Final Draft DEA Report Asian Paints Ltd Patancheru

8/10/2019 Final Draft DEA Report Asian Paints Ltd Patancheru

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Confederation of Indian IndustryConfederation of Indian IndustryCII-Sohrabji Godrej Green Business CentreCII-Sohrabji Godrej Green Business Centre

Detailed Energy Audit

At

Asian Paints Limited,

Patanheru

!une "#$%

Confederation of Indian IndustryCII&Sohrabji Godrej Green Business Centre


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C'()E()SC'()E()S

Cha*ter(o+

Desri*tionPage(o+

Executive Summary 1

I Introduction 3

II Acknowledgement 4

III List of Energy Saving Proposals

I! Energy Saving Proposals "

! #anagement Aspects and conclusion ""

!I Annexure $%

!II &ack'up (alculations )%

Total Pages: 116


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EEC)I.E S//A01

Asian Paints is one of t*e India+s largest paint companies w*ic* manufacturepaints for decorative and industrial use,Since its foundation in 1)4-. AsianPaints *as come up a long way to /ecome India0s largest and Asia0s t*irdlargest paint company. wit* a turnover of s, 1-$,1 /illion, Asian Paintsoperates in 1$ countries and *as -3 paint manufacturing facilities in t*e worldservicing consumers in over " countries,

2*e plant team *as done exceedingly well in incorporating certain energyefficiency aspects in design stage, urt*er. plant team *as taken many stepstowards t*e improvement in energy efficiency,

(II *as conducted t*e etailed Energy Audit at Asian Paints Limited,.Patanc*eru Plant from 1 to -1 5anuary. -%14, A detailed presentation was

made to t*e plant team covering various energy conservation opportunities on-t*5anuary. -%14, 2*e com/ined efforts of Asian Paints Limited,. Patanc*eruand (II'6odre7 6&( team *ave toget*er identified. annual energy savingpotential of 0s+ 23+3$ La4hs. /ased on present energy cost,

)he summary of the annual energy sa5ings identified is as belo67

)otal Annual Sa5ings 8$% *ro*osals9 7 0s+ 23+3$ La4hs

In5estment re:uired 8$# *ro*osals9 7 0s+ ;


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SPECI=IC AC)I'( PLA(

a8 Asian Paints Limited. Patanc*eru s*ould identify specific person ordepartment to facilitate implementation of t*e a/ove proposals andac*ieve t*e savings,

/8 Specific target date for implementation of proposals s*ould /e set andimplementation s*ould /e taken up on priority,

c8 2*e plant team s*ould prioriti9e t*e a/ove proposals and implementt*em in a p*ased manner,

d8 In our opinion t*e following proposals can /e implemented straig*tawayand s*ould /e on top priority,

:ESP ;os, . ". 13. 148

2*e a/ove proposal doesn0t re. ). 1%. 118

f8 As a t*ird priority. due to t*e *ig*er pay/ack. t*e following proposals*ould /e implemented /efore twelve mont*s,

:ESP ;os, 3. 1-8

g8 Asian Paints Limited. Patanc*eru s*ould form an energy conservationcommittee, 2*e 6eneral #anager s*ould *ead t*e committee, 2*ecommittee s*ould meet once in a mont* and review t*e progress ofimplementation activity,


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C>AP)E0 & I

I()0'DC)I'(

Asian Paints Limited. Patanc*eru evinced keen interest in availing t*e servicesof (II ' 6odre7 6reen &usiness (entre :(II ? 6odre7 6&(8 of t*e (onfederationof Indian Industry :(II8 for conducting a detailed energy audit at t*eir unit,

2*e (II'6odre7 6&( proposal for conducting a detailed energy audit at AsianPaints Limited. Patanc*eru was accepted /y management@ vide t*eir eferenceP,=, ;o, 11)1>43. dated -"t*;ovem/er. -%13,

2*e field activities of t*e detailed energy audit were conducted in one visit andt*e final presentation to t*e plant team was made on -t*5anuary. -%13,

2*e met*odology adopted for conducting t*e detailed energy audit atAsian Paints Limited. Patanc*eru is as follows

&asic data collection on list of power consuming e


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C>AP)E0 & II

AC?('@LEDGE/E()

(II acknowledges wit* t*anks t*e co'operation and t*e support extended tot*e (II energy audit team during t*e detailed energy audit at Asian PaintsLimited, Patanheru+

2*e interactions and deli/erations wit* Asian Paints Limited, Patanheruteam were exemplary and t*e w*ole exercise was t*oroug*ly a rewardingexperience for (II,

2*e arrangements and support during t*e energy audit were excellent, Bedeeply appreciate t*e interest. ent*usiasm and commitment of Asian PaintsLimited, Patanheru team towards t*e energy conservation,

Be would also like to place on record our sincere t*anks and appreciation forall t*e senior plant executives,


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C>AP)E0 & III

LIS) '= E(E0G1 SA.I(G P0'P'SALS

Sl+(o

Energy Sa5ing Pro*osalsAnnualSa5ings

80s+ La4hs9

In5estment0e:uired

80s+ La4hs9

Payba4Period

8/onths9

1eplace 2*e -x3"B 2> Lamps Bit*1x-% B LEs -> 31 13

- eplace - x 3"B (Ls wit* 1>B LEs %,) 1,> -4

3enewa/le energy for lig*ting :longterm8 -,> 13 "

4

=ptimi9e t*e excess air supply in resin*ouse t*ermopac 2P'4% for

improving com/ustion efficiency --,3 3

=ptimi9e t*e excess air supply in resin*ouse revomax /oiler CA%" forimproving com/ustion efficiency 1 % %

"

=ptimi9e t*e 2P 4% t*ermic fluidpump operation /ased on t*e resin*ouse reactors re=ptimi9e t*e operation of B&D coolingwater pumps 1,)$ 3 1)

