Professional Documents
Culture Documents
June 2014June
CONTENTS
Chapter
No.
Description
Page
No.
Executive Summary
Introduction
II
Acknowledgement
III
IV
56
VI
Annexure
60
VII
Back-up Calculations
79
EXECUTIVE SUMMARY
Asian Paints is one of the India's largest paint companies which
manufacturesmanufacture paints for decorative and industrial use. Since its
foundation in 1942, Asian Paints has come up a long way to become Indias
largest and Asias third largest paint company, with a turnover of Rs. 127.15
billion. Asian Paints operates in 17 countries and has 23 paint manufacturing
facilities in the world servicing consumers in over 65 countries.
Asian Paints has always been a leader in the paint industry, pushing new
concepts in India like Colour Worlds, Home Solutions, Colour Next, and Kids
World.
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 Asian Paints Limited.,
Patancheru Plant from 15 to 21 January, 2014. A detailed presentation was
made to the plant team covering various energy conservation opportunities on
25th January, 2014. The combined efforts of Asian Paints Limited., Patancheru
and CII-Godrej GBC team have together identified, annual energy saving
potential of Rs. 98.81 Lakhs, based on present energy cost.
The summary of the annual energy savings identified is as below:
Total Annual Savings (14 proposals)
: 9 months
proposals
doesntproposal
doesnt
requiresrequire
any
CHAPTER I
INTRODUCTION
Asian Paints Limited, Patancheru evinced keen interest in availing the services
of CII - Godrej Green Business Centre (CII Godrej GBC) of the Confederation
of Indian Industry (CII) for conducting a detailed energy audit at their unit.
The CII-Godrej GBC proposal for conducting a detailed energy audit at Asian
Paints Limited, Patancheru was accepted by management; vide their Reference
P.O. No. 15191843, dated 26th November, 2013.
The field activities of the detailed energy audit were conducted in one visit and
the final presentation to the plant team was made on 25th January, 2013.
The methodology adopted for conducting the detailed energy audit at
Asian Paints Limited, Patancheru is as follows:
Basic data collection on list of power consuming equipments, design
specifications of the major equipments and actual operating parameters
Power measurements of major electrical energy consumers
Measurement of operating parameters of various equipments to estimate
their operating efficiency
Analysis of data collected and measurements, to develop specific energy
saving proposals
Discussion with the plant personnel on the identified proposals
Presentation on the findings of the detailed energy audit to the plant
personnel, with the cost economic analysis
We are pleased to mention that all the identified energy saving proposals have
been discussed with the plant executives before finalizing the ideas.
The contents of the report are based on the data provided by the plant
personnel and actual measurements conducted jointly by the CII-Godrej GBC
and plant team during the detailed energy audit.
The plant personnel should implement the suggestions made in this report,
after verifying the necessary regulatory safety aspects. It is solely the
responsibility of the plant personnel to observe statutory regulations, if any, as
applicable to their plant.
CHAPTER II
ACKNOWLEDGEMENT
CII acknowledges with thanks the co-operation and the support extended to
the CII energy audit team during the detailed energy audit at Asian Paints
Limited, Patancheru.
The interactions and deliberations with Asian Paints Limited, Patancheru
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 Asian Paints
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
7
8
9
10
11
12
13
14
Annual
Savings
(Rs. Lakhs)
Investment
Required
(Rs. Lakhs)
Payback
Period
(Months)
28
31
13
0.9
1.8
24
2.8
13
56
22.3
0.31
13.45
14.5
13
1.97
19
0.44
0.6
17
12
4.2
1.6
3.5
42
9.9
11.54
98.81
75.0
Chapter IV
Energy Saving Proposals
Watt
Quantity
Power in
kW
Other Offices
36w x 2
746
53.71
2432
Engg Store
36w x 2
40
2.88
2432
Production Blocks
(floor wise)
36w x 2
849
61.13
4984
BSR
36w x 2
90
6.48
4984
DC
36w x 2
10
0.72
4272
RMG
36w x 2
219
15.77
4984
PMG
72 w
80
5.76
4984
S.No
Location
hours
Please discuss the LED technology and their benfits. Make a paragraph
Proposed Technology
Give one or two lines about LED technology amnd how it works 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
Confederation of Indian Industry
Type of Lamp
Lumen/Watt
CRI
Life hours
Fluorescent lamps
50
Good (67-77)
5,000
LED lamps
120
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 2X36W T8 lamps with 1X20 W LEDs.
The energy saving that can be obtained by shifting to LEDs is around 106 kW.
Confederation of Indian Industry
Type of Lamp
Lumen/Watt
CRI
Life hours
Fluorescent lamps
50
Good (67-77)
5,000
LED lamps
120
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.
10
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 2X36W CFL lamps with 1X18 W
LEDs. The energy saving that can be obtained by shifting to LEDs is around 5.8
KW.
Benefits
The estimated annual savings that can be obtained by replacing CFL lamps
with LEDs is Rs. 0.9 lakhs. The investment required is Rs. 1.8 lakhs. The
payback period is 24 months.
11
12
13
O2: 9.0 %
Temp:
175oC
Thermop
ac
20 Lakh
kcal/hr
Flue gas:
APH
6556 m3/hr
O2: 7.5 %
Temp: 283oC
Ambient air:
28oC
14
Temperature
Thermopack TP 405
% O2
CO (ppm)
Thermopac immediate
outlet before APH
7.5
5.0
283
9%
3.0
175
(Deg C)
The above figure clearly indicates higher combustion air is been supplied
leading to excess of oxygen in thermopac outlet. The CO levels were found to
be in very low range which indicates good condition of the thermopac and
possibility to further optimize the excess air to improve the performance
further.
Effect of excess oxygen
Controlled supply of combustion air is an important criterion for optimum
energy efficiency of a gas fired thermopack. This is because the heat loss
caused by the flue gas leaving the thermopack would be minimal when
controlled excess quantity of excess air near to stoichiometric quantity of
theoretical air required is supplied for combustion.
LPG requires around 15.6 kg to 16 kg of air per kg of LPG being fired. As
gasesous fuels have better combustion properties, the optimum quantity of
excess air to be supplied should not excess 10%. This corresponds to
oxygen concentration of 2% in the flue gas.
Higher air quantity supplied above this will result in increase carryover of
heat from the furnace without significantly aiding in the combustion
process. On the other hand, supplying lesser quantity of combustion air
than optimum may result in incomplete combustion and thus loose some
amount of heat energy in the form of unburnt fuel or Carbon-mono-oxide.
High air quantity additionally leads to higher combustion air blower power
consumption also.
Also provide the recommended value based on the mixability of fuel
The above figure clearly indicates higher combustion air is been supplied
leading to excess of oxygen in thermopac outlet. The CO levels were found to
be in very low range which indicates good condition of the thermopac and
possibility to further optimize the excess air to improve the performance
further.
Recommendation
Confederation of Indian Industry
15
16
investment required for procuring a gas analyzer would be Rs. 3.50 lakhs
which would have a very attractive pay back of 2 months.
Option 2:
Optimizing the combustion air supply to the thermopac by reducing the
combustion air installing an online gas analyzer with a feedback controller to
the blower frequency control and maintaining 3 % O2 at exit flue gases at all
conditions would result in an annual savings of Rs. 22.30 lakhs. The
investment required for analyzer, controller and blower VFD would be Rs. 5.00
lakhs which would pay back on 3 months.
