 5082
Mr Rahul S. Tamboli
Telephone: 040-3063-5271
Mobile: +91-998-550-6261
Mech-Well Industries Limited
Head Office: Contact person
Mr V T Jadhav
Marketing Executive
Mobile: 09223393614
7 - A, Old Anijrwadi, Mazgaon
Mumbai - 400 010
Tel: +91 - 22 - 2373 74 54
+91 - 22 - 2374 23 54
Fax: +91 - 22 - 2371 94 46
PL Engineering Limited
(A Punj Lloyd Group Company)
76 Institutional Area, Sector 32
Gurgaon - 122001, India
Contact Person
Mr Priya Ranjan Kumar
DGM - Business Development
Mob: 07411021920, Bangalore
Supplier for Paddle Mixers

BHS-Sonthofen (India) Pvt. Ltd.
6-3-252/1/7/B, 3rd floor
Opp. IIPM, Erramanzil
Banjara Hills, Hyderabad- 500 034
Tel: +91-40-23315341 /45
Fax: +91-40-23315346
Contact Person
Mr Neelesh Desai
National Sales Manager
Mobile no: +91 - 9350990680
Sanghavi Engineering
121, C.I.E, balanagar Expansion
Gandhinagar, Hyderabad -500 037
Andhra Pradesh
Ph 040-23086631/33
E mail se@sanghavigroup.com
Conveyor Belts
Mr Vijay Kumar K
Regional Manager-South
Phoenix Yule (P) Limited
1st Floor, P M Modi, Commercial Complex
Karbala Maidan, 5-4-187/6
Mahatma Gandhi Road
Secunderabad 500 003
Ph: 040-66324542, 66314542
Mob: 0-93932 23112
Email: pylhyd@yahoo.co.in; kandukurivijay@yahoo.com
Disclaimer
While every care has been taken in compiling this list, Confederation
of Indian Industry does not accepts any claim for compensation, if any
entry is found to be wrong, abbreviated, omitted or inserted
incorrectly either as to the wording space or position in the list. While
attempts are being made continuously to make the list as elaborate,
as possible CII wishes to inform that neither the list of technologies
nor list of suppliers for a given product / technology is
comprehensive. The list is only an attempt to create awareness on
energy conservation and sharing of best practices being adopted in
Indian Industry.
Annexure-B
FORMAT FOR MONITORING THE IMPLEMENTATION OF ENERGY SAVING PROPOSALS
Sl.
No
Energy Saving Propsals
Annnual
Savings
(Rs.Lakhs)
Investment Payback
Required
Period
(Rs.Lakhs) (Months)
Replace the 1x36W And 2x36W T8 Lamps

with 1x20 W LEDs
5.83
9.8
20
Replace the 1x28W And 2x28W T5 Lamps

with 1x20 W LEDs
0.24
0.66
33
Optimize the Lighting Voltage in the Plant
1.85
1.75
12
Switch of Lights in Canteen During Day

Time
0.03
0.00
Install New Energy Efficient Pump in 100

T.R Cooling Tower
2.21
0.8
Replace Inefficient Raw Water

Transportation Pump with Energy Efficient
Pump
1.91
1.50
10
Replace Aluminum Blades with FRP Blades

for Cooling Tower Fans
0.06
0.10
20
Person/
Department
Responsible
Target
Date
Remarks
Optimise the Operation of the Chilled

Water System
11.05
7.00
Excess Air Optimization in 3 Ton Boiler
7.20
6.00
10
10
Excess Air Optimization in Thermic Fluid

Heater
1.51
0.00
11
Avoid Idle Steam Flow Through VAM
10.45
3.0
12
Insulate Suction Pipeline of Feed Pump for

3-Ton Boiler
2.28
1.00
13
Avoid Heat Loss From Tanks in Shell

Treatment Plant
0.53
0.70
16
14
Avoid Compressed Air Usage in Shell

Treatment Plant
0.60
0.60
12
15
Replace Thermic Fluid Heater with Electric

Heating Process in Old Oil Seal Section
23.00
10.00
16
Replace FO Boiler with Wood/Briquette

Fired Boiler
20.44
20.00
12
17
Optimize the Operation of the Pumps in

the RO Plant
Total
0.98
3.0
37
90.22
65.85
93.5
800.00
104
.50
4.00
96
0.35
1.62
55
Long Term Proposal
Install Solar Steam Generator to

Supplement FO Boiler
Renewable Energy for Lighting
Replace CFLs with LEDs
Backup Calculations
REPLACE THE 1X36W and 2X36W T8 LAMPS WITH 1X20

W LEDs
Patancheru, a detailed study of plant lighting load was carried out to identify
energy saving opportunities.
Present Status
The T8 lamps were installed in the plant at the following locations:
1X36 W2X36W
Nos
Nos
S.No. Location
1
Heavy Plant
Power in Operating
kW
Hours per day
14
1.22
16
V Belt
21
115
9.04
16
Old Oil seal
20
61
5.11
16
New Oil seal
23
1.66
12
Old STP
0.36
10
Grinding room
0.65
12
Buffing sheds
0.72
22
MRPS
16
1.37
18
Eaton
12
0.94
10
10 RM stores
20
1.15
11 FG stores
75
2.84
10
0.22
12
11
0.40
12
14 RMC Lab
21
1.58
12
15 Generator shed
0.04
12
16 Technical lab
0.43
12
0.86
12 Boiler house
Air
compressor,
13 chilling plant, rig
test room
17 Canteen
18 Time office
0.43
Total kW
Power consumption of T8 lamps
12
Say 29 kW
say 29 kW
Proposed Scenario
It is recommended to replace these T8 lamps with 1X20 W LEDs.
Power consumption of LEDs
Savings
490 Nos X 20 W each
9.8 kW
29 - 9.8 kW
Say19 kW
Annual Savings is calculated based on operating hours at individual locations.