)=ptimi9e t*e operation of L! coolingwater pump in B&D section %,44 %," 1$

1%=ptimi9e t*e operation of new /a9aarcooling water pumps 1 1 1-

11=ptimi9e t*e operation of industrialcooling water pumps 4,- 1,"

1-eplace inefficient pumps wit* newefficient pumps 1 3, 4-

13educe t*e generating pressure of t*eair compressors in t*e plant ),) % %

14#inimise (ompressed Air LeakageIn 2*e Plant 11,4 % %

)otal 23+3$ ;


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Chapter IV

Energy Saving Proposals


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LIG>)I(G S1S)E/ A) ASIA( PAI()S LI/I)ED,PA)A(C>E0

uring t*e course of detailed energy audit at Asian Paints Limited,Patanheru,a detailed study of plant lig*ting load was carried out to identifyenergy saving opportunities,

2*e lig*ting at Asian Paints. Patanc*eru was done /y (L. 2L. P#! andPS! lamps,

LA)ES) DESIG( )0E(D I( LIG>)I(G

2*e latest trend in lig*ting is to utili9e t*e rig*t amount of pupil lumen, 2*epupil lumen also considers t*e variation in sensitivity of t*e eye in relation tot*e environment, 2*e sensitivity of t*e eye varies /etween daytime lig*ting

and nig*t time lig*ting as s*own in t*e figure /elow.


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2*e scotopic curve and p*otopic curve mention t*e day'time lig*ting andnig*t'time lig*ting respectively, 2*e eye colour is more sensitive towards t*egreen colour for p*otopic curve and is correspondingly for /lue colour in t*ecase of scotopic vision, 2*is data of relative sensitivity of eye *elps us indesigning t*e correct colour of t*e lamp re "')% "%'$-

< Color !ariety ellow B*ite B*ite B*ite

Colortem*erature

-1%%'1%%%%J

-1%%J'3%%%J

3%%%'"%%%J

4%%%'%%%J 3%%%'"%%J

; SP 0atioDpto

-,4%,"- 1,3'-,- 1," 1,3

3

@arm u*

time 2#Lumen

Instant4minutes

1minute minutes

1%'%Seconds


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2 =li4er free yes ;o ;o ;o ;o

Ad5antages of LEDs

As identified from t*e a/ove ta/le. LE lamps offer t*e following advantages

Lower energy consumption

ig* SKP ratio

Longer life time

aster switc*ing

6reater dura/ility and relia/ility

6ood (olour endering Index :(I8

#ore focused lig*t and reduced glare

oes not contain pollutants like mercury

ig*ly compati/le for solar lig*ting as low'voltage power supply is sufficient

for LE illumination

ig*er Lig*t =utput atio :L=8 2*e Lig*t =utput atio indicates t*e actual

amount of lig*t t*at can /e o/tained after considering t*e losses inluminaire, As can /e seen from t*e figure /elow. t*e lig*t output also

depends on t*e lig*t fixture, In t*e first fixture. certain amount of lig*t islost, 2*e second fixture *as a mirror finis* reflecting t*e lig*t lost to t*eceiling in t*e first case is directed downwards and t*e loss of lig*t is low incomparison to t*e fixture on left, 2*e lig*t fixtures t*at *ouse LE lampsare latest and *ence t*e loss of lig*t is low, LE fixtures *ave an L= closeto 1%%G,


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0e*laement methodology of lam*s 6ith LEDs

)3 lam*s 6ith LEDs

2*e following met*odology can /e adopted w*en replacing a lig*ting fixture

wit* LEs, 2*e p*otopic efficacy of t*e present lamp can /e o/tained /ymultiplying t*e lamp efficacy and SKP ratio of t*e lamp, P*otopic efficacy isindicated in pupil lumenKBatt, 2*is p*otopic efficacy s*ould /e multiplied wit*t*e Battage of t*e lamp to o/tain t*e pupil lumen, 2*is pupil lumen s*ould /emultiplied wit* L= to get t*e actual amount of pupil lumen, ivide t*e pupillumen o/tained wit* -4%, -4% is t*e pupil lumenKBatt of LE, 2*e re lamps wit* LEs is also indicated,

Say for a 2> lamp 2*e lamp efficacy is "% lumenKBatt, 2*e SKP ratio is 1,3and t*e pupil lumenKBatt will /e $>, (onsidering a $- B 2> lamp and an L=of )%G. t*e Pupil lumen is %4, 2*e wattage of LE re lamp is -% B,

2*e comparison for 2>. (L. #. P#! and PS! lamps is indicated /elow,2*e approximate replacements can /e considered /ased on t*e ta/le /elow,2*ese values for exact calculation can /e taken from supplier,


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)y*eof

Lam*

@attageof lam*

Luminouseffiay

8lumen@att9

Corretionfator8SPratio9

Photo*ieffiay8*u*il

lumen@att9

Pu*illumen

Can bere*laed

6ith

LED@att

)3 $- B "% 1,3 $> "1" -% B

C=L $- B " 1,3 >4, "%>4 1> B

>PS. $% B )% %,"- ,> 3)%" 1> B

>PS. 1% B )% %,"- ,> >3$% 3% B

>P/.