17
Temp: 96oC
O2: 6.5 %
Removax
LPG/HSD
Fired
RXA 06
Flue gas:
Temp: 196 C
1669 m3/hr
With in
built feed
water
economis
er
Ambient air:
28oC
% O2
CO (ppm)
Thermopac immediate
outlet before APH
6.5
43
Temperature
(Deg C)
196
18
The above figure clearly indicates higher combustion air is been supplied
leading to excess of oxygen in boiler outlet. The CO levels were found to be in
lower ranges which indicate good condition of the boiler and possibility to
further optimize the excess air to improve the performance further.
Effect of excess oxygen
Controlled supply of combustion air is an important criterion for optimum
energy efficiency of a boiler. This is because the heat loss caused by the
flue gas leaving the boiler would be minimal when controlled excess
quantity of excess air near to stoichiometric quantity of theoretical air
required is supplied for combustion.
LPG requires around 15.6 to 16 kg of air per kg of LPG being fired and for
HSD 14 to 15 kg of air per kg of HSD. As gasesous/liquid fuels have better
combustion properties, the optimum quantity of excess air to be supplied
should not excess 10%. This corresponds to oxygen concentration of 2% in
the flue gas.
Higher air quantity supplied above this will result in increase carryover of
heat from the furnace without significantly aiding in the combustion
process. On the other hand, supplying lesser quantity of combustion air
than optimum may result in incomplete combustion and thus loose some
amount of heat energy in the form of unburnt fuel or Carbon-mono-oxide.
Recommendation
We recommend the following:
Reduce the combustion air supply by altering the combustion air blower
damper in steps and measure the O2 and CO level.
Continue to reduce the combustion air supply in steps of 1 % reduction in
O2 at exit and observe the performance and reduce further to reach a level
of 2 % O2 at exit flue gas.
Purchase a portable combustion analyzer and regularly monitor O 2 and CO
level in flue gas to access the combustion performance.
Ensure that the following at the end of this trail
o O2 level should be maintained at less then 2% in flue gases
o Monitor the fuel consumption on daily basis to observe the saving
achieved
Saving in blower power consumption also would be achieved by reducing
the volume of air handled.
Minimum saving of 0.56 Kg of LPG/HSD can be achieved by optimization of
the combustion air supply.
Confederation of Indian Industry
19
CIISohrabji Godrej Green Business Centre
Benefits
Optimizing the combustion air supply to the boiler by reducing the combustion
air by modulating the inlet damper and maintaining 3 % O2 at exit flue gases
would result in an annual savings of Rs. 1.00 lakhs. The investment required
for procuring a gas analyzer is already considered in the similar excess air
optimization project for thermopac operation and would have no additional
investment requirement.
20
21
R1
R3
R6
R8
R9
Bypass Valve
Thermopac
20 Lakh kcal
Recommendation
We recommend the following:
The thermic fluid pump is already installed with VFD
Interlock the thermic fluid pump discharge pressure header pressure to
the pump speed.
As per the optimization plan, thermic fluid pump speed can be varied
between 90 to 100 % of the rated speed.
As the pump seal air fan is build in pump main shaft, we recommend to
conduct trails during the night hours when the ambient air temperature
are lower compared to day time. (Caution should be taken in setting the
pump speed control limits to upto maximum reduction to 47.5 Hz)
Benefits
The annual energy saving potential by optimizing the thermic fluid circulation
pump operation based on the heat requirement in the resin house reactors
would be Rs. 0.31 lakhs which doesnt calls for any investment as VFD is
already installed in the pump.
22
CII and plant team jointly carried out pressure and flow measurements in the
blowers
The detailed flow and pressure measurements are as follows:
Fan
Number
VSP301
(Blower 1)
VSP302
(Blower 2)
VSP303
(Exhaust 1)
VSP304
(Exhaust 2)
VSP305
(Discharge1)
Flow
(m3/hr)
43000*
Flow
(CFM)
25298
Power
(KW)
19
Efficiency SEC
SEC Norm
(%)
(W/CFM) (W/CFM)
0.75
0.18
39347
23149
17.79
28
0.77
0.18
43801
25770
8.55
56
0.33
0.18
45512
26776
8.46
49
0.32
0.18
69386
40822
28.44
48
0.70
0.18
* Actual flow to system for VSP 301 was measured to be 22480 m3/hr. This
reduced flow was mainly due to leakage at immediate blower discharge
ducting. For calculation the specific energy consumption (SEC) the rated flow
was considered for comparing the savings possible.
The specific energy consumption of the blowers were measured and are
compared with the specific energy consumption of high efficiency blower of
comparable capacity.
23
Blower VSP 303 AND VSP 304 SEC is in the range of 0.32 to 0.33 W/CFM
whereas for the other three blower is over 0.70 W/CFM. This clearly indicates
lower operating efficiency of the blowers.
Recommendation
We recommend the following:
Phase I
Replace the discharge blower VSP 301 & 302 with either a two new high
efficient blower of 40000 m3/hr capacity.
Considering the new operating SEC of 0.25 W/CFM, the saving potential
for phase I blower would be 18.7 KW.
Phase II
Replace the discharge blower VSP 305 with a new high efficient blower of
70000 m3/hr capacity.
Considering the new operating SEC of 0.35 W/CFM, the saving potential
for phase I blower would be 9.9 KW.
Benefits
Replacing the low efficiency blower with new high efficiency lower SEC blower
would result in an annual saving of Rs. 13.45 Lakhs. This calls for an
investment of Rs. 14.50 Lakhs for installation of new blower and would have
an simple payback of 13 Months.
24
As indicated in the figure, when only 5kL reactor pump was running,
recirculation of 27 m3/hr (22%) was observed through 3 kL pump. When only
3kL pump was running, recirculation of 15 m 3/hr (12%) was observed through
5kL pump.
Confederation of Indian Industry
25
CIISohrabji Godrej Green Business Centre
Minimum recirculation in the circuit is 15m3/hr when any one reactor runs.
Recirculation is happening due to the failure of non return valves (NRV). This
results in higher power consumption of the pump.
Plant team have already replaced existing NRVs with new ones. CII
congratulates the plant teams efforts in replacing passing NRV to
avoid recirculation.
Temperature difference across each reactor is only 1.5 0C. Minimum
temperature difference that can be maintained across any heat exchanger is 340C. This indicates there is an excess flow through reactor, can be optimized.
A trail can be taken by throttling the pumps in steps of 10% till temperature
difference of 40C is achieved across the reactor. Simultaneously, please
monitor the reactor bulk temperature, as it is critical.
The cooling requirement for each equipment was analyzed in WBU section.
After assessment the combined cooling requirement in WBU section for
(Reactors, LDV, 70TR chiller) is 200TR.
The details are given as below:
S.No
User
Cooling load
(TR)
3 kL Reactor
50
5 kL Reactor
46
LDV
15
70TR Chiller
condenser
90
Total
200
Each equipment runs at a different batch cycle time. When all the equipment
run simultaneously, the cooling requirement is maximum, i.e., 200TR.
