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ENERGY & SAFETY AUDITFOR THE YEAR 2012-13

For

SONTHALIA RICE MILLS-3/36,37 SEC-A, ZONE-BMANCHESWAR INDUSTRIAL ESTATEBHUBANESHWAR-10

22nd. July -2012

AUDITED BY

V S RAI ASSOCIATESENERGY MANAGEMENT CONSULTANTSTIRUPATI APARTMENT, FLAT-1DBD-205/206, KAMALPARKKOLKATA-700101

V S RAI ASSOCIATES-ENERGY MANAGEMENT CONSULTANTS

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C O N T E N T S

SECTIONS DESCRIPTION PAGE NO.

Summary of Findings 3

1.0 Power scenario at the Rice mill 4

2.0 Power Requirement with CPP 7

3.0 Power distribution & PF improvement8

4.0 Compressed Air at Color sorting machine10

5.0 Electrical safety audit & precaution11

6.0 General maintenance & Prevention of break downs 12

Annexure I-II

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SUMARY OF FINDINGS

Ref no. Action Suggested Recurring Saving/yearRs.

Budgetary Investment Rs.

Page No

1.0 Power scenario of rice mill operation is illustrated

Details are specifically illustrated 4

2.0 Power requirement with envisaged CPP Details are specifically illustrated 7

3.0 Power distribution & PF improvement 167000 52500 8

4.0 Reduction of Air pressure from 7.0 Kg/cm²to 5.0 kg./cm²

60200 nil 10

5.0 Interconnecting Present Earthing system Specific suggestions are made to improve safety of electrical system.

11

6.0 Initiate cleaning schedule for Electrical Equipment

Specific measures are made to minimize break downs.

12

Total Rs.2,27,200/year Rs. 52,500

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1.0 POWER SCENARIO AT THE MILL

1.1 BACKGROUND

i. Sonthalia Rice Mill (SRM),Paribasudevpur , Khurda Orissa) is rice mills equipped with 3 parallal production lines of 3Ton/hour capacity each.Two production lines are equipped with parboiling process while other line is of Arua section. The total power consumption of the plant is about 11,40,000 kwh/annum which amount to Rs.75.00 Lac/annum. SRM purchase power from Orissa power supply & distribution company Limited on 11KV power line to cater power requirement of the mill besides it has also installed 100 KVA DG set to manage power requirement of critical equipment only during non availability of purchase power.

Further SRM is also facing regular power interruption problems besides very poor quality of power supply w.r.t low voltage. To overcome low voltage problem, the management has also installed 500KVA automatic voltage stabilizer. However many times, the said stabilizer is not able to boost power voltage for the efficient operation of Electric motors & their controls. The matter of very poor quality of power supply coupled with power interruption is one the key concern before management to main productivity. The management is contemplating to go for its own captive power plant to sort out recurring power problems for their steady growth with higher productivity.

ii. Power Demand & consumption Profile.

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iii. Total Connected Electrical load of Entire Rice Mill

Sections Connected HP Connected-KW Remarksi.Arua ketel 22.5 16.785 i.Total actual running load with

two lines ( parboiling Operation) was found to the order of 300KW with running Power demand of 320KVA

ii Powqer factor was observed to the order of 0.94-0.96

ii.Arua section 172.5 128.68iii.Old mill with Dryers

222+27 165.612+20

iv. New mill with dryers

116.5+20 86.909+15

v.color sorting with air compressor

40 30

vi Boiler 30 22vii.Other Misc (Lighting, Packing etc)

47 35

Total Load 697.50 HP 519.986 KW

iv. Total Running Power Requirement

Power measurement exercise was conducted to ascertain actual power requirement of rice mill with two line operation. Details are out lined below:

Sections Running load-KW

Running Load-KVA

Remarks

i.New line with dryers 90 96 i.Total actual running load with two lines ( parboiling ii. Old line with 135 143.9

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dryers Operation was found to the order of 300KW.

ii. Power was found to the order of 0.94-0.96.

iii.Colour sorting m/c with Compressor

30 33

iv Boiler section 10 10.70v. Other misc load 35 37Total load 300 KW 320.06 KVAProposed load withArua section& ketel

110 120

Total Plant running load

410 KW 440 say 450KVA

v. Projected Power Requirement with 3 lines operation:

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2.0 POWER REQUIREMENT WITH PROPODSED CPP

In case SRM, plan for CPP ( Captive Power Plant ), the requirement would be as follows

a. The power requirement with 3 lines operation =460Kwb. Power demand requirement with 3 lines operation = 515 KVAc. Proposed rating of CPP would be = 590KW

2.1 SELECTION CIRITERIA OF CPP

i. Running load of entire Rice mill = 410 KWii. Running power demand of entire rice mill =450 KVAiii. Considering 10% misc loadd, the power requirement would be =460 Kw or 515 KVA