Sl
No.
Dept.
1x36 W
TL
2x36 W
TL
Burning
Hrs in
day
Burning
Hrs in
night
Total
burning
hours
Total
kW
Saving
s in kW
Heavy Plant
14
12
16
1.224
0.824
V Belt
21
115
12
16
9.036
6.316
Old Oil Seal
20
61
12
16
5.112
3.492
New Oil
Seal
23
12
12
1.656
1.196
Old STP
10
10
0.36
0.22
4765.2
12
12
0.648
0.468
12164.
3
10
12
22
0.72
0.48
22873
7
8
Grinding
room
Buffing
sheds
Savings
in Rs
28556.
5
21888
7
12101
9
31086.
4
MRPS
16
12
18
1.368
0.928
36180.
9
10
Eaton
12
10
10
0.936
0.656
14209
11
RM Stores
20
1.152
0.632
12
FG Stores
75
10
2.844
1.304
13
Generator
shed
12
12
0.036
0.016
14
Boiler House
12
12
0.216
0.136
15
Air
Compressor
12
12
0.072
0.032
5475.6
5
28244.
6
415.87
2
3534.9
1
831.74
4
1247.6
2
2495.2
3
16
Chilling
plant
12
12
0.108
0.048
17
Rig Test
room
12
12
0.216
0.096
18
RMC Lab
21
12
12
1.584
1.124
29215
19
Technical
Lab
0.432
0.312
6082.1
3
20
Canteen
12
0.864
0.624
8109.5
21
Time Office
12
12
0.432
0.312
8109.5
29.016
19.216
583503
TOTAL
174
316
Annual Savings
Rs. 5.83 Lakhs
Investment (Rs. 2000 for LED)
490 Nos X Rs. 2000/LED
Rs. 9.80 Lakhs
(Investment) X 12 months
(Savings)
Rs. 9.80 Lakhs X 12 months

Rs. 5.83 Lakhs
20 months
Payback period
REPLACE THE 1X28 W and 2X28 W T5 LAMPS WITH

1X20 W LEDs
Present Status
11 Nos of 1 X28 W T5 lamps were installed in the power house and 22 Nos of
2 X 28W T5 lamps were installed in Heavy plant.
The power consumption of these T5 lamps is around 1.5 kW.
Power consumption of T5 lamps
(11 X 28) W + (22 X 2 X 28) W
1.54 kW
Say1.5 kW
Proposed Scenario
It is recommended to replace these T5 lamps with 1X20 W LEDs.
Power consumption of LEDs
Savings
33 Nos X 20 W each
0.66 kW
1.54-0.66 kW
0.88 kW
The operating hours for T5 lamps in Heavy plant area are indicated as 16
hours a day, by the plant team. The operating hours for the lamps in Power
house are 12 hours a day. Considering plant operation around 300 days
Annual Savings in Rs.(Heavy plant) =
=
Annual Savings in Rs.(Power house) =
=
0.088 kW X 4800 hours X

Rs. 7.22/kWh
Rs. 0.03 Lakhs
0.792 kW X 3600 hours X
Rs. 7.22/kWh
Rs. 0.21 Lakhs
Total Annual Savings in Rs.
Investment (Rs. 2000 / LED) =
Payback period
Rs. 0.24 Lakhs
Rs. 0.66 Lakhs
(Savings)

Rs. 0.24 Lakhs
33 months
OPTIMIZE THE LIGHTING VOLTAGE IN THE PLANT

Present Status
The lighting load is catered by a separate feeder. The lighting load was
measured during day time and night time.
Day time
Night time
Voltage
Current
kW
R-phase
239.0
53.3
11.2
Y-phase
238.3
60.1
13.55
B-phase
238.5
48.2
9.84
R-Phase
238.2
49.0
10.80
Y-Phase
240.6
76.1
17.85
B-Phase
241.1
51.0
12.41
The lighting voltage is maintained around 239 V. Present lighting circuit

voltage is being maintained on higher side. The optimum voltage for
lighting should be in the range of 210-220 V. It is recommended to
install a lighting transformer and maintain the output voltage at 220 V.
Reduction in Voltage %
(239 V 220 V) X 100

220 V
=
8.63
Say 8 %
1 % reduction in voltage results in power reduction by 1%.

Reduction in kW
=
0.08 X (41 kW)
Say 3.2 kW
Savings in kW
=
3.2 kW X 8000 hrs X Rs. 7.22/kWh
=
Rs. 1,84,832
Say Rs. 1.85 Lakhs
Investment for transformer
Rs. 1.75 Lakhs
Payback period
(Savings)

Rs. 1.85 Lakhs
12 months
SWITCH OF LIGHTS IN CANTEEN DURING DAY TIME

Patancheru, it was observed that lights were on during day time in canteen,
at the dining area. 8 Nos of 2X36 W T8 lamps were switched on. As there is
adequate day lighting in the canteen, it is recommended to switch off these
lamps.
Recommendation
It is recommended to switch off these lamps, as there is adequate day
lighting.
Power consumption of the T8 lamps
=
=
2 X 36 W X 8 Nos
0.58 kW
Savings in kW
0.58 kW
Annual Savings in Rs.
=
=
=
0.58 kW x 3 hrs/day
x 300 days/year x Rs. 7.22/kWh
Rs. 3,768/Rs. 0.03 Lakhs
Nil
Investment
INSTALL NEW ENERGY EFFICIENT PUMP IN 100TR