But the installed capacity of the cooling tower is only 120TR. Because of this
insufficient cooling tower capacity, chilled water is being used to cool return
cooling water from the users during summer. Installing one more cooling tower
of 120 TR capacity will increases the heat rejection capacity & cooling
efficiency. And the need to use chilled water to cool the return cooling water
during summer can also be avoided, which is an energy intensive method.
Recommendation
We recommend to
Confederation of Indian Industry
26
Install VFD for one pump and operate only that pump even for 2 reactors
Before installing VFD, plant can take a trail by reducing the flow by
throttling the pump in steps of 10% till temperature difference of 40C is
achieved across the reactor
Install a separate cooling tower of 120TR for chiller condenser and avoid
using chilled water to cool return water during summer
Benefits
Implementing the above recommendation will save Rs 1.90 Lakhs annually.
This requires an investment of Rs 3.0 Lakhs for VFD, control valves & new
cooling tower, which will be paid back with a simple pay back period of 19
months.
27
28
The temperature difference across LDV is only 20C. For a heat exchanger, the
minimum temperature difference that can be maintained is 4 0C. This indicates
excess flow through LDV which , can be optimized.
This can be done by throttling the pump or installing VFD and operating it with
pump discharge pressure as feedback.
Trail can be taken by throttling the pump in steps till the temperature
difference of 40C is achieved & simultaneously monitoring the material
temperature.
Optimizing the flow by reducing the speed with VFD will save more power.
Recommendation
We recommend to
Before installing VFD, trail can be taken by throttling the pump in steps
till temperature difference across LDV reaches 40C.
Install VFD for the pump
Operate VFD in closed loop with the header pressure
Benefits
Installing VFD and operating VFD in closed loop with header pressure will save
Rs 0.44 Lakhs annually. This requires an investment of Rs 0.60 Lakhs,
which will be paid back with a simple pay back period of 17 months
29
490
49
0.4
8.3
3500
491
25
0.2
2400
492
71
1.2
58.5
5500
470
74
2.6
27
160
481
28
39
100
482
64
3.7
58
1300
483
3500
30
31
Cooling tower fans were operating based on the cold well temperature. Fans
switch on when cold well temperature reaches 270C and switches off when it
reaches 250C.
When measurements were taken, CT fans were in OFF condition. Even when
the fans were in OFF condition, 20C cooling was being achieved.
Generally, cooling tower are designed to give a range of 6-80C. By switching on
the fans and running them continuously, cooling tower can give minimum
range of 40C i.e., range will get doubled. Cooling water flow can be halved.
Currently, 2 pumps are running continuously and delivering 93m3/hr (P458)
and 62m3/hr(P457) continuously. Total cooling water flow is around 150m 3/hr.
Confederation of Indian Industry
32
One pump P457 can be switched off. Then the second pump (P458) will deliver
more flow than before as the system resistance reduces as the cooling water
flow reduces.
The power consumption of the second pump can be optimized by installing
VFD and operating it with pump discharge pressure of 2 kg/cm 2 as feedback.
Cooling tower fans can be installed with VFD and operated in closed loop with
cold well temperature interlock of 320C.
Recommendation
We recommend the following
Install VFD for CT fans and operate the VFDs in closed loop with the cold
well temperature of 320C
Operate the VFD in closed loop with the discharge header pressure of 2
kg/cm2
Benefits
Optimizing the operation of industrial cooling water pumps will save Rs 1.60
Lakhs annually. This requires an investment of Rs 4.20 Lakhs, which will be
paid back with 5 months
33
Design
Parameters
Operating Parameters
Motor
Flow Head Loading Efficiency
m3/hr (m)
kW
%
Flow
m3/hr
Head
(m)
60
43
21.00
24
6.15
24
18
33.00
10*
2.4
41
11-39
21.00
32
5.79
34
23.5-9.5
The operating efficiency of above pumps is low due to mismatch between the
design and operating head / ageing of the pumps / low efficiency by design. In
* marked pumps head is estimated value as provision for measuring pressure
was not available.
Give curve to explain how head mismatch happens
Recommendation
It is recommended to replace the pumps (70 TR chiller monomer pump, 70TR
chiller hot well pump, pump house P504) with new pumps of efficiency >70%.
Specifications of 70TR chiller monomer pump:
Flow
25 m3/hr
Head
25 m
Efficiency
> 70%
Benefits
Installing new high efficiency pumps in identified areas will save Rs 1.0 Lakh
annually. This requires an investment of Rs 3.50 Lakhs for three new pumps,
which will be paid back with a simple pay back period of 42 months.
34
OF
THE
AIR
Present status
During the detailed energy audit of Asian Paints Limited Patancheru, a detailed
study of all the compressed air units was carried out for possible energy saving
opportunities.
The plant has installed a centralised compressed air system consisting of two
screw compressors which maintain the pressure of the receiver at 5.7 bar. This
centralized compressed air system supplies air to all the sections of the plant
viz. Water Based Unit, Solvent Based Unit, Industrial Paint Unit, Resin Block
and the Monomer block..
Monomer
Tank
P405
587 CFM
5.7 bar
5.6 bar
10m3
Receiver
5.5 bar
Refrigerant
Drier
P406
587 CFM
5.5 bar
Industrial Based Unit
Phase I & II
5.5
bar
Resin
Block
5.4
bar
35
Compressor
P405
P406
Location
Compressor
House
Compressor
House
Loading
Pressure
bar
Unloading
Pressure
bar
Average
Pressure
bar
Power
kW
5.7
6.2
5.95
88.30
5.5
6.0
5.75
86.03
It was observed that when the plant is in full load operation, one compressor is
continuously running and the second compressor is running for 10 % of the
time. This compressor has been set in such a way that if it is in unload for
more than 10 minutes it automatically switches off. The limit of switching on
and off for a 110 kW motor is not more than four times in an hour.
During the detailed energy audit of the plant, a comprehensive compressed air
distribution study was carried out to understand the compressed air
requirement at the end users and the pressure drop at the farthest point in the
plant. During the compressed air user study of the plant, it was observed that
the compressed air pressure drop at the farthest point from the generation
was not more than 0.2 bar.
The compressed air applications and pressure requirementscompressed air
pressure being maintained at different applications in the plant is as follows
are:
Purpose of Compressed Air
Pressure Maintained
Open/Close valves
4.0 bar
Hopper Aeration
3.0bar
Bag Filters
4.0bar
3.0bar
4.0bar
5.0bar
Cleaning Purpose
3.0bar
It was observed that in most of the end users the pressure setting being
maintained was between 3.0 bar to 4.0 bar. The only operation which requires
a pressure of 5.0 bar is the Lid pressing operation in packer area. The
manufacturer has advised a pressure setting of 6.0 bar considering a safety
Confederation of Indian Industry
36
CIISohrabji Godrej Green Business Centre
margin but the plant is running the packer machine successfully maintaining a
pressure setting of 5.0 bar. It was also observed that these packing machines
were already installed with additional booster compressors, which cater to the
higher pressure compressed air requirements of these machines. CII
congratulates the plant team for this excellent initiative towards
energy conservation activity.
Here is a good opportunity to utilise this booster compressor so that it supplies
high pressure compressed air to the packer machine and reduce the
compressor air pressure at the generation end itself.