( 410+50 Kw)iv. Maximum power demand with starting kick load=645 KVA say 650 KVA

( 515x1.25 )v. Therefore if mill wants to go for a Captive power plant to cater power requirement

with all three line operation ,the power requirement would be = 590 KW or 650KVA KVA

vi. The selection of captive power should be such that it can supply power to the order of 590 KW

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3.0 POWER DISTRIBUTION & POWER FACTOR (PF) IMPROVEMENT

3.1 STATUS REVIEW

Sonthalia Rice Mill (SRM) purchase power from Orissa power supply & distribution company Limited at 11 KV power line & with help of 500KVA transformer (11/0.433KV), the available power is distributed to various sections of mills. Power requirement at the mill is tabulated below:

a. Sanctioned power demand = 200 KVAb. Running power demand =384-480 KVAc. Power Factor = 93-94%d. Power consumption/month = 90,000-108700 Kwhe. Power cost bill/month = Rs.6.50-7.0 Lac

The PF is an index for the effective utilization of available power. The plant has already installed 1no.x200 &1x100 KVAR APFC ( Automatic power factor controllers to improve the power factor. However the location of the above said APFC is across main distribution board (Adjacent to 500 KVA LT voltage stabilizer) which does not effectively utilized to optimize power loss at various key load centers. Further APFC does not correct the low level power factor hence necessity was felt to install additional capacitors at load centre to optimize line loss & improvement of motor performances.

3.2 PF Mapping

PF mapping was carried out to ascertain PF at load centers at Line No.1&2 power distribution panels, dryers power distribution panel, Sortec panel, Boiler panels, & others. Details are summarized below:

Equipments Main I/C panel line.-1

Main I/C panel line.-2

PolishingMotor-130HP

PolishingMotor-230HP

PolishingMotor-330HP

PolishingMotor-430HP

Silky50HP

Dryers. No.1

Power factor

0.55-0.61

0.0.49-0.60

0.74 0.46 0.35 0.63 0.82 0.65

Equipments DryersNo2

Air Blowers

Air Comp.18.5 Kw

Boiler panel

LT TrsO/G

Remarks

Power factor

0.70-0.77

0.0.60-0.75

0.55-0.87 063-.071 0.90-.94 PF At load centrs is very poor & call for improvement to optimize power loss

In view of above, the need of PF improvement was felt at following locations:

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a. Installation of Capacitors across transformer.b. Installation of Capacitors across key lad centers.

3.2.1 CAPACITOR ACROSS TRANSFORMER

In view of above a necessity was felt to connect separate additional capacitor across 500 KVA transformer besides separate capacitors should be connected on the key loads centers. Typical connection for proposed capacitors

Details of capacitor, SFU & HRC fuses are out lined below which are to be connected on secondary side of transformer preferably across LT out going ACB. These capacitors should remain in circuit even on off or holidays or on part load. a. Capacitor for 500KVA Trs = 25 KVARb. Rating of SFU =63 Amp.c. HRC fuse rating = 63 amp.Total investment for item no a, b & c would be around Rs.12500

3.2.2 ADDITIONAL CAPACITOR ACROSS KEY LOAD CENTRE

In view of low power factor across key load centers it is strongly felt to install additional capacitors to improve PF up to 95% and above. Details are summarized below:

Particular

Line-1PDB

Line-2PDB

Line-3PDB

Dryer PDB-1

Dryer PDB-2

Boiler PDB

SortexPDB

OtherPDB

Total

Capacitor -Kvar

20 20 20 7.5 7.5 5 10 10 100 Kvar

Capacitors requirement would be =3 nos.x20KVAR,2nos.x10KVAR, 2 nos.x7.5 KVAR &1 no.x5 KVAR rating. These capacitor bank would be installed with proper SFU &HRC fuses for effective control & operation.

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3.3 ANTICIPATED BENEFITS

The likely reduction of maximum power demand and reduction of power distribution loss would be of Rs 167,700/annum against the budgetary investment of Rs 52,500.

3.4 RECOMMENDATION

It is strongly recommended to install 25 Kvar static capacitor delta connected at LT side of 500 KVA transformer, preferably across LT ACB (adjacent to transformer) out going feeder. The envisaged capacitor would be connected through SFU and HRC fuses and would remain on always on irrespective of mill operation.

It is also strongly recommended to install 100 KVAR additional capacitor across power distribution board as indicated above to optimize power loss and improvement of electric motors efficiency.

4.0 COMPRESSED AIR AT COLOUR SORTING MACHINE

4.1 STATUS REVIEW

Plant has installed Elegi make air compressor of 2.97 NM³/minute capacity to generate compressed air at 7 kg/cm². The plant has installed Delair make air dryer to supply instrument air for colour sorting machine. Plant has also installed air receiver to supply steady air pressure for the proper functioning of sorting machine.