COOLING TOWER
Present Status
The cooling water supply system is explained by the following diagram:
Cooling
Tower
31.2 m3/hr
CT Pump
230C
1.2 bar
5.37 kW
60% open
16.5 m3/hr
Hot Well
Process Pump
25.60C
It was observed that 4 % of water was being re-circulated back into the hot
well at the outlet of the cooling tower pump. The remaining water was supplied
to the cooling tower with the pipeline being throttled to a 60% open position.
It was also observed that only 16 m 3/hr water was being pumped to the plant
by the process pump and an excess 14.7 m 3/hr (45 % of the water being
pumped) water is being re-circulated back to the hot well. This shows that the
water supplied to the cooling tower is more than that of the water supplied to
the plant.
Calculations
Detailed measurements were carried out to measure the energy consumption
and operational efficiencies.
The following are the measured operating values:
Operating flow
32.6m3/hr
Operating head
12 m
Operating power
5.37 kW
Present operating efficiency
32.6 m3 / hr x 12 m x 100
3.6 x 102 x 0.90 x 5.37 kW
22%
Step - 1
If the impeller of the pump is trimmed to 10 percent, the power consumed by
the pump is reduced proportionally
Operating power of the pump
5.37 kW
Power consumption after trimming =

=
5.37 kW x (0.9)5
3.17 kW
Savings
=
=
5.37 kW 3.17 kW
2.2 kW
Annual savings
=
=
2.2 kW x 7000 hr x Rs 7.22 / kWh

1.11 Lakhs
Investment
0.2 Lakhs
Simple payback period
0.2 Lakhs x 12 months

1.11 Lakhs
2 months
Step - 2
If a correct size pump with an operating efficiency more than 70% at the
present operating parameters is installed,
The recommended specifications of the new Cooling tower pump can are:
Volumetric Flow
20m3/hr
Head
12 m
Power
1 kW
Savings
=
=
5.37 kW 1 kW
4.37 kW
Annual savings
=
=
4.37 kW x 7000 hr x Rs 7.22 / kWh

2.21 Lakhs
Investment
0.8 Lakhs

2.21 Lakhs
5 months
REPLACE INEFFICIENT RAW WATER TRANSPORTATION

PUMP WITH ENERGY EFFICIENT PUMP
Present Status
This process is represented with the help of the following diagram:
19.76 m3/hr
6.81 kW
10 m
Cooling Return Water Sump
Hot Well of Cooling Tower
The design specification of return water supply pump is:

Design flow
: 65 m3/hr
Design head
: 35 m
Design power
: 11 kW
Calculations
The operating parameters of the pump are:
Operating flow
19.76 m3/hr
Operating head
15 m
Operating power
6.81 kW
It is observed that the design head and capacity of the pump is much higher
than the actual requirementdue to which the pump is operating at the lowest
efficiency zone.
=
=
19.76 m3 / hr x 15 m x 100
3.6 x 102 x 0.90 x 6.81 kW
13%
Specifications of the new high energy efficient pump are:
Volumetric Flow
20m3/hr
Head
15 m
Power
1.5 kW
Savings
=
=
6.81 kW 1.5 kW
5.31 kW
Annual savings
=
=
5.31 kW x 5000 hr x Rs 7.22 / kWh

1.92 Lakhs
Investment
1.5 Lakhs

2.21 Lakhs
10 months
REPLACE ALUMINUM BLADES WITH FRP BLADES FOR

COOLING TOWER FANS
Present Status
One cooling tower in the plant is running the CT fan with aluminium blades.
The present trend is to install fibre reinforced plastic (FRP) blades. A fan with
FRP blades has better aerodynamic properties and is more energy efficient and
less in weight compared to fan with aluminium blades.
The FRP blades will reduce the power consumption by 4%. This has been
operating successfully in many industries including Engineering, Process and
Chemical etc.
Calculations
Power consumed by the fan
3.18 kW
Replacing the aluminium blades with FRP blades will save upto 4 % of the fan
power
Savings
=
=
3.18 kW x 0.04
0.13 kW
Annual savings
=
=
0.13 kW x 7455 hr x Rs 7.22 / kWh

0.06 Lakhs
Investment
0.10 Lakhs

0.06 Lakhs
20 months
OPTIMISE THE OPERATION OF THE CHILLED WATER

SYSTEM
Present Status
Screw Chiller
Comp kW: 36.5
Chiller TR: 39.35
17.10C
Hot Well Pump
Cold Well Pump

2 bar
70 m3/hr
60% open
3.8 bar
49.8 m3/hr
Process
18.90C
180C
Hot Well
The plant has adopted a hot well & cold well system for the chiller system. The
return water from the plant is collected into the hot well and a hot well pump
takes the hot water and reduces the temperature in the chiller.
The design and operating parameters of the hot well pump are as follows:
Hot Well Pump
Head (m)
Flow (m3/hr)
Power (kW)
Design
18.5
72
7.4
Operating
20
70
8.01
Efficiency()
50%
The design specifications and the operating conditions of the process pump
are:
Process Pump
Head (m)
Flow (m3/hr)
Power (kW)
Design
31
93
10.5
Operating
39
49.8
8.9
Efficiency()
61%
Proposed System
Screw Chiller
New Pump with