$% B 4 %,> 43,- 3%-4 1> B

/> 1% B " 1," 1%4 1"%% $% B

/> -% B " 1," 1%4 -"%%% 1%% B

;ot all fixtures can /e retrofitted wit* LE lamps directly and t*e fixtures mayneed modification, 2*e a/ove met*odology can /e followed w*en consideringany future replacement of existing lamp fixtures,

Strategy for lighting fiture re*laement

2*e following strategy can /e adopted w*en replacing t*e existing lamps wit*LEs, uring t*e audit. it was noted t*at t*e plant team *as installed LEs atsome locations on a trial /asis, (II congratulates t*e plant team for t*eexcellent initiative taken, (II along wit* t*e plant team identified furt*erpotential to replace t*e existing lamps wit* LEs,

2*e lamps can /e replaced in a p*ase'wise manner. prioriti9ing t*e ones wit**ig*er energy savings and minimum pay /ack, 2*ese energy saving proposalsand t*e /enefits were explained /elow,

1, eplacement of PS! and P#! lamps for street lig*ting

-, eplacement of 2> lamps wit* LEs

3, eplacement of (L lamps wit* LEs

4, =pting renewa/le energy for street lig*ting


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E(E0G1 SA.I(G P0'P'SAL (o+ $

0EPLACE )>E EIS)I(G "@ )3 =L'0ESCE()LA/PS @I)> $"# @ LED LA/PS


Ba4ground

Presently at Asian Paints. Patanc*eru. -%34 ;os, of 2> lamps were installed int*e plant in t*e following areas Production /locks. engineering stores. (.#6. P#6 and ot*er office areas,

2*e total power consumption of t*ese 2> lamps is around 14" kB andindividual power consumption of eac* 2> fixture is $- watts, 2*e ta/le given/elow indicates t*e 2> lamp


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Benefits

2*e estimated annual savings t*at can /e o/tained /y replacing 2> lamps wit*LEs is 0s+ "3 la4hs, 2*e investment re


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E(E0G1 SA.I(G P0'P'SAL ('+ "

0EPLACE )>E EIS)I(G " @ C=L LA/PS @I)> $3@ LED LA/PS


Present status

1%> ;os of - C 3" B (L lamps were installed in t*e admin /lock, 2*e powerconsumption of t*ese (L lamps is around 1,3 JB, Power consumption of eac*(L is around $- Batts

&ased on t*e factors like SKP ratio and L=. t*ese lamps can /e replaced wit*1> B LE lamps, Lig*t Emitting iode :LE8 is t*e latest tec*nology, Asdiscussed earlier. LEs offer t*e advantages of Lower energy consumption.*ig* SKP ratio. longer life time. faster switc*ing. greater dura/ility andrelia/ility. good (I. more focused lig*t and reduced glare,

0eommendation

It is recommended to replace t*e existing -C3"B (L lamps wit* 1C1> BLEs, 2*e energy saving t*at can /e o/tained /y s*ifting to LEs is around ,>JB,

Benefits

2*e estimated annual savings t*at can /e o/tained /y replacing (L lampswit* LEs is 0s+ #+2 la4hs, 2*e investment re


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L'(G )E0/ E(E0G1 SA.I(G P0'P'SAL ('+ $

I(S)ALL S'LA0 @I(D >1B0ID S1S)E/ ='0 S)0EE)LIG>)I(G

uring t*e course of detailed energy audit at Asian Paints Limited,Patanheru,a detailed study of plant lig*ting load was carried out to identifyenergy saving opportunities, 2*e option of using renewa/le energy for lig*tingwas explored,

Present Status

At present. 1-% ;os of $% B P#! and 3% ;os of PS! lamps are installed forstreet lig*ting in t*e plant, 2*e power consumption of eac* lamp is $%B andt*e total power consumption is around 1%, JB,

Pro*osed )ehnology

Lig*t Emitting iode :LE8 is t*e latest energy efficient tec*nology in lig*ting,As discussed earlier. LEs offer t*e advantages of Lower energy consumption.*ig* SKP ratio. longer life time. faster switc*ing. greater dura/ility andrelia/ility. good (I. more focused lig*t and reduced glare, 2*ere is a goodpotential to replace t*ese P#! and PS! lamps wit* LEs and to tap solarenergy for street lig*ting,

It is recommended to replace t*ese P#! and PS! lamps wit* 1C1> B LEs,A 3 JB capacity solar wind *y/rid system can /e installed and t*ere


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Solar @ind >ybrid System

A Solar wind *y/rid system taps solar and wind energy, It is suita/le foroperation at - mKs to 1$ mKs of wind speed, As it is a *y/rid system. t*ecapacity utili9ation is also *ig*,

0eommendation

It is recommended to replace t*e existing $% B PS! and P#! lamps wit*1C1> B LEs, A 3 JB capacity solar wind *y/rid system can /e installed andt*e re


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E(E0G1 SA.I(G P0'P'SAL (o+ %

'P)I/IE )>E ECESS AI0 SPPL1 I( 0ESI( >'SE)>E0/'PAC )P-%#< ='0 I/P0'.I(G C'/BS)I'(

E==ICIE(C1uring t*e detailed energy audit at Asian Paints Limited, Patanheru,detailed measurements of t*e com/ustion air supply. exit gas gases analysisand operational modulation of t*e /urner in t*ermopac 2P 4% :-% Lak*JcalK*r8 were studied in detailed to identify. possi/le energy savingsopportunities,

Present Status

Presently 2P 4% :-% Lak* kcalK*r8 t*ermopac is used for providing *eat

re '), 2*e t*ermopac is in continuous operation and is operating wit*/lower modulation control for *ig* and low flame /ased on t*e t*ermic fluidoutlet temperature set point,

2*e sc*ematic of t*e 2P 4% t*emopac is as /elow

2*e flue gas analysis was carried out 7ointly /y (II and plant team and t*eresults are ta/ulated /elow


Ambient air: 28oC

Combustion air: 4284m3/hr

Thermopac

20 Lakhkcal/hr

APH

Fuel Feed Rate: 120 Kg/hrof !"