Proposed System
The compressed air pressure maintained for most of the applications in the
plant is not more than 4.0 bar. Only the lid pressing operation in the packing
machine requires a higher compressed air pressure requirement of 5.0 bar.
These packer machines are already installed with booster compressors. We
can use these booster compressors in such a way that when we give an input
of 4.0 bar compressed air, it gives an output of air at a pressure of 5.0 bar.
Utilizing this booster compressor we will be able to cater to the pressure
requirement of 5.0 bar for the lid pressing machine and at the same time we
will be able to reduce the pressure of the compressed air at the generation end
to less than 4.5 bar average pressure which is sufficient for all the other
compressed air applications.
When we utilize this booster compressor, it increases the amount of
compressed air usage as it increases the pressure of the incoming air and
produces high pressure air. But this increase in compressed air consumption is
not as significant when compared to the savings we will achieve by reducing
the compressed air generation pressure.
37
and at the same time adjust the compressed air pressure setting in the
booster compressor of all the packing machines such that these booster
compressors gives an output of 5.0 bar compressed air to the packer
machines.
Run the plant in normal operation for a few days.
Step 2:
If there is no issue with the operation of the plant,k keep on reducing itthe
generation pressure in steps of 0.2 bar until the generating set points
arepressure is set to an average pressure of 4.5 bar and utilizing the
booster compressor in the packing machines so that the required pressure
of 5.0 bar is continuously maintained in the packing machines:.
keep on reducing it until the generating set points are:
Load point
- 4.2 bar
Unload point
- 4.7 bar
The above set points have been suggested on a conservative basis and there is
still further scope for the plant team to reduce the generation air pressure.
By reducing the generating pressure of compressed air, energy savings of
around 29 kW is possible.
Load point - 4.2 bar
Unload point
- 4.7 bar
38
Area
Leakage (%)
Total Leakage
Confederation of Indian Industry
47
39
24
12
11
10
11
12
13
At AML area near mixer 253, lid pressing unit FRL leakage
Solvent Based Paint Unit - First Floor (Processing)
14
15
16
17
18
19
20
40
21
22
Dust collector TSD 211 air inlet line leakage QRC fitting
Industrial Paint Unit
23
24
25
26
27
28
29
30
31
32
CA inlet to BL P413
Resin House (1st Floor)
33
34
35
CV BLP 402
36
37
38
39
40
FRV bottom
41
42
41
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
42
68
69
Pug mill hopper 183 I/L to purge line 3rd from top
70
71
Diverter valves
Terrace
72
73
Hopper no - 5
43
16. Behind sand mill 202 diaphragm pump air inlet leakage
17. Work centre 2, pneumatic valve leakage near FMT P202
18. Pneumatic valve leakage above drier tub 1
19. Behind sand mill 209 copper tube leakage
20. Near OHM 209, diaphragm pump inlet line valve leakage
21. Minor leakage in TR P202, additive tub inlet valve leakage
22. Dust collector TSD 211 air inlet line leakage QRC fitting
Industrial Paint Unit
23. LP P304, pipeline leakage
24. SMP 311, diaphragm pump pipeline leakage
25. SMP 304, diaphragm pump pipeline leakage
26. VSP 351, diaphragm pump pipeline leakage
27. SMP 307, diaphragm pump pipeline leakage
Resin House
28. Auto control valve near pre coating tub TRP 408
29. Cut-off valve TRP 407
30. Header FM 10, FM 6 near platform Opp: TRP - 404
31. BL 408 bottom valve copper tube fittings
32. CA inlet to BL P413
Resin House (1st Floor)
33. Solenoid valve BLP418
34. Compressed air pipeline
35. CV BLP 402
36. Steam condensate R7 tub middle Control Valve
37. Steam condensate drain valve 3rd coil
38. FRL bottom near R7 tub
39. Control valve in R7 tub middle cooling inlet line
40. FRV bottom
41. DLP 406 condensate cooling line Control Valve
42. Control valve vent line is open O/L
Confederation of Indian Industry
44
45
Recommendations
It is recommended to
Avoid unwanted purging of compressed air
Arrest the leakages at identified locations
Avoid the use of High Pressure compressed air for cleaning
Increase the awareness among the operators and the workers on the value
of compressed air
Promote Red-tag system among the workers in the plant, wherein
whenever any worker identifies a leakage point, he will attach a red tag at
the leakage point
The maintenance staff then addresses the leakage with the help of the tag
and minimum leakages are maintained in the plant
Conduct leakage test during shut down time
Identify & arrest the leakages
46
Observation
47
OBSERVATION No. 1
L is used when speed and accuracy is not important and task is executed
occasionally.
48
The lux measurements were carried out at various locations in the plant,
during the detailed energy audit. The lux levels were low at the following
areas:
Location
Time
Avg lux
Recommend
ed Lux
23
100
Corridor- 1
28
100
Filling area
58
100
23
100
Corridor- 1
20
100
Filling area
27
100
Filling vessels
18
100
Reactors area
101-105
33
100
Reactors area
159-167
22
100
Process area
34
100
Pugmill area- 1
49
100
Pugmill area- 2
26
100
Liquid storage
25
100
Filling vessels
20
100
Reactors area
101-105
22
100
Area
Day time
WBU - Ground
floor
Night time
WBU- First
floor
Day time
Night time
49
Day time
Day time
Reactors area
159-167
18
100
Process area
34
100
Pugmill area- 1
40
100
Pugmill area- 2
30
100
Liquid storage
25
100
Reactors
28
100
Walk away
corridor
27
50
Hoppers
65
100
TSD
24
100
Storage area
34
75
Reactors
20
100
Walk away
corridor
18
50
Hoppers
30
100
TSD
38
100
Storage area
20
75
53
100
61
100
70
100
circle 1
Below tanks &
filling stationscircle 2
Below tanks &
filling stationscircle 3
50
77
100
56
100
56
100
80
100
89
100
Corridor
37
50
BOPT changing
area
27
100
Process stations
-1
62
100
Process stations
-2
43
100
Process stations
-1
47
100
Process stations
-2
22
100
Corridor
19
50
Day time
Below tanks
36
100
Night time
Below tanks
18
100
Process stations
-1
68
100
circle 4
Below tanks &
filling
stations -circle 1
Below tanks &
filling
stations -circle 2
SBU Ground
floor
Night time
Day time
SBU
First floor
Night time
SBU MF
SBU - second
floor
Day time
51
Night time
Day time
IPU GF
Night time
IPU FF
Day time
Night time
Process stations
-2
34
100
Corridor
32
50
Process stations
-1
50
100
Process stations
-2
20
100
Corridor
16
50
Mixer/packing
floor ph- 1
63
100
Batching area
18
100
Mixer/ packing
floor ph -2
30
100
Mixer/packing
floor
34
100
Batching area
15
100
Mixer/ packing
floor ph -2
19
100
48
100
Premixing area
Ph-1
56
100
51
100
Passage area Ph
-2
29
50
14
100
Lab area ph -1
86
100
Premixing area
ph-1
19
100
22
100
52
Day time
IPU SF
Night time
Day time
Passage area Ph
-2
22
50
Spray booth
room Ph - 2
43
100
SM/TR area
77
100
TSD/ATT area
53
100
FG storage area
25
100
Solvent storage
tank area
42
100
Reactor area
(355-389)
25
100
SM/TR area
34
100
TSD/ATT area
17
100
FG storage area
15
100
Solvent storage
tank area
41
100
below and
behind tanksleft side
47
100
below and
behind tanksright side
21
100
Corridor
37
50
MCC room
20
200
below and
behind tanksleft side
12
100
below and
behind tanksright side
10
100
50
17
200
RH GF
Night time
Corridor
MCC room
Confederation of Indian Industry
53
Day time
RH- MF
Night time
Tank area
20
100
entrance corridor
33
50
filter areas
63
100
Tank area
20
100
entrance corridor
33
50
filter areas
63
100
50
32
100
Reactor arearight
36
100
Charging area
36
100
31
200
15
200
28
100
Reactor arearight
30
100
50
Charging area
15
100
22
200
20
200
stair case
Day time
RH- SF
Night time
Walk way
corridor
54
OBSERVATION No. 2
HARMONIC MEASUREMENTS
During the course of detailed energy audit at Asian Paints,
Patancheru Unit, harmonic measurements were carried out in detail.