VFD Control
60 m3/hr
17.10C
5 bar
To Process
18.90C
Hot Well
In this proposed system, the return water from the process accumulates in the
hot well. From the hot well, the new VFD operated hotwell pump will supply
water to the chiller and then to the process. This new hotwell pump will
operate in closed loop with the pumps discharge pressure and optimum flow
throughout the process will be maintained.
Calculations
Operating efficiency of Hot well pump

=
=
Operating efficiency of process pump
=
=
70 m3 / hr x 20 m x 100
3.6 x 102 x 0.90 x 8.01 kW
50%
49.8 m3 / hr x 39 m x 100
3.6 x 102 x 0.90 x 8.9 kW
61%
The recommended specifications of the new pump may be as follows:
Volumetric Flow
60 m3/hr
Head
60 m
Power
14 kW
Pump Savings
=
=
8.01 kW + 8.9 kW 14 kW
2.91 kW
The condenser measurements and the TR estimation are given below:

Chilled water inlet Temp
18.9 OC
Chilled water outlet Temp
17.1 OC
Temperature in Hot well
18.9 OC
Temperature in Cold well
18 OC
Delta T
1.8 OC
Water flow `
70 m3/hr
TR
39.35
kW/TR
0.92
Heat lost due to mixing
70 m3/hr x 1000 kg/m3 x 0.9 OC

x 1 Kcal / kgC
63000 Kcal / hr
=
TR Savings
63000 Kcal / hr
3024 kCal / TR
20.6 TR
Chiller savings
=
=
20.6 TR x 0.92 kW/TR

18.95 kW
Total savings
2.91 kW + 18.95 kW
21.86 kW
Annual savings
=
=
21.86 kW x 7000 hr x Rs 7.22 / kWh

11.05 Lakhs
Investment
3 Lakhs
Payback
3 Lakhs
x 12 months
11 Lakhs
4 months
EXCESS AIR OPTIMIZATION IN 3 TON BOILER

Present Status
The furnace oil feed is controlled in an Auto-mode for low flame and high
flame. The combustion air is also controlled by an auto damper. There is a
significant pressure drop across the damper irrespective of the firing scenarios.
The pressure required for the boiler varies between 100 & 150 mm WC for low
flame and high flame scenarios.
The blower has been designed for the higher head to circulate the combustion
air through air preheater and then to the burner but the air preheater was
bypassed.
FO
O2: 11 %
Temp: 210 oC
514 mm WC
Boiler
3 TPH
100 mm WC
Ambient air:
Low Flame Scenario
30 0C
The measured excess air % during the low flame scenario is 111%. Some
quantity of excess air is required for ensuring complete combustion of any
fuel. But the norm for excess air % required for furnace oil fired boilers is
around 15 %. The heat generated by the boiler is partly lost to the excess air,
resulting in an increase in fuel consumption to generate the same amount of
steam. This leads to a drop in the efficiency of the boiler.
Savings
Oxygen % in flue gas
11 %
Excess Air supplied
O2 %
20.9 O2%
11
20.9-11
111 %
14 kg/kg of fuel
Theoretical requirement of Air
Density of FO
0.92 kg/lit
12.88 kg/lit of fuel
Actual Air supplied
=
=
(1 + 1.11) x 12.88 kg/lit of fuel

If Oxygen % is regulated and maintained at 5 %, less air should be provided

by the Blower
Excess Air supplied
O2 %
20.9 O2%
5
20.9-5
31.5%
Actual Air supplied
=
=
(1 + 0.315) x 12.88 kg/lit of fuel

Reduction in Dry flue gas losses
(27.177 16.937) kg/lit of fuel

x 0.24 kcal/kg 0C x (200 40)0C
393.21 kcal/lit of fuel
The average consumption of FO per day as per the Log book is 2200 l/day i.e
91.6 lit/hr
Fuel Saving
=
=
Thermal Savings
=
=
Fan Head
Pressure
Damper
mm WC
514
After
393.21 kcal/lit of fuel x 91.6 lit/hr

9660 kcal/lit of fuel
3.73 lit /hr
3.73 lit/hr x 3000 hrs/annum
x Rs. 42.7/lit
Rs. 4.77 Lakhs
Fan Power
Operating Flow Efficiency
mm WC
kW
m3/hr
150
8.1
2100
40
New Blower design specifications: 2500 m3/hr, 250 mm WC, 65 % efficiency

New Blower power
=
=
Saving Potential
2500 m3/hr x 250 mmWC

102 x 3600 x 0.9 x 0.65
2.9 kW
= 8.1 2.9 kW
= 5.2 kW
Say 5 kW
Annual Savings
= 5 kW x 7000 hrs/yr x Rs. 7.22/kWh

= Rs. 2,52,700/Say Rs. 2.5 Lakhs
Total Savings
Rs. 7.2 Lakhs
Investment
Rs. 6 Lakhs
Payback
Rs. 6.0 Lakhs x 12 months

Rs. 7.2 Lakhs
10 months
EXCESS AIR OPTIMIZATION IN THERMIC FLUID HEATER

Present Status
A 2 Lakh kcal HSD-fired Thermic Fluid Heater is installed providing hot
therminol-55 to the Oil based heaters of the Old Oil Seal Section. It operates
in on/off mode interlocked with the thermic fluid outlet temperature. The set
points for the on/off operation are given below:
On at 206 0C
Off at 239 0C
HSD
O2: 11 %
Temp: 200 oC
TFH
Stack
Ambient air:
30oC
The measured excess air % in the TFH is 111%. Some quantity of excess air is
required for ensuring complete combustion of any fuel. But the norm for
excess air % required for diesel fired TFH is around 15 %. The heat generated
by the TFH is partly lost to the excess air, resulting in an increase in fuel
consumption to transfer the same amount of heat to the thermic fluid. This
leads to a drop in the efficiency of the TFH.
Savings
Oxygen % in flue gas
11 %
Excess Air supplied
O2 %
20.9 O2%
11
20.9-11
111 %
14 kg/kg of fuel
Density of Diesel
0.84 kg/lit
Actual Air supplied
=
=
(1 + 1.11) x 11.76 kg/lit of fuel