The observation of sorting machine operation indicate that the pneumatic air pressure at machine was found to the order of 2.6 kg/cm². In view of machine requirement it is our considered observation to reduce the air pressure of compressor for the comfortable and effective operation of sorting machine. The reduction of the said air pressure would reduce the power consumption besides the stress of compressor would be significantly reduced. The said reduction of air pressure would be adopted in two phases which are out lined below:

Activities Present air generation Cut off prs. Restart prs

Proposed air pressureCut off prs. Restart prs.

Reccurring saving/year

Phase-I 7.2 kg/cm² 5.5kg/cm² 6 kg/cm² 5.5 kg/cm² Rs 36000

Phasr-II 7.2 kg/cm² 5.5kg/cm² 5 kg/cm² 4.5 kg/cm² Rs 61250

4.2 ANTICIPATED BENEFIT

The likely power cost saving with the reduce air pressure generation would be Rs 60,200/annum without any investment. However it is suggested that initially the present air pressure generation

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should be reduce to 6 kg/cm² and later on the air pressure setting should be restricted to 5 kg/cm² only.

4.3 RECOMMENDATION

It is strongly recommended to reduce the operating pressure of sorting air compressor from 7 kg /cm² to5 Kg/ cm² in two phases to optimize power consumption without any investment.

5.0 ELECTRICAL SAFETY AUDIT & PRECAUTIONS

5.1 STATUS REVIEW

Electric Safety Audit is an organized effort to identify various problems and evolve specific safety measures at measurable cost & time. Electrical safety audit also provides an effective tool to the management to identify, implement & sustain safety measures.

Electrical Earthing : The main function is to protect electrical equipment from insulation fault (a "short circuit") or a very high current flows, which will trigger an over – current relay to isolate the power circuit. It also avoid the risk of electrical shock to personnel working with machines.Sonthalia Rice mill has installed separate earthing system for every power distribution panels located in each lines & other areas. .The said earthing is connected to two separate earthing pits adjacent to building for grounding earthing wires. However since last many years no assessment is made to ascertain the effectiveness of earthing strips..

5.2 OBSERVATION & ANALYSIS

a.. No physical inspections or regular cares are carried out to ascertain the effectiveness of earthing system.

b.Earthing pits are rarely inspected by plant personnel and no measurement of earth resistance are being carried out since last many years.

5.3 ACTION SUGGESTED

It is our considered recommendation that all parallel earthings of various sections/locations are to be inter connected immediately so as to improve the effectiveness of installed earthing system. The said interconnection should be carried out with 1 inch Aluminum or MS flats. This would augment present earthing system and improve overall protection.

It is our considered suggestion that regular monitoring & inspection of earthing pits is essential at least once in 3years. The frequency of Earth resistance & Voltage measurement should be carried out once in 3 years.The organization may approach some local agency to carry out above said inspection & measurement.

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6.0 GENERAL MAINTENACE & PREVENTION OF BREAK-DOWNS

6.1 STATUS REVIEW

The organization is equipped with number of electrical mototors, Distribution Board/panels *& motor starters. To cater the power requirement of entire mill.Presently as and when equipment fails, electrician is called for the necessary repair and maintenance. This is a time consuming and SAS type maintenance repair arrangement and call for review.

It has been observed during audit period that most of the distribution boards/panels are filled with fine dirt & dust particles which seeped through joints and gaskets of panel board, switches and starters. The said dirt and dust deposits are injurious to the health of the electrical system and accelerate faults. Further electric motors are muscles of production & are taken them granted because they usually perform so well. But when a motor fails, entire machine and some time system goes down. Break downs are quite frequent & causes significant production loss.

6.2 ACTION SUGGESTED

In view of above, a strong possibility was exlored to initiate a preventive care for electrical equipment to enhance the reliability and minimize the outage of plant machinery.

a.It is our considered suggestion that management should initiate preventive care (maintenance) with help of a semi skilled workers which would be supplied with air blower, pliers and a set of spanner to clean all the distribution panel, motor starter and electric motors with following regular frequency :

Normal season Frequency of cleaning should be once in 15-20 days monthPeak season Frequency of cleaning should be once in 7-8 days

B .Electric motors fitted with grease nipple must be lubricated with grease gun at least once in six months.c. Gear Box/Radicon Gear box: The lubricant of Gear box must be topped to maintain minimum level on regular basis.

c. Cleaning o f suction air filters of Air compressor must be done at -least once in a month to main good performance.

Place: KolkataDate: 26.07.2012

For V SRAI ASSOCIATES-ENERGY MANEGEMENT CONSULTANTS

V . S. RAI

V S RAI ASSOCIATES-ENERGY MANAGEMENT CONSULTANTS