#2: $.% &

'em(: 283oC

#2: ).0 &

'em(:

1$%oC

Flue gas:

*%%* m3/hr

Flame Modulation: High FlameScenario

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Effet of eess oygen

(ontrolled supply of com/ustion air is an important criteria for optimumenergy efficiency of a gas fired t*ermopack, 2*is is /ecause t*e *eat losscaused /y t*e flue gas leaving t*e t*ermopack would /e minimal w*en

controlled


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Ensure t*at t*e following at t*e end of t*is trial

=-level s*ould /e maintained at less t*en -G in flue gases

#onitor t*e fuel consumption on daily /asis to o/serve t*e saving

ac*ieved

Saving in /lower power consumption also would /e ac*ieved /y reducing

t*e volume of air *andled,

Saving of ",4> Jg of LP6K*r can /e ac*ieved /y optimi9ation of t*e

com/ustion air supply and around 1 JB of /lower power consumption,

'*tion "7

Install a com/ustion analy9er wit* auto controller wit* feed/ack control on

t*e com/ustion air /lower panel to regulate t*e fre


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E(E0G1 SA.I(G P0'P'SAL (o+ E 0ESI( >'SE 0EAC)'0S 0EFI0E/E()S

uring t*e detailed energy audit atAsian Paints Limited, Patanheru,t*eresin *ouse reactor operation cycle and t*ermopac 2P 4% :-% Lak* kcalK*r8t*ermic fluid circulation pump operation was studied in detail to identifypossi/le optimi9ation for t*e pump operation /ased on t*e *eat demand of t*ereactors,

Present Status

2P 4% :-% Lak* kcalK*r8 t*ermopac is used for providing *eat re '),

It was o/served t*at not all t*e reactors are in *eating cycle at all t*e timesw*ic* result in /y passing of t*ermic fluid from t*at particular reactor w*en itis in cooling stage, owever. t*e t*ermic fluid pump is continuously pumpingt*e t*ermic fluid in t*e circuit and is /een routed t*oug* a /ypass valve and/eing sent to *eader :located after users8 /y control valvesKmanual valveoperation,

2*e t*rottling at t*e end user will result in increase in /ack pressure to t*et*ermic fluid pump, 2*is increase in /ack pressure will lead to reduction in


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0eommendation

Be recommend t*e following

2*e t*ermic fluid pump is already installed wit* !

Interlock t*e t*ermic fluid pump disc*arge pressure *eader pressure to

t*e pump speed,

As per t*e optimi9ation plan. t*ermic fluid pump speed can /e varied

/etween )% to 1%% G of t*e rated speed,

As t*e pump seal air fan is /uild in pump main s*aft. we recommend to

conduct trails during t*e nig*t *ours w*en t*e am/ient air temperatureare lower compared to day time, :(aution s*ould /e taken in setting t*epump speed control limits to up to maximum reduction to 4$, 98

Benefits

2*e annual energy saving potential /y optimi9ing t*e t*ermic fluid circulationpump operation /ased on t*e *eat re


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E(E0G1 SA.I(G P0'P'SAL (o+ ;

0EPLACE EIS)I(G AI0 >A(DLI(G BL'@E0S @I)> >IG>E==ICIE(C1 BL'@E0S I( I(DS)0AIL PAI() BL'C?

uring t*e detailed energy audit atAsian Paints Limited, Patanheru,t*eindustrial paint /lock air *andling /lowers were studied in detail for possi/leenergy saving opportunity, 2*ese /lowers are installed for maintaining t*einside air %,$$ %,1>

!SP3%3:Ex*aust 18

43>%1 -$$% >, " %,33 %,1>

!SP3%4:Ex*aust -8

41- -"$$" >,4" 4) %,3- %,1>

!SP3%

:isc*arge18

")3>" 4%>-- ->,44 4> %,$% %,1>

* Actual flow to system for VSP 301 was measured to be 22480 m3/hr. Thsreduced flow was ma!ly due to lea"a#e at mmedate blower dschar#educt!#. $or calculato! of s%ecfc e!er#y co!sum%to! &S'() the rated flowwas co!sdered to obta! the e!er#y sa+!#s co!ser+at+ely.

2*e specific energy consumption of t*e /lowers were measured and arecompared wit* t*e specific energy consumption of *ig* efficiency /lowers ofsame capacity,

&lower !SP 3%3 A; !SP 3%4 SE( is in t*e range of %,3- to %,33 BK(#w*ereas for t*e ot*er t*ree /lower is over %,$% BK(#, 2*is clearly indicateslower operating efficiency of t*e /lowers,


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0eommendation


Phase I

eplace t*e disc*arge /lower !SP 3%1 3%- wit* two new *ig* efficient

/lower of 4%%%% m3K*r capacity,

(onsidering t*e new operating SE( of %,- BK(#. t*e saving potential

for p*ase I /lower would /e 1>,$ JB,

Phase II

eplace t*e disc*arge /lower !SP 3% wit* a new *ig* efficient /lower of

$%%%% m3K*r capacity,

(onsidering t*e new operating SE( of %,3 BK(#. t*e saving potentialfor p*ase I /lower would /e ),) JB,

Benefits

eplacing t*e low efficiency /lower wit* new *ig* efficiency lower SE( /lowerwould result in an annual saving of 0s+ $+%< La4hs, 2*is calls for aninvestment of 0s+ $%+


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@B SEC)I'( & C''LI(G )'@E0 'PE0A)I'(

uring t*e detailed energy audit at Asian Paints Limited+, Patanheru nitt*e operation of t*e cooling tower in B&D section was studied in detail,

2*e B&D cooling tower is used to cater to t*e cooling re


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additional cooling tower of 1-% 2 will solve t*e issues related to cooling w*ent*e operation of t*e users of t*e cooling tower overlap,

It *as /een understood from t*e plant team t*at t*ere is issue of o/taininglesser cooling from t*e cooling towers and increasing t*e duration of cooling

for reactors and L!, 2*is is an indication t*at t*e cooling tower *eat re7ectionis not sufficient w*en more users are in operation, If t*e cooling tower returnwater temperature increases t*ere is a possi/ility t*at t*e c*iller may trip dueto *ig* pressure,

In t*e su/se


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E(E0G1 SA.I(G P0'P'SAL (o+ 3

'P)I/IE )>E 'PE0A)I'( '= @B C''LI(G @A)E0P/PS

uring t*e detailed energy audit at Asian Paints Limited+, Patanheru nitt*e cooling water pumps in B&D section were studied in detail for identifyingenergy saving opportunity,