If Oxygen % is regulated and maintained at 5 %, less air should be provided

by the Blower
Excess Air supplied
O2 %
20.9 O2%
5
20.9-5
31.5%
Actual Air supplied
=
=
(1 + 0.315) x 11.76 kg/lit of fuel

Reduction in Dry flue gas losses
(24.813 15.564) kg/lit of fuel

x 0.24 kcal/kg 0C x (180 40)0C
310.76 kcal/lit of fuel
The average consumption of Diesel per day as per the Log book is 390 l/day
i.e 16.25 lit/hr
Fuel Saving
=
=
Thermal Savings
Investment required
310.76 kcal/lit of fuel x 16.25 lit/hr

9150 kcal/lit of fuel
0.55 lit/hr
0.55 lit/hr x
x Rs. 59.7/lit
Rs. 1.51 Lakhs
Nil
4600
hrs/annum
AVOID IDLE STEAM FLOW THROUGH VAM

Present status
Earlier, Vapour Absorption Machine was operated utilizing the steam from the
boiler to generate the chilled water. The plant has installed the Screw Chiller in
place of VAM. Presently the VAM is in standby mode. Though the valve is
closed, still the steam is passing through the control valve and the condensate
is collected in the condensate tank without doing any useful work.
60 %
7.5 Bar
VAM
0.05 - 0.09 TPH
By pass for VAM
The measured steam flow through the line was 0.09 TPH. This test was carried
out with the support of bucket test.
Savings
Condensate flow
0.9 m3/hr
On a conservative basis, Condensate flow of 0.6 m3/hr is taken

Enthalpy of steam at 14 bar, h1
667.18 kcal/kg
Enthalpy of condensate @ 850C, h2 =
85.18 kcal/kg
Heat loss per hour
0.6 m3/hr x 968 kg/m3

x (667.18 85.18) kcal/kg
33,802.56 kcal/hr
=
=
Annual Savings in Fuel
=
=
=
=
33,802.56 kcal/hr x 7000 hrs/yr

10500 kcal/kg
22,535.04 kg/yr
22,523.04 kg/yr
0.92 kg/lit
24,481.56 lit/yr
Annual Savings
= 24,481.56 lit x Rs. 42.7/lit

= Rs. 10,45,362/Say Rs. 10.45 Lakhs
Investment
Rs. 3 Lakhs
Payback

Rs. 10.45 Lakhs
4 months
INSULATE INLET PIPELINE OF FEED PUMP FOR 3-TON

BOILER
Present status
The pipeline from the feed water tank to the feed pump inlet is 20 m long and
not insulated. The temperature drop within this circuit is around 912 0C.
The radiation losses from the line can be avoided by insulating the line
completely. Every 10C drop in the Boiler feed temperature is equivalent to a
loss of 1480 kcal/hr.
Feed Tank
800C
Boiler
1.45 TPH
700C
1 running
Savings
Current steam consumption was estimated at 1.48 TPH
The T between the Feed tank and the pump inlet was found to be 8-10 0C.
On a conservative basis, atleast 5 0C drop can be avoided through proper
insulation
Heat Loss across the line
=
=
1480 kg/hr x 1 kcal/kg0C x 50C

7400 kcal/hr
Annual Savings in fuel
7400 kcal/hr x 7000 hrs/yr

10500 kcal/kg x 0.92 kg/lit
5362 lit/yr
=
Annual Saving Potential
=
5362 lit/yr x Rs. 42.7/lit
=
Rs. 2,28,957
Say Rs. 2.28 Lakhs
Investment for Insulation
Rs. 1 Lakh
Payback

Rs. 2.28 Lakhs
6 months
AVOID HEAT LOSS FROM TANKS IN SHELL TREATMENT

PLANT
Present Status
The shell treatment plant consists of 13 tanks which are used to clean and
coat shells. Out of these, 5 tanks use the process steam for heating
application.
1. Degreasing tanks 2 tanks
2. Phosphating tanks 2 tanks
3. Passivasing tanks 1 tank
There is scope to reduce steam consumption by either insulating the tanks or
coating it with nansulate paint to decrease the radiation losses.
Savings
The tanks surface temperature was measured with a Pyrometer and the
following were the observations:
Tank
Degreasing Degreasing Phosphating Phosphating Passivasing
-1
2
-1
-2
Bigger Side
Area (m2)
0.95
0.95
0.95
0.95
0.475
Bigger Side
Temp. (0C)
81
48
90
90
65
Smaller
Side Area
(m2)
0.725
0.725
0.725
0.725
0.725
Smaller
Side Temp.
(0C)
48
48
66
67
40
Consider Phosphating tank 1 for sample calculation

Radiation loss formula
T4 A
Emissivity of material,
0.87
Heat Loss from tank bigger side
=
=
Heat Loss from tank bigger side
=
=
Total Radiation losses for all the tanks