Harmonics are measured at the transformer and main incomers at the
following locations:
Location
THD-V%
THD-I%
Main incomer
0.9
4.3
Transformer
2.6
6.3
WBU 1
2.2
22.3
WBU 2
2.7
16.8
Resin House 1
2.7
8.5
Resin House 2
2.6
4.2
SBU 1
2.9
10.5
SBU 2
2.9
5.9
IPU 1
16
IPU 2
8.6
Recommendation
In most of the places, harmonic levels are with in the permissible limit of 5%
for voltage harmonics and 15% for current harmonics (as per IEEE standard).
It was observed that % Current THD is higher than the permitted range at
WBU and IPU.
The 5th order current harmonics were observed to be high at WBU and IPU.
Confederation of Indian Industry
55
Order of harmonics
WBU 1
I1= 187.2 A
WBU 2
I1= 193.5 A
IPU 1
I1= 95.6 A
THD
22.3 %
16.8 %
16 %
3rd
0.4 %
3%
0.6 %
5th
22.4 %
18 %
10.2 %
7th
4%
7.7 %
8%
9th
0%
1.8 %
1.1 %
11th
0.4 %
3.1 %
4.2 %
It was observed that there isnt much difference in the harmonic levels with
the reactors switched on or off. These reactors can be shifted to the areas of
concern, to eliminate the 5th and 7th order harmonics.
Confederation of Indian Industry
56
57
OBSERVATION No. 3
Voltage at
PCC (V)
Voltage at
MCC (V)
Drop (V)
SBU 1
247.50
244.83
2.57
SBU 2
246.30
243.30
3.00
WBU 1
244.13
243.67
0.47
WBU 2
243.30
239.00
4.30
RH 1
244.83
241.00
3.83
RH 2
248.84
244.30
4.54
IPU 1
242.73
241.00
1.73
IPU 2
243.20
242.00
1.20
58
120 m length
20 m underground (open trench)
100 m in air cable tray
The current carrying capacity of the compressor cable is:
Current carrying capacity
381 A
270.51 A
339.09 A
59
OBSERVATION No. 4
RECOVER HEAT FROM RESIN HOUSE CONDENSATE FOR
PREHEATING THE BOILER FEED WATER
During the detailed energy audit at Asian Paints Limited, Patancheru, the
resin house boiler and condensate recovery system was studied in details to
identify any possible energy savings.
The revomax boiler are used to provide steam to the industrial resin reactors
and the condensate from the reactor discharge is been collected in condensate
tank. The Condensate was observed to be at a temperature of above 60 Deg C
at all the time.
As the TDS levels of the condensate is very higher cause of intermixing of
cooling water and steam being passed though the same reactor coils it is not
possible to recycle the same condensate though the boiler feed water pump
due to increased chances of scaling in boiler coils.
This condensate at over 60 Deg C can be used for pre heater the boiler feed
water to reduce the boiler fuel consumption. The heat available in condensate
at 60 Deg C can be used for heating up the boiler feed water which is at 30
Deg C.
Preheating the boiler feed water would increase the feed water vapour
pressure which again can effect the NPSH of the boiler feed water pump. After
installation of heat exchanger for preheating boiler feed water from process
condensate would increase the water temperature to around 45 Deg C. The
vapour pressure of the water at 45 Deg C is 0.15 bar, so at all the time a
positive head of over 0.15 bar has to be maintained for smooth operation of
boiler feed water pump.
The water vapour pressure curve is as below:
60
30 Deg C
Condensate temperature
60 Deg C
0.65 m3/hr
0.65 m3/hr
At least 10 Deg C increase in boiler feed water can be achieved at all the time
Heat savings
6500 kcal/hr
LPG GCV
10700 kcal/kg
Saving in LPG
6500 Kcal/hr
10700 kcal/kg
0.60 kg of LPG
Running hours
3000 Hours/Annum
Annual savings
=
0.60 kg x 3000 hrs/annum x Rs.
60/kg of LPG
=
Rs. 1, 08, 000
Say Rs. 1.08 Lakhs
61
Investment required
Payback
62
Chapter V
Management Aspects and Conclusions
63
CHAPTER V
5.1
5.2
Specific Recommendations
Asian Paints Limited, Patancheru should form an energy conservation
committee. The committee should consist of senior operating, electrical
and maintenance personnel.
The committee should meet once in a month with a specific agenda to
review the progress of implementation of proposals and to guide the
implementation team.
Asian Paints Limited, Patancheru should also select a senior person as
energy manager and he should coordinate all the implementation
activities. 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 Asian Paints Limited, Patancheru should be to
implement the identified proposals and get the savings.
We would recommend Asian Paints 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.
Confederation of Indian Industry
64
5.3
5.4
Monitoring of Proposals
All the implemented proposals are to be monitored on a proposal-byproposal basis for actual achievement of savings on a monthly basis.
5.5
Motivational Aspects
The successful management of energy depends on motivation of
technical personnel and their commitment. For this reason, Asian Paints
Limited, Patancheru should carry out the following motivational aspects
to sustain energy conservation activities.
Send operating, electrical and maintenance personnel for training
programs in specific areas like:
Pumps
Fans & Blowers
Air Compressors
Refrigeration and Air conditioning
Motors
Organise visits for executives to similar units to know the energy
conservation / process development, etc.
5.6
Conclusions
The Asian Paints Limited, Patancheru and CII Godrej GBC
teams have jointly identified 14 energy saving proposals worth an
annual savings potential of Rs. 98.81 Lakhs. The investment
required for implementation of energy saving proposals is
Rs. 75.0 Lakhs. The total investment will have a simple payback
period of 9 months.
Implementation of identified proposals should be given top priority
and should be done step-by-step.
Confederation of Indian Industry
65
5.7
66
Annexure
67
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
68
2.
3.
6.
5.
69
70
71
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
72
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
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
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
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
73
Flat belts
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
74
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
75
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
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
76
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
HOC Dryers
Fax: 91-44-2553-2205
Email: nadiair@vsnl.net
Website: www.nadiindia.com
Insultions
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
2.