Present status

In B&D section. t*ere are two no0s of reactors of capacities 3 kL kL, awmaterials will /e fed to t*ese reactors and *eated using steam, #onomers arecontinuously added to /ased on t*e product re*rs,

#onomer addition in t*e reactor is an exot*ermic reaction. w*ic* takes placefor 4 *rs, 5acket cooling is re


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failure of non ? return valve, 2*e stand ? /y pump of kL was o/served to /erotating in opposite direction wit*out any electrical input, Similarly. w*en only3kL pump was running. recirculation of 1 m3K*r :1-G8 was o/served t*roug*kL pump also due to t*e failure of non ? return valve, 2*erefore. minimumrecirculation in t*e circuit is 1m3K*r w*en any one reactor is in operation,

ecirculation is a loss in t*e system, Pump is *andling t*e recirculated volumealso. w*ic* is not /eing used in process, Be can understand t*at t*e powerconsumed /y t*e pump in *andling t*at amount of recirculated volume is lostcompletely, 2*ere is a good potential to save energy /y avoiding recirculationdue to failed ;!s,

Plant team *ave already replaced existing ;!s wit* new ones, CIIongratulates the *lant teamHs efforts in re*laing *assing (0. toa5oid reirulation,

2*e cooling re


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0eommendation

Be recommend to

Ste* $7

Avoiding recirculation

Avoid recirculation /y installing new ;!

Plant team *ave already replaced existing ;!s wit* new

ones

Ste* "7

Increasing t*e capacity of cooling tower

Install a separate cooling tower of 1-%2 for c*iller condenser and

avoid using c*illed water to cool return water during summer

Ste* 7

=ptimi9ing t*e flow

Install auto control valve at t*e outlet of t*e reactor

(ontrol t*e flow t*roug* reactor /ased on t*e temperature

difference across t*e reactor

Increase t*e Q2 set value slowly in steps of 1%( up to 4%(

Install ! for one pump and operate only t*at pump even for -

reactors

=perate ! /ased on t*e *eader pressure -, kgKcm-

&efore installing !. plant can take a trial /y reducing t*e flow /y

t*rottling t*e pump in steps of 1%G till temperature difference of4%( is ac*ieved across t*e reactor

Benefits

Implementing t*e a/ove recommendation will save 0s $+2# La4hsannually,2*is re


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E(E0G1 SA.I(G P0'P'SAL (o+ 2

'P)I/IE )>E 'PE0A)I'( '= LD. C''LI(G @A)E0P/P I( @B SEC)I'(

uring t*e detailed energy audit at Asian Paints Limited+, Patanheru nitt*e L! cooling water pumps in B&D section were studied in detail foridentifying energy saving opportunity,

Present status

After cooling t*e entire mass in t*e reactor to "'$%%(. material will /e sent toL!, 2otal /atc* cycle time in L! is 4*rs, In L!. addition of digestionmaterial takes place for - *ours. is an exot*ermic process, (ooling is re


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low can /e reduced /y t*rottling t*e pump or installing ! and operating itwit* pump disc*arge pressure as feed/ack, (ontrolling t*e flow /y t*rottlingleads to partial energy savings, Some of t*e power will /e lost in overcomingt*e pressure drop across t*e t*rottle valve, (ontrolling t*e flow /y reducingt*e speed of t*e pump /y installing ! will save more power,

&efore installing !. trail can /e taken /y t*rottling t*e pump in steps till t*etemperature difference of 4%( is ac*ieved simultaneously monitoring t*ematerial temperature,

0eommendation

Be recommend to

Install additional cooling tower of capacity 1-%2 :same included in

proposal no,> also8

&efore installing !. trail can /e taken /y t*rottling t*e pump in steps

till temperature difference across L! reac*es 4%(,

Install ! for t*e pump

=perate ! in closed loop wit* t*e *eader pressure

Benefits

Installing ! and operating ! in closed loop wit* *eader pressure will save

0s #+%% La4hs annually, 2*is re


36/119

E(E0G1 SA.I(G P0'P'SAL (o+ $#

'P)I/IE )>E 'PE0A)I'( '= (E@ BAAA0 C''LI(G@A)E0 P/PS

uring t*e detailed energy audit at Asian Paints Limited+, Patanheru nitt*e ;ew /a9aar cooling water pumps in B&D section were studied in detail foridentifying energy saving opportunity,

Present status

Seven pumps are installed for t*e cooling water re- 1- 3,- "4 3,$ 1-,3 > 13%%

$ 4>3 1- 3,- % 3%%

2*e following o/servations can /e made from t*e measurements

uring t*e audit it was o/served t*at two out of 4)%.4)1 and 4)- were foundin operation, Pumps 4)%. 4)1 4)- are pumps of same specifications, &ut. itcan /e o/served t*at pumps 4)%. 4)1 were delivering very less flow comparedto pump 4)-, rom t*e discussions wit* t*e plant team. t*is must /e due toworn out impeller,

2*e plant team *as started working on t*e failed impeller replacements, Pump4)- is delivering t*e flow w*ic* is /eing delivered /y t*e pumps 4)%. 4)1toget*er, 2*erefore. /y operating only 4)- pump for t*e maximum *ours andavoiding operating 4)% 4)1. power of kB can /e saved,

Pump 4>- was found to operate at *ig*er efficiency t*an pump 4>1,2*erefore. 4>- pump can /e operated for t*e maximum *ours to save powerconsumption, 2*e efficiency of pumps 4)%. 4)1. 4$% and 4>1 were found low,


34


37/119

Since t*e running *ours of pump were low. replacement wit* energy efficientpump was not via/le,

0eommendation


eplace t*e existing impeller wit* a new one for t*e pump 4)1

Avoid running t*e pump 4)%. 4)1 till t*e impeller gets replaced

un only pump 4)- as it can deliver re


38/119

E(E0G1 SA.I(G P0'P'SAL (o+ $$

'P)I/IE )>E 'PE0A)I'( '= I(DS)0IAL C''LI(G)'@E0 =A(S C''LI(G @A)E0 P/PS

uring t*e detailed energy audit at Asian Paints Limited+, Patanheru nitt*e industrial cooling water pumps in industrial paint section were studied indetail for identifying energy saving opportunity,