=
Annual Savings in fuel
=
=
=
=
4.87 x 10-8 kcal/hr.m2.K4 x 0.87 x

0.95 m2 x ((273+90)4(273+40)4) K4
312 .55 kcal/hr
4.87 x 10-8 kcal/hr.m2.K4 x 0.87 x
0.95 m2 x ((273+66)4(273+40)4) K4
110.85 kcal/hr
1270.58 kcal/hr
1270.58 kcal/hr x 7000 hrs/yr
10500 kcal/kg x boiler x H.E
1270.58 x 7000
10500 x 0.82 x .9
1147.77 kg/yr
0.92 kg/lit
1247.57 lit/yr
Annual Saving Potential
=
1247.57 lit/yr x Rs. 42.7/lit
=
Rs. 53,271
Say Rs. 0.53 Lakhs
Investment for Insulation
Rs. 0.64 Lakhs
Payback for Insulation
=
=

Rs. 0.53 Lakhs
15 months
Investment for Nansulate paint
Rs. 0.7 Lakh
Payback for Nansulate paint

Rs. 0.53 Lakhs
16 months
AVOID COMPRESSED AIR USAGE IN SHELL TREATMENT

PLANT
Present status
Currently Compressed air is used for aeration in the treating tanks in the Shell
treatment plant. For aeration, quantity of air is more important than the
pressure. 0.1-0.2 bar pressure would be sufficient for aeration but currently air
at pressure of 6 bar is being used. The compressed air usage can be replaced
with air from blowers instead. The comparison between the specific energy
consumption for compressed air and blower air is given below:
SEC of the Compressor 0.19 kW/CFM
SEC of Blower 0.05 kW/CFM
By replacing the compressed air with blower air will reduce in the
operating specific energy consumption by 0.14 kW/CFM
Savings
Velocity of compressed air taken as 5 m/s
Air Requirement for one user
=
=
5 m/s x 0.002945 m2 x 2118.88

31.2 CFM
SEC of Compressor
0.19 kw/CFM
SEC of Blower
0.05 kW/CFM
Savings
=
=
(0.19-0.05) kW/CFM x 31.2 CFM

4.37 kW
Annual Savings
Investment required
Rs. 0.60 Lakhs
Payback Period

Rs. 0.60 Lakhs
12 months
4.37 kW x 6.4 hrs/day x 300 days

x Rs. 7.22/kWh
= Rs. 60,578
Say Rs. 0.60 Lakhs
REPLACE THERMIC FLUID HEATER WITH ELECTRIC

HEATING PROCESS IN OLD OIL SEAL SECTION
Present status
There is a 2 Lakh kcal rated Thermic Fluid Heater installed in the Old Oil Seal
Section to provide hot thermic fluid (Therminol - 55) to 20 oil seal moulding
machines.
There were originally 23 oil seal moulding machines utilizing hot thermic fluid,
but plant has retrofitted three machines with electric heaters to replace the
thermic fluid requirement. Due to the high cost of diesel, there is potential to
reduce costs by retrofitting more machines with electric heaters.
A secondary option is to replace the thermic fluid heater with a wood/briquette
fired TFH of same capacity. Due to the relatively less cost of wood, there is
potential to install and operate a Wood fired TFH to provide hot thermic fluid to
the Moulding machines.
Savings
Current Diesel Consumption as per log book is 390 lit/day
Current Annual Operating Cost
390 lit/day x 300 days/yr

x Rs. 59.7/lit
=
Rs. 69.84 Lakhs
Say Rs. 69.8 Lakhs
Option 1
The current Machines retrofitted with Electric heaters were observed to take
5.1 kW for an on-time of 100 seconds out of 120 seconds cycle time
Power consumed in 1 hr
5.1 x 100
120
=
4.25 kW
Say 4.5 kW
Power taken by 20 Machines in one year

=
20 x 4.5 kW x 24 hrs/day x 300 days
=
6,48,000 kWh
Annual Cost
=
6,48,000 kWh x Rs. 7.22/kWh
=
Rs. 46,78,560/Say Rs. 46.8 Lakhs
Annual Savings
=
=
Rs. 69.8 Lakhs Rs. 46.8 Lakhs

Rs. 23 Lakhs
Investment for Retrofit
Rs. 10 Lakhs
Payback period

Rs. 23.0 Lakhs
6 months
Option 2
If the TFH is replaced by a wood fired TFH,
Required Heat Content
200000 kcal/hr
Gross Calorific Value
3500 kcal/kg
Mass of Fuel required per hour
=
=
200000 kcal/hr
3500 kcal/kg x 0.7
81.63 kg/hr
Mass of Fuel required per year
=
=
81.63 kg/hr x 16 hrs/day x 300 days

3,91,824 kg/yr
Annual Cost of Fuel
=
=
3,91,824 kg/yr x Rs. 6/kg

Rs. 23.5 Lakhs
Annual Savings
=
=

Rs. 46.3 Lakhs
Investment for Wood Fired TFH
Rs. 10 Lakhs
Payback period

Rs. 46.3 Lakhs
3 months
REPLACE FO BOILER WITH WOOD/BRIQUETTE FIRED

BOILER
Present Status
A 3 Ton Furnace oil-fired boiler and a 2 Ton Furnace oil fired boiler are installed
for steam generation. The 3 ton boiler is currently used to generate of around
1.6 TPH of steam at 14 bar for various users in the plant.
Due to relatively inexpensive nature of wood, there is potential to reduce
operating cost by installing and operating a wood/briquette fired boiler of
similar capacity instead of the Furnace oil fired boiler.
Savings
Current Furnace oil Consumption as per log book is 2200 lit/day

x Rs. 42.7/lit
=
Rs. 2,81,82,000
Say Rs. 281.82 Lakhs
The current steam consumption is around 1.5 TPH, but the calculations were
made for replacing boiler with a wood fired 3 Ton boiler
If the Boiler is replaced by a wood fired 3 T Boiler,
Required Heat Content
=
3000 kg/hr x (666.3980.32) kcal/kg
=
17,58,210 kcal/hr
Say 18,00,000 kcal/hr
Gross Calorific Value
3500 kcal/kg
Mass of Fuel required per hour
=
=
18,00,000 kcal/hr
3500 kcal/kg x 0.85
605.04 kg/hr
Mass of Fuel required per year
=
=
605.04 kg/hr x 24 hrs/day x 300 days