Investment
Required
(Rs. Lakhs)
Payback
Period
(Months)
28
31
13
0.9
1.8
24
2.8
13
56
22.3
Sl.
No
0.31
13.45
14.5
13
1.97
19
3
4
Person/Depa
rtment
Responsible
Target
Date
Remarks
0.44
0.6
17
10
12
11
4.2
1.6
3.5
42
13
9.9
14
11.54
Total
98.81
75.0
12
Backup Calculations
86
Watt
Quantity
Power in
kW
Other Offices
36w x 2
746
53.71
2432
Engg Store
36w x 2
40
2.88
2432
Production Blocks
(floor wise)
36w x 2
849
61.13
4984
BSR
36w x 2
90
6.48
4984
DC
36w x 2
10
0.72
4272
RMG
36w x 2
219
15.77
4984
PMG
72 w
80
5.76
4984
S.No
Location
Total
hours
146.45
Proposed
It is recommended to replace these T8 lamps with 1X20 W LEDs.
Power consumption of LEDs
Savings
40.68 kW
Say 40 kW
146 - 40 kW
87
Say 106 kW
S.No
Location
Watt
W1
Quantity
Nos (Q)
Power
in kW
Annual
Operating
hours (h)
Savings kW
= Q*(W120)
Savings=
kWhXRs
6.7/kWh
Other Offices
36w x 2
746
53.71
2432
38.79
6,32,059.78
Engg Store
36w x 2
40
2.88
2432
2.08
33,892.35
Production
Blocks (floor
wise)
36w x 2
849
61.13
4984
44.15
14,74,292.10
BSR
36w x 2
90
6.48
4984
4.68
1,56,278.30
DC
36w x 2
10
0.72
4272
0.52
14,883.65
RMG
36w x 2
219
15.77
4984
11.39
3,80,343.99
PMG
72 w
80
5.76
4984
4.16
1,38,914.05
2034
146.45
105.77
28,30,664.24
Total
Annual Savings
2034 X 1500
(Investment) X 12 months
(Savings)
12.9 Months
Say 13 months
Payback period
88
108 X 2 X 36 W
7.776 kW
Say 7.78 kW
Proposed
It is recommended to replace these CFL lamps with 1X18 W LEDs.
Power consumption of LED lamps
Savings in KW
Payback period
108 X 18 W
1.94 kW
7.78 1.94 kW
5.84 kW
Say 5.8 kW
Rs. 94,507/-
2,16,000/-
Investment X 12 Months
Savings
28 months
89
150 X 70 W
10.5 kW
150 X 18 W
2.7 kW
A 3 KW solar mill can be installed at the plant. 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.
The street lighting requirement can be met through this.
Investment for LEDs
Rs. 9 Lakhs
Total Investment
Say 13 Lakhs
Savings
Rs 13.0 Lakhs x 12
Rs 2.80 Lakhs
55 months
90
7.5 %
7.5 x 100 %
(20.9 7.5)
55.9 %
3 x 100 %
(20.9 3)
16.7 %
4284 m3/hr
3885.5 Nm3/hr
3885.5 Nm3/hrx(55.9%-16.7%)
1523.5 Nm3/hr
175 Deg C
Ambient temperature
28 Deg C
Heat savings
=
0.31 kcal/kg/DegC x 1523.5 Nm3/hr
x (175- 28) Deg C
=
69426 Kcal/hr
LPG GCV
10700 kcal/kg
Saving in LPG
69426 Kcal/hr
10700 kcal/kg
6.48 kg of LPG
5500 Hours/Annum
Running hours
91
Annual savings
=
6.48 kg x 5500 hrs/annum x Rs.
60/kg of LPG
=
Rs. 21, 38, 400
Say Rs. 21.38 Lakhs
4284 m3/hr
7.68 KW
Option 1:
Combustion
modulation:
air
supply
blower
capacity
controlled
by
damper
55.9 % - 16.7 %
39.2 %
39.2 % x 7.68 KW
3 KW
=
1 KW x 5500 hrs/annum x Rs.
6.7/KWh
=
Rs. 36,850
Thermal savings
Total savings
Payback
=
Option 2:
55.9 % - 16.7 %
39.2 %
39.2 % x 7.68 KW
3 KW
92
As VFD reduces the capacity of the blower by altering the operating speed this
arrangement doesnt calls for any need of damper control operation. Saving of
at least 2.5 KW can be achieved.
Annual savings
=
2.5 KW x 5500 hrs/annum x Rs.
6.7/KWh
=
Thermal savings
Total savings
Investment for online gas analyser with controller for blower frequency
(includes the VFD cost)
Payback
93
6.5 %
6.5 x 100 %
(20.9 6.5)
45.1 %
3 x 100 %
(20.9 3)
16.7 %
520 m3/hr
471 Nm3/hr
133 Nm3/hr
175 Deg C
Ambient temperature
28 Deg C
Heat savings
=
0.31 kcal/kg/DegC x 133 Nm3/hr x
(175- 28) Deg C
=
6060 Kcal/hr
LPG GCV
10700 kcal/kg
6060 Kcal/hr
10700 kcal/kg
0.56 kg of LPG
10200 kcal/kg
HSD GCV
94
6060.0 Kcal/hr
10200 kcal/kg
0.59 kg of LPG
Running hours
3000 Hours/Annum
Annual savings
=
0.56 kg x 3000 hrs/annum x Rs.
60/kg of LPG
=
Rs. 1, 00, 800
Say Rs. 1.0 Lakhs
Investment required
NIL
95
: 55 m
Discharge
Power
: 31.8 KW
31.8 KW
10 % x 31.8 KW
3.1 KW
Considering the operation can be only carried out during the night hours when
the ambient temperatures are lower, the above only 1500 hours of the above
4000 hours are taken for savings calculations.
Annual savings
=
3.1 KW x 1500 hrs/annum x
Rs. 6.7/KWh
=
Investment required
NIL
NOTE:
As the pump seal air fan is build in pump main shaft, we recommend to
conduct trails during the night hours when the ambient air temperature are
lower compared to day time. (Caution should be taken in setting the pump
speed control limits to upto maximum reduction to 47.5 Hz)
96
Flow
(m3/hr)
43000*
Flow
(CFM)
25298
Power
(KW)
19
Efficiency SEC
SEC Norm
(%)
(W/CFM) (W/CFM)
0.75
0.18
39347
23149
17.79
28
0.77
0.18
43801
25770
8.55
56
0.33
0.18
45512
26776
8.46
49
0.32
0.18
69386
40822
28.44
48
0.70
* Actual flow to system for VSP 301 was measured to be 22480 m3/hr. The
reduction in the flow was mainly due to leakage at immediate blower discharge
ducting. For calculation the specific energy consumption (SEC) the rated flow
was considered for comparing the savings possible.
The specific energy consumption of the blowers were measured and are
compared with the specific energy consumption of high efficiency blower.
Blower VSP 303 AND VSP 304 SEC is in the range of 0.32 to 0.33 W/CFM
whereas for the other three blower is over 0.70 W/CFM. This clearly indicates
lower operating efficiency of the blowers.