Ba4ground

2*ree pumps are installed to circulate t*e cooling water t*roug* t*e *eatexc*angers of industrial reactors solvent recovery plant, =ut of t*e t*reepumps. one is kept stand /y, 2*e sc*ematic layout of t*e pumping circuit iss*own as /elow

(ooling tower fans were operating /ased on t*e cold well temperature, ansswitc* on w*en cold well temperature reac*es -$%( and switc*es off w*en itreac*es -%(, (urrently. t*e temperature feed/ack to t*e fan to switc* on andoff *as failed and t*e cooling tower sump temperature of 3-o( *as /eeno/served. instead of desired temperature of -o(,

2*e energy saving /y switc*ing on and off t*e cooling tower fan is partial, 2*ecooling tower re


39/119

temperature can /e maintained and t*e calculations *ave /een considered for3-o(, If t*e temperature of - '-$o( is considered. t*e energy savings will /elower,

B*en measurements were taken. (2 fans were in = condition, 2*e range of

-%( was /eing ac*ieved /y t*e cooling tower, 6enerally. cooling towers aredesigned to give a range of "'>%(, &y switc*ing on t*e fans and running t*emcontinuously wit* a !. cooling tower can give minimum range of 4%( i,e,.range will get dou/led and t*e cooling water flow can /e *alved,

(urrently. - pumps are running continuously and delivering )3m3K*r :P4>8and "-m3K*r:P4$8 continuously, 2otal cooling water flow is around 1%m3K*r,=ne pump P4$ can /e switc*ed off, 2*en t*e second pump :P4>8 will delivermore flow t*an /efore as t*e system resistance reduces as t*e cooling waterflow reduces,

2*e power consumption of t*e second pump can /e optimi9ed /y installing! and operating it wit* pump disc*arge pressure of - kgKcm -as feed/ack,(ooling tower fans can /e installed wit* ! and operated in closed loop wit*cold well temperature interlock of 3-%(,

0eommendation


un t*e cooling tower fans continuously

Install ! for (2 fans and operate t*e !0s in closed loop wit* t*e cold

well temperature of 3-%(

Switc* off t*e pump P4>

Install ! for t*e pump P4$

=perate t*e ! in closed loop wit* t*e disc*arge *eader pressure of -

kgKcm-

Benefits

=ptimi9ing t*e operation of industrial cooling water pumps will save 0s $+#La4hsannually, 2*is re


40/119

E(E0G1 SA.I(G P0'P'SAL (o+ $"

0EPLACE I(E==ICIE() P/PS @I)> (E@ E(E0G1

E==ICIE() P/PSuring t*e detailed energy audit at Asian Paints Limited+, Patanheru nitt*e performance of t*e water pumps in t*e plant were studied in detail foridentifying energy saving opportunity,

Ba4ground

2*e water flow and *ead measurement was carried out for all pumps in t*eplant, 2*e design parameters and measured values are as follows,

Pum*sDesign

Parameters '*erating Parameters

)ag J=lo6

mhr>ead8m9

=lo6mhr

>ead8m9

/otorLoading

4@Effiieny

$% 2 c*illermonomer pump "% ' -1,%% -4 ",1 -4

$% 2 c*iller *ot wellpump ' 1> 33,%% 1%M -,4 41

Pump *ouse P%4 -3,'), 11'3) -1,%% 3- ,$) 34

Mmarked pumps *ead is estimated value as provision for measuring pressurewas not availa/le,

2*e operating efficiency of a/ove pumps is low due to mismatc* /etween t*edesign and operating *ead K ageing of t*e pumps K low efficiency /y design,

2*e /elow diagram s*ows *ow efficiency of t*e pump reduces wit* mismatc*/etween design and operating parameters


38


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B*en t*e operating parameters are different from design parameters.operating point falls into low efficiency region,

2*erefore. it is recommend to install energy efficient pumps designed tooperate at /est efficiency for operating parameters,

0eommendation

It is recommended to replace t*e pumps :$% 2 c*iller monomer pump. $%2c*iller *ot well pump. pump *ouse P%48 wit* new pumps of efficiency R$%G,

S*eifiations of ;#)0 hiller monomer *um*7

low - m3K*r

ead - m

Efficiency R $%G

S*eifiations of ;#)0 hiller hot 6ell *um*7

low 3 m3K*r

ead *as to /e decided after installing

pressure guage Efficiency R $%G

S*eifiations ofPum* house P


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Installing new *ig* efficiency pumps in identified areas will save 0s $+# La4hannually, 2*is re


43/119

E(E0G1 SA.I(G P0'P'SAL (o+ $

0EDCE )>E GE(E0A)I(G P0ESS0E '= )>E AI0

C'/P0ESS'0S I( )>E PLA()Present status

uring t*e detailed energy audit of Asian Paints Limited, Patanheru nit.a detailed study of all t*e compressed air units was carried out for possi/leenergy saving opportunities,

2*e plant *as installed a centralised compressed air system consisting of twoscrew compressors w*ic* maintain t*e pressure of t*e receiver at ,$ /ar, 2*iscentrali9ed compressed air system supplies air to all t*e sections of t*e plant

vi9, Bater &ased Dnit. Solvent &ased Dnit. Industrial Paint Dnit. esin &lockand t*e #onomer /lock,

2*e following o/servations were taken from t*ese compressors

Com*ressor Loation LoadingPressurebar

nloadingPressurebar

A5eragePressurebar

Po6er4@

P4%(ompressor

ouse,$ ",- ,) >>,3%

P4%"(ompressor

ouse, ",% ,$ >",%3

It was o/served t*at w*en t*e plant is in full load operation. one compressor iscontinuously running and t*e second compressor is running for 1% G of t*etime, 2*is compressor *as /een set in suc* a way t*at if it is in unload for

more t*an 1% minutes it automatically switc*es off, 2*e limit of switc*ing onand off for a 11% kB motor is not more t*an four times in an *our,