43,56,288 kg/yr
Annual Cost of Fuel
=
=
43,56,288 kg/yr x Rs. 6/kg

Rs. 261.38 Lakhs
Annual Savings
=
=

Rs. 20.44 Lakhs
Investment for Wood Fired Boiler
Rs. 20 Lakhs
Payback period
Rs. 20.44 Lakhs

12 months
OPTIMIZE THE OPERATION OF THE PUMPS IN THE RO

PLANT
Present status
During the detailed energy audit study at JK Fenner (India) Ltd.,
Patancheru detailed study was carried out on pumps of the reverse osmosis
circuit for identifying possible energy saving opportunities.
There are two HP pumps in the reverse osmosis plant. Pump 1, supplies raw
water from the tank to NGMF and ion exchange units and pump 2 supplies
water into the reverse osmosis membrane. The water after treatment is
collected in the RO water storage tank.
Raw
Wat
er
RO Rejects
0.8 m3/hr
Recirculat
ion
0.8 m3/hr
45%
Ion
Exchan
ge
NGM
F
0.9
bar
40%
1.96
3
m
/hr
Pump
1
1.96
Pump
m3/hr
2
RO
Wat
er
It was observed that there is a pressure drop across pump 1 due to valve
throttling, pressure drop across pump 2 due to valve throttling, 43% water
recirculation across pump 2, all of which led to consumption of excess power in
both the pumps.
Calculation
The observed operating parameters of Pump 1 are:
Volumetric flow
1.96 m3/hr
Throttling
40% open
Pressure after throttling
0.9 kg/cm2
1.96 m3 / hr x 30 m x 100
3.6 x 102 x 1.5 kW x 0.90
11.76%
The recommended specifications of a new pump with an operating efficiency of

more than 60% are:
Volumetric Flow
1.2 m3/hr
Head
3 bar
Power
1.5 kW
Savings
Annual savings
=
=
0.536 kW x 7000 hrs x Rs 7.22/ kWh

0.27 Lakhs
Investment
1.0 Lakhs

0.27 Lakhs
44 Months
1.4 0.9 x 1.5 kW

1.4
= 0.536 kW
The observed operating parameters of Pump 2 are:

Design pressure
22 bar
Throttling
45% open
Discharge pressure
8 bar
Recirculation
41%
Recirculated quantity
0.8 m3/hr
Power
1.95 kW
Margin pressure taken
15 bar
Savings due to
avoided recirculation
0.8 m3 / hr x 1.95 kW = 0.80 kW

1.96 m3 / hr
Savings due to
avoided throttling
=
=
22 bar 15 bar x 1.95 kW

(22 bar + 1 bar)
0.6 kW
Total savings
0.80 kW + 0.6 kW = 1.4 kW
Annual savings
1.4 kW x 7000 hrs x Rs 7.22/kWh
0.71 Lakhs
Investment
2.0 Lakhs

0.71 Lakhs
34 Months
INSTALL SOLAR STEAM GENERATOR TO SUPPLEMENT FO

BOILER
Present Status
A 3 Ton Furnace oil-fired boiler and a 2 Ton Furnace oil fired boiler are installed
for steam generation. The 3 ton boiler is currently used to generate of around
1.6 TPH of steam at 14 bar for various users in the plant.
The average daily consumption of Furnace oil for the Boiler is 2200 litres/day
at a cost of Rs. 42.7 per litre. This accounts to an operating cost of Rs. 93,940
per day and Rs. 281.82 Lakhs per year.
On a long term basis, there is potential to install a solar steam generator to
supplement the Furnace oil boiler. The solar steam generator would supply
steam to plant during the day and reduce the furnace oil consumption. The
steam generator supplies steam at a maximum pressure of 10 bar.
discussions with the plant team, it was understood that the plant is planning
reduction in roller diameter to reduce required pressure to 7.5 bar. After this
modification, the maximum pressure of steam required would be 8 bar. Then
there would be scope to go for a 10 bar solar steam generator.
Savings
Current Furnace oil Consumption as per log book is 2200 lit/day

x Rs. 42.7/lit
=
Rs. 2,81,82,000
Say Rs. 281.82 Lakhs
If a solar steam generator is installed, taking 8 hrs of sunlight every day

Furnace oil consumption would be avoided for the 8 hrs
Annual Savings in Fuel
=
=
2200 lit/day x 8 hrs/day x 300 days

24 hrs/day
2,20,000 lit
Annual Savings
=
2,20,000 lit x Rs. 42.7/lit
=
Rs. 93,94,000
Say Rs. 93.5 Lakhs
Investment for Solar Boiler
Rs. 800.0 Lakhs
Payback period