Recommendation:
Confederation of Indian Industry
97
43000 m3/hr
17.79 KW
0.75 W/CFM
0.25 W/CFM
Saving potential
(0.75 0.25) x 19 KW
9.5 KW
* Actual flow to system for VSP 301 was measured to be 22480 m3/hr. This
reduced flow was mainly due to leakage at immediate blower discharge
ducting. For calculation the specific energy consumption (SEC) the rated flow
was considered for comparing the savings possible.
39347 m3/hr
17.79 KW
0.77 W/CFM
0.25 W/CFM
Saving potential
9.25 KW
98
Annual savings
(9.5 + 9.25) KW
18.75 KW
=
18.75 KW x 7000 hrs/annum x Rs.
6.7/KWh
=
Phase II:
Present Flow of VSP 302
69386 m3/hr
28.44 KW
0.70 W/CFM
0.35 W/CFM
9.95 KW
9.95 KW
Annual savings
=
9.95 KW x 7000 hrs/annum x Rs.
6.7/KWh
Saving potential
Investment requirements
Phase I
Two blower of 40000 m3/hr capacity would be Rs. 7.5 Lakhs
Phase II
Single blower of 70000 m3/hr capacity would be 7.0 Lakhs
Total investment
Payback
=
=
=
99
As indicated in the figure, when only 5kL reactor pump was running,
recirculation of 27 m3/hr (22%) was observed through 3 kL pump. When only
3kL pump was running, recirculation of 15 m 3/hr (12%) was observed through
5kL pump.
Confederation of Indian Industry
100
Minimum recirculation in the circuit is 15m3/hr when any one reactor runs.
Recirculation is happening due to the failure of non return valves (NRV). This
results in higher power consumption of the pump.
Plant team have already replaced existing NRVs with new ones. CII
congratulates the plant teams efforts in replacing passing NRV to
avoid recirculation.
Temperature difference across each reactor is only 1.5 0C. Minimum
temperature difference that can be maintained across any heat exchanger is 340C. This indicates there is an excess flow through reactor, can be optimized.
A trail can be taken by throttling the pumps in steps of 10% till temperature
difference of 40C is achieved across the reactor. Simultaneously, please
monitor the reactor bulk temperature, as it is critical.
The cooling requirement for each equipment was analyzed in WBU section.
After assessment the combined cooling requirement in WBU section for
(Reactors, LDV, 70TR chiller) is 200TR.
The details are given as below:
S.No
User
Cooling load
(TR)
3 kL Reactor
50
5 kL Reactor
46
LDV
15
70TR Chiller
condenser
90
Total
200
Each equipment runs at a different batch cycle time. When all the equipment
run simultaneously, the cooling requirement is maximum, i.e., 200TR.
But the installed capacity of the cooling tower is only 120TR. Because of this
insufficient cooling tower capacity, chilled water is being used to cool return
cooling water from the users during summer. Installing one more cooling tower
of 120 TR capacity increases the heat rejection capacity & cooling efficiency.
And the need to use chilled water to cool the return cooling water during
summer can also be avoided, which is an energy intensive method.
Recommendation
We recommend to
Confederation of Indian Industry
101
Install VFD for one pump and operate only that pump even for 2 reactors
Before installing VFD, plant can take a trail by reducing the flow by
throttling the pump in steps of 10% till temperature difference of 40C is
achieved across the reactor
Install a separate cooling tower of 120TR for chiller condenser and avoid
using chilled water to cool return water during summer
Savings calculation
Avoiding Recirculation in the circuit
Minimum recirculation in the circuit
15m3/hr
120 m3/hr
Minimum % of recirculation
=
=
15 m3/hr x 100
120 m3/hr
12.5%
7.7 kW
Annual Saving
=
=
=
=
(1-0.753)x7.7kW
4.4 kW
=
=
(1-0.753)x6.3kW
3.6kW
102
=
=
Annual saving
=
8kW x 10hrs x 330days x Rs
6.7/kWh
=
Rs 1, 76, 880/=
Rs 1.76 Lakhs
=
=
=
=
=
Rs 1.50 Lakhs
Rs 1.50 Lakhs
Total investment
Rs 3.0 Lakhs
Rs 3.0 Lakhs x 12
Rs 1.97 Lakhs
19 months
4.4kW + 3.6kW
8 kW
103
104
The temperature difference across LDV is only 20C. For a heat exchanger, the
minimum temperature difference that can be maintained is 4 0C. This indicates
excess flow through LDV, can be optimized.
This can be done by throttling the pump or installing VFD and operating it with
pump discharge pressure as feedback.
Trail can be taken by throttling the pump in steps till the temperature
difference of 40C is achieved & simultaneously monitoring the material
temperature.
Optimizing the flow by reducing the speed with VFD will save more power.
Recommendation
We recommend to
Before installing VFD, trail can be taken by throttling the pump in steps
till temperature difference across LDV reaches 40C.
Install VFD for the pump
Operate VFD in closed loop with the header pressure
Saving calculation
Operating power of LDV pump
5kW
50% of the flow can be reduced, i.e, VFD will operate at 50% speed
As Power (speed)3, considering at least 25% reduction in speed
New operating speed
=
75%
Annual saving
=
(1-0.753) x 5kW
330days x Rs 6.7/kWh
=
Rs 44, 738/=
Rs 0.44 Lakhs
Rs 0.60 Lakhs
Rs 0.60 Lakhs x 12
Rs 0.44 Lakhs
17 months
7hrs
105
490
49
0.4
8.3
3500
491
25
0.2
2400
492
71
1.2
58.5
5500
470
74
2.6
27
160
481
28
39
100
482
64
3.7
58
1300
483
3500
106
5kW
3200 hrs
=
=
=
Investment
Rs 1.0 Lakh
Rs 1.0 Lakh x 12
Rs 1.0 Lakh
12 months
107
Cooling tower fans were operating based on the cold well temperature. Fans
switch on when cold well temperature reaches 270C and switches off when it
reaches 250C.
When measurements were taken, CT fans were in OFF condition. Even when
the fans were in OFF condition, 20C cooling was being achieved.
Generally, cooling tower are designed to give a range of 6-8 0C. By switching on
the fans and running them continuously, cooling tower can give minimum
range of 40C i.e., range will get doubled. Cooling water flow can be halved.
Currently, 2 pumps are running continuously and delivering 93m 3/hr (P458)
and 62m3/hr(P457) continuously. Total cooling water flow is around 150m 3/hr.
Confederation of Indian Industry
108
One pump P457 can be switched off. Then the second pump (P458) will deliver
more flow than before as the system resistance reduces as the cooling water
flow reduces.
The power consumption of the second pump can be optimized by installing
VFD and operating it with pump discharge pressure of 2 kg/cm 2 as feedback.
Cooling tower fans can be installed with VFD and operated in closed loop with
cold well temperature interlock of 320C.