P%# L /ottom near $ tu/

3) (ontrol valve in $ tu/ middle cooling inlet line

4% ! /ottom

41 LP 4%" condensate cooling line (ontrol !alve

4- (ontrol valve vent line is open =KL

0esin >ouse 8"nd=loor9


46


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43 Sor/ital control valve IKL line )

44 L near ) :Ex*aut )8 pus* /utton station

4 L /ottom air *eader :near 1'1 function /ox8

4" (ondenser cooling IKL 1 reactor

4$ &ypass line t*ermo pack opposite to vacuum cooler area

0esin >ouse 8rd=loor9

4> ! IKL *eader 2P- expansion tank

4) Auto control valve not in use $ condenser

% Auto control valve to inlet line to condenser 1% :#'seal Jept8

1 (opper tu/e opened

@ater Based Paint nit

- L# ? P1-1 solenoid spool valve

3 L# ? P1-1 valve at t*e /ottom of t*e funnel

4 rom ( near L# P11". poor silencer valve

LPP 131 silencer ? - Pts

" L# 1-4 L top damaged

$ #ixer P14$ /ottom cut'off valve leakage from upper tu/e

> Air *eader near mixer P13 ( leakage

) #ixer P1"1 leakage from copper tu/e

"% Air *eader near L! ? P1"

"1 S2P 1$ near auto control valve silencer

@ater Based Paint nit 8$st=loor9

"- L unit pug mill inlet to purging line $>)

"3 P# ? 1>1 gate valve L inlet fitting

"4 P# 1>4 /ottom of L

" P#P 1>" /ottom gate valve seal leakage


47


50/119

"" L *eader near 2S ? P1%

@ater Based Paint nit 8"nd=loor9

"$ S!A S!E ? two different *eaders li3 IKL to purge line 3rd from top

$% Pug mill *opper P ? 1>1 IKL to purge line

$1 iverter valves

)errae

$- !ent line in *opper no ? -

$3 opper no ?

Dsually t*e norm is of maintaining compressed air leakage to less t*an 1G ina plant, In some of t*e energy efficient plants. compressed air leakage waso/served to /e as less as "G, 2*erefore. *ere is a good opportunity toconserve energy and minimi9e t*e leakages in t*e plant,

0eommendations

It is recommended to

Avoid unwanted purging of compressed air

Arrest t*e leakages at identified locations

Avoid t*e use of ig* Pressure compressed air for cleaning

Increase t*e awareness among t*e operators and t*e workers on t*e value

of compressed air

Promote ed'tag system among t*e workers in t*e plant. w*erein

w*enever any worker identifies a leakage point. *e will attac* a red tag att*e leakage point

2*e maintenance staff t*en addresses t*e leakage wit* t*e *elp of t*e tag

and minimum leakages are maintained in t*e plant

(onduct leakage test during s*ut down time

Identify arrest t*e leakages

(onsidering reduction in t*e leakage to 3%G from t*e current values.

Benefits


48


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2*e annual energy saving potential /y arresting t*e compressed air leakagepoints is 0s+ $$+


52/119

Observation


50


53/119

'BSE0.A)I'( (o+ $

ADEFAC1 '= L LE.ELS A) .A0I'S L'CA)I'(S

uring t*e course of detailed energy audit at Asian Paints, Patanherunit. detailed lux measurements were carried out in t*e plant, 2*e lux levelswere measured and compared wit* t*e recommended standards,

2*e purpose of Industrial lig*ting is to aid as a production tool. aids safety andmaintains t*e comfort and well'/eing of t*e users, 6ood industrial lig*tings*ould take care of ade


54/119

2*e lux measurements were carried out at various locations in t*e plant.during t*e detailed energy audit,

2*e lux levels measured and t*e recommended values are mentioned /elow,2*e lux levels were sufficient at t*e following areas

Loation )ime Area A5g lu0eommende

d Lu

S&D ? 6round

flooray time

(orridor 13% %

S&D ? 6roundfloor

ay time&=P2 c*anging

area-$% 1%%

IPD' ay timeSpray /oot* room

P* ' -1>) 1%%

IPD' ay time La/ area p* '1 1%3 1%%

IPD ? S ay timeeactor area :3'

3>)84 1%%

' # ay time stair case 1%% %

' S ay time Balk way corridor %

2*e lux levels were low at t*e following areas

Loation )ime Area A5g lu0eommende

d Lu

B&D ' 6roundfloor

ay time

Pug #ill platform -3 1%%

(orridor' 1 -> 1%%

illing area > 1%%

;ig*t timePug #ill platform -3 1%%

(orridor' 1 -% 1%%


52


55/119

illing area -$ 1%%

B&D' irst floor

ay time

illing vessels 1> 1%%

eactors area 1%1'

1%33 1%%

eactors area 1)'

1"$-- 1%%

Process area 34 1%%

Pugmill area' 1 4) 1%%

Pugmill area' - -" 1%%

Li


56/119

Balk away corridor 1> %

oppers 3% 1%%

2S 3> 1%%

Storage area -% $

S&D ? 6roundfloor

ay time

&elow tanks

filling stations'

circle 1

3 1%%

&elow tanks

filling stations'

circle -

"1 1%%

&elow tanks filling stations'

circle 3

$% 1%%

&elow tanks

filling stations'

circle 4

$$ 1%%

;ig*t time

&elow tanks filling

stations 'circle 1

" 1%%

&elow tanks

filling

stations 'circle -

" 1%%

&elow tanks filling

stations 'circle 3>% 1%%

&elow tanks

filling

stations 'circle 4

>) 1%%

(orridor 3$ %

&=P2 c*anging

area-$ 1%%

S&D ? ay time Process stations ? "- 1%%


54


57/119

irst floor

1

Process stations ?-

43 1%%

;ig*t time

Process stations ?