Rs. 20.44 Lakhs
=
=
103 months
8.6 years
Benefits
Annual savings of Rs. 93 Lakhs can be achieved by implementing this project.
The investment required for installing a solar steam generator is around Rs.
800.00 Lakhs(Not Considering Govt. Subsidies). The simple payback period is
8.6 years.
RENEWABLE ENERGY FOR LIGHTING

energy saving opportunities. The option of using renewable energy for lighting
was explored.
Present Status
The total lighting load at present was around 41 kW in the plant. The following
approach can be followed to shift to renewable energy for lighting:
Step 1: Installation of LED lamps in place of T8, T5, CFLs and other
conventional lamps.
Step 2: Solar powered street lighting. At present, 14 Nos of 65W LEDs and 10
Nos of 90W LEDs are installed for street lighting. It is recommended to install
a 2 kW capacity solar panel and the requirements of street lighting can be met
through renewable energy.
The following options can be explored:
Option 1 : Solar PV and Battery
Present energy consumption of LEDs
=
(14X65) W + (10X90)W
Say 1.8 kW
A 2 kW roof top solar panel can be installed at the plant. The street lighting
requirement can be met through this.
Investment
Rs. 5 Lakhs
Option 2 : Solar Mill

A Solar Mill is a hybrid system and taps solar and wind energy. It is suitable for
operation at 2 m/s to 17 m/s of wind speed. As it is a hybrid system, the
capacity utilization is also high.
Investment
Rs. 4 Lakhs
Savings
1.8kWX4000hrs X Rs.7.22/kWh
Say Rs. 0.5 Lakhs
Step 3: Installation of a solar PV/ solar mill to cater to the entire lighting load
requirement.
Present lighting system load
41 kW
Load after shifting to LEDs
15 kW
A 15 kW solar PV/solar mill can be installed.

Investment
Rs. 40 Lakhs
Savings
=
=
15 kW X 4800 hrs X Rs.7.22/kWh

Say Rs. 5 Lakhs
REPLACE CFL LAMPS WITH LEDs

Present Status
CFL lamps were installed in the following locations:
FG Stores
Technical production office
EDC
Power consumption of the CFL lamps

=
(28 X 36)W + (26 X 72 W)
=
2.88 kW
Say 2.9 kW
Proposed Scenario
It is recommended to replace these CFL lamps with 1X18 W LEDs.
Power consumption of LED lamps
54 X 18 W
0.97 kW
2.88 0.97 kW
1.91 kW
Say 1.9 kW
=
=
=
0.5 kW X 3000 hrs X Rs. 7.22/kWh

Rs.10,830/Rs. 0.11 Lakhs
Annual Savings in Rs. (Office & EDC)

=
=
=
1.4 kW X 2400 hrs X Rs. 7.22/kWh

Rs. 24,328/Rs. 0.24 Lakhs
Total Annual Savings in Rs.
Rs. 0.35 Lakhs
Investment (Rs.3000 for LED)
=
=
=

Rs. 1,62,000/Rs. 1.62 Lakhs
Savings in kW
Annual Savings in Rs. (FG stores)
Payback period
Investment X 12 Months
Savings
Rs.1.62 Lakhs X 12 Months

Rs.0.35 Lakhs
55 months
The pay back period is high as the operating hours of the lamps is low. It is
recommended to replace these CFL lamps with LEDs as a failure replacement
policy or as a part of technology up-gradation as the investment is quite low
(around Rs. 1.6 Lakhs).

CII-Sohrabji Godrej Green Business Centre
Survey No. 64, Near Kothaguda Cross Road
Kothaguda Post, Ranga Reddy (Dt)
Hyderabad 500 084
Ph: + 91 40 44185111;
Fax +91 40 23112837
Email: encon@cii.in
Web: www.greenbusinesscentre.com

Replace T8 lamps with LEDs for huge energy savings at JK Fenner plant

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Replace T8 lamps with LEDs for huge energy savings at JK Fenner plant

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Confederation of Indian Industry

CII-Sohrabji Godrej Green Business Centre

Detailed Energy Audit

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

List of Energy Saving Proposals

Energy Saving Proposals

Management Aspects And Conclusions

Total No of Pages: 117

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

Annual savings with investment (Rs. Lakhs)

Total Annual savings (Rs. Lakhs)

Average payback period for capital proposals

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

SPECIFIC ACTION PLAN

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

Energy Saving Propsals

Replace the 1x36W And 2x36W T8 Lamps with 1x20 W

Replace the 1x28W And 2x28W T5 Lamps with 1x20 W

Optimize the Lighting Voltage in the Plant

Switch of Lights in Canteen During Day Time

Install New Energy Efficient Pump in 100 T.R Cooling

Replace Inefficient Raw Water Transportation Pump with

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

Replace Aluminum Blades with FRP Blades for Cooling

Optimise the Operation of the Chilled Water System

Excess Air Optimization in 3 Ton Boiler

Excess Air Optimization in Thermic Fluid Heater

Avoid Idle Steam Flow Through VAM

Insulate Suction Pipeline of Feed Pump for 3-Ton Boiler

Avoid Heat Loss From Tanks in Shell Treatment Plant

Avoid Compressed Air Usage in Shell Treatment Plant

Replace Thermic Fluid Heater with Electric Heating

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

Replace FO Boiler with Wood/Briquette Fired Boiler

Optimize the Operation of the Pumps in the RO Plant

Long Term Proposal

Install Solar Steam Generator to Supplement FO Boiler

Renewable Energy for Lighting

Replace CFLs with LEDs

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL No. 1

REPLACE THE 1X36W and 2X36W T8 LAMPS WITH

Hours per day

Old Oil seal

New Oil seal

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

It is recommended to replace these T8 lamps with 1X20 W LEDs. Light

Very Good (> 80)

CII Sohrabji Godrej Green Business Centre