Recommendation
We recommend the following
Install VFD for CT fans and operate the VFDs in closed loop with the cold
well temperature of 320C
Operate the VFD in closed loop with the discharge header pressure of 2
kg/cm2
Saving calculation
Power consumption of CT fans
6kW
By installing VFD for CT fans, at least 25% of the flow can be reduced
i.e., VFDs will operate at 75% of the speed
As Power (Speed)2,
Annual saving in the fans
=
=
Investment
Rs 0.8 Lakhs
9kW
=
=
=
Rs 0.80 Lakhs
109
=
=
Rs 4.20 Lakhs
Rs 1.60 Lakhs
Rs 1.60 Lakhs x 12
Rs 4.20 Lakhs
5 months
110
Design
Parameters
Flow
m3/hr
Head
(m)
60
43
21.00
24
6.15
24
18
33.00
10*
2.4
41
11-39
21.00
32
5.79
34
70 TR chiller
monomer pump
70 TR chiller hot well
pump
Pump house P504
Operating Parameters
Motor
Flow Head Loading Efficiency
m3/hr (m)
kW
%
23.5-9.5
The operating efficiency of above pumps is low due to mismatch between the
design and operating head / ageing of the pumps / low efficiency by design. In
* marked pumps head is estimated value as provision for measuring pressure
was not available.
The efficiency calculation of 70TR chiller monomer pump is as below.
Measured flow
21 m3/hr
Head
24 m
Power consumption
2.4 kW
Operating efficiency
= 21 m3/h x 24 m x 1 x 100%
3.6x102x 6.15 kWx0.90(motor )
=
24 %
6.15 6.15 x 24 %
111
70 %
=
4 kW
* 70% new pump efficiency is considered only for savings calculatio n.
Specifications of 70TR chiller monomer pump:
Flow
25 m3/hr
Head
25 m
Efficiency
> 70%
6.15 kW
Annual savings
=
4 kW x 3300 hrs/year
/kWh
=
Rs. 0.8 Lakhs
x Rs. 6.7
112
OF
THE
AIR
Present status
During the detailed energy audit of Asian Paints Limited Patancheru, a detailed
study of all the compressed air units was carried out for possible energy saving
opportunities.
The plant has installed a centralised compressed air system consisting of two
screw compressors which maintain the pressure of the receiver at 5.7 bar. This
centralized compressed air system supplies air to all the sections of the plant
viz. Water Based Unit, Solvent Based Unit, Industrial Paint Unit, Resin Block
and the Monomer block.
Monomer
Tank
P405
587 CFM
5.7 bar
5.6 bar
5.5 bar
Refrigerant
Drier
10m3
Receiver
P406
587 CFM
5.5 bar
Industrial Based Unit
Phase I & II
5.5
bar
Resin
Block
5.4
bar
Compressor
P405
P406
Location
Compressor
House
Compressor
House
Loading
Pressure
bar
Unloading
Pressure
bar
Average
Pressure
bar
Power
kW
5.7
6.2
5.95
88.30
5.5
6.0
5.75
86.03
It was observed that when the plant is in full load operation, one compressor is
continuously running and the second compressor is running for 10 % of the
time. This compressor has been set in such a way that if it is in unload for
more than 10 minutes it automatically switches off. The limit of switching on
and off for a 110 kW motor is times in an hour.
During the detailed energy audit of the plant, a comprehensive compressed air
distribution study was carried out for the compressed air requirement of the
Confederation of Indian Industry
113
end users and the pressure drop at the farthest point in the plant. During the
compressed air user study of the plant, it was observed that the compressed
air pressure drop at the farthest point from the generation was not more than
0.2 bar.
The compressed air pressure being maintained at different applications in the
plant is as follows:
Purpose of Compressed Air
Pressure Maintained
Open/Close valves
4.0 bar
Hopper Aeration
3.0bar
Bag Filters
4.0bar
3.0bar
4.0bar
5.0bar
Cleaning Purpose
3.0bar
It was observed that in most of the end users the pressure setting being
maintained was between 3.0 bar to 4.0 bar. The only operation which requires
a pressure of 5.0 bar is the Lid pressing operation in packer area. The
manufacturer has advised a pressure setting of 6.0 bar considering a safety
margin but the plant is running the packer machine successfully maintaining a
pressure setting of 5.0 bar. It was also observed that these packing machines
were already installed with additional booster compressors, which cater to the
higher pressure compressed air requirements of these machines. CII
congratulates the plant team for this excellent initiative towards
energy conservation activity.
Here is a good opportunity to utilise this booster compressor so that it supplies
high pressure compressed air to the packer machine and reduce the
compressor air pressure at the generation end itself.
Proposed System
The compressed air pressure maintained for most of the applications in the
plant is not more than 4.0 bar. Only the lid pressing operation in the packing
machine requires a higher compressed air pressure requirement of 5.0 bar.
These packer machines are already installed with booster compressors. We can
Confederation of Indian Industry
114
CIISohrabji Godrej Green Business Centre
use these booster compressors in such a way that when we give an input of
4.0 bar compressed air, it gives an output of air at a pressure of 5.0 bar.
Utilizing this booster compressor we will be able to cater to the pressure
requirement of 5.0 bar for the lid pressing machine and at the same time we
will be able to reduce the pressure of the compressed air at the generation end
to less than 4.5 bar average pressure which is sufficient for all the other
compressed air applications.
When we utilize this booster compressor, it increases the amount of
compressed air usage as it increases the pressure of the incoming air and
produces high pressure air. But this increase in compressed air consumption is
not as significant when compared to the savings we will achieve by reducing
the compressed air generation pressure.
Recommendation
Step 1:
Firstly, we recommend to reduce the compressor pressure by 0.2 bar at the
generating point and at the same time adjust the compressed air pressure
setting in the booster compressor of all the packing machines such that
these booster compressors gives an output of 5.0 bar compressed air to the
packer machines.
Run the plant in normal operation for a few days.
Step 2:
If there is no issue with the operation of the plant, keep on reducing the
generation pressure in steps of 0.2 bar until the generating pressure is set
to an average pressure of 4.5 bar and utilizing the booster compressor in
the packing machines so that the required pressure of 5.0 bar is
continuously maintained in the packing machines.
keep on reducing it until the generating set points are:
Load point
- 4.2 bar
Unload point
- 4.7 bar
Calculations
For Compressor P405:
Percentage Pressure reduction
Annual Savings
Annual Savings
Investment
= Nil
116
Area
Leakage (%)
Total Leakage
47
24
12
11
It is difficult to find out the leakages in a continuous process plant. The ideal
time to find out the leakages is during shut down time by conducting a leakage
test.
A simple procedure for conducting leakage test is:
Close all the user end points
Start the compressor and allow it to run
If there are no leakages, the compressor once unloaded should not load
again as there is no consumption at the user point
If there are leakages, it will operate in load and unload mode
Note down the loading and unloading time of the compressor. The
percentage loading indicates the percentage leakage.
Walk along the compressed air lines to identify the leakage points
Arrest the leakage at all the identified points
However, leakage test and arresting leakages is not one time activity. It is a
continuous activity. Leakage may not be avoided but can be brought down to a
very minimum level by continuous efforts.
Recommendations
Confederation of Indian Industry
117
It is recommended to
Avoid unwanted purging of compressed air
Arrest the leakages at identified locations
Avoid the use of High Pressure compressed air for cleaning
Increase the awareness among the operators and the workers on the value
of compressed air
Conduct leakage test during shut down time
Identify & arrest the leakages
Calculations
For Compressor P405:
Leakage Test:
Loading time (LT)
= 83 sec
= 92 sec
% Leakage
Total Savings
=
=
Investment
Nil
118
119
120