14$ 1%%

Process stations ?

--- 1%%

(orridor 1) %

S&D ? #ay time &elow tanks 3" 1%%

;ig*t time &elow tanks 1> 1%%

S&D ' second

floor

ay time

Process stations '1 "> 1%%

Process stations '- 34 1%%

(orridor 3- %

;ig*t time

Process stations '1 % 1%%

Process stations '- -% 1%%

(orridor 1" %

IPD ? 6

ay time

#ixerKpackingfloor p*' 1

"3 1%%

&atc*ing area 1> 1%%

#ixerK packing

floor p* '-

3% 1%%

;ig*t time

#ixerKpackingfloor

34 1%%

&atc*ing area 1 1%%

#ixerK packing

floor p* '-1) 1%%

IPD ? ay time #ixer floor area P*

'14> 1%%

Premixing area P*'1

" 1%%


55


58/119

#ixer floor area

P*'-1 1%%

Passage area P* ?

--) %

;ig*t time

#ixer floor area p*

'114 1%%

La/ area p* '1 >" 1%%

Premixing area p*'

11) 1%%

#ixer floor area

P*'--- 1%%

Passage area P* ?

--- %

Spray /oot* room

P* ' -43 1%%

IPD ? S

ay time

S#K2 area $$ 1%%

2SKA22 area 3 1%%

6 storage area - 1%%

Solvent storagetank area

4- 1%%

;ig*t time

eactor area :3'3>)8

- 1%%

S#K2 area 34 1%%

2SKA22 area 1$ 1%%

6 storage area 1 1%%

Solvent storagetank area

41 1%%

? 6 ay time /elow and /e*indtanks' left side

4$ 1%%

/elow and /e*ind

tanks' rig*t side-1 1%%

(orridor 3$ %

#(( room -% -%%


56


59/119

;ig*t time

/elow and /e*indtanks' left side

1- 1%%

/elow and /e*ind

tanks' rig*t side1% 1%%

(orridor 3 %

#(( room 1$ -%%

' #

ay time

2ank area -% 1%%

entrance corridor 33 %

filter areas "3 1%%

;ig*t time

2ank area -% 1%%

entrance corridor 33 %

filter areas "3 1%%

stair case 3 %

' S

ay time

eactor area' left 3- 1%%

eactor area' rig*t 3" 1%%

(*arging area 3" 1%%

#(( room p*'1 31 -%%

#(( room p*'- 1 -%%

;ig*t time

eactor area' left -> 1%%

eactor area' rig*t 3% 1%%

Balk way corridor 3 %

(*arging area 1 1%%

#(( room p*'1 -- -%%

#(( room p*'- -% -%%

It is recommended to improve t*e lux levels in t*ese areas. after conducting adetailed study of lig*ting design, Instead of replacing t*e lamps wit* t*e sameno, of LEs w*en replacing t*e existing 2>. (l lamps. t*e plant team may gofor slig*tly more no of lamps to improve t*e lux levels, 2ask lig*ting can /e


57


60/119

provided at re


61/119

'BSE0.A)I'( (o+ "

>A0/'(IC /EAS0E/E()S

uring t*e course of detailed energy audit at Asian Paints,Patanheru nit. *armonic measurements were carried out in detail,

armonics are measured at t*e transformer and main incomers at t*e

following locations

Loation )>D-. )>D-I

#ain incomer %,) 4,3

2ransformer -," ",3

B&D 1 -,- ""+

B&D - -,$ $+3

esin ouse 1 -,$ >,

esin ouse - -," 4,-

S&D 1 -,) 1%,

S&D - -,) ,)

IPD 1 - $

IPD - - >,"

0eommendation

In most of t*e places. *armonic levels are wit* in t*e permissi/le limit of Gfor voltage *armonics and 1G for current *armonics :as per IEEE standard8,

It was o/served t*at G (urrent 2 is *ig*er t*an t*e permitted range atB&D and IPD,

2*e t*order current *armonics were o/served to /e *ig* at B&D and IPD,

'rder of harmonis @B $I$K $3;+" A

@B "I$K $2+< A

IP $I$K 2


62/119

2 --,3 G 1",> G 1" G

3rd %,4 G 3 G %," G

t* --,4 G 1> G 1%,- G

$t* 4 G $,$ G > G

)t* % G 1,> G 1,1 G

11t* %,4 G 3,1 G 4,- G

2*e *armonics a/ove t*e recommended values may result in failure ofcapacitor /anks. mal functioning of relays and false tripping of /reakers.over*eating of motors and transformers, It is recommended to install

*armonic filters at B&D and IPD after carrying out detailed study,

A trail was carried out to assess t*e impact of reactors installed in IPP panelin t*e following scenarios

Scenario 1 IPP switc*ed off :All capacitors and reactors switc*ed off8

Scenario - (apacitor panel #((& on

Scenario 3 #anual operation of (apacitor and reactor

Scenario 4 Auto mode

2*e measured values are as follows

0-*hase 1-Phase B-Phase

(ase P 2! G

2I G

P 2! G

2I G

P 2! G

2I G

#ain (ap/ank wit*reactors

switc*ed off

%,)3 1,%% -,$% %,) 1,1% 3,>% %,)3 1,%% 3,$%

Bit*capacitorpanel #((&on

%,)4 1,%% -,3% %,) 1,1% 4,-% %,)4 1,%% 3,-%

#anually all( and L on

%,)) 1,%% -,>% %,)) %,)% 3,3% %,)) 1,%% 3,4%

Auto #ode %,)) 1,%% -,>% %,)) %,)% 3,-% %,)) %,)% 3,1%


60


63/119

It was o/served t*at t*ere isn0t muc* difference in t*e *armonic levels wit*t*e reactors switc*ed on or off, 2*ese reactors can /e s*ifted to t*e areas ofconcern. to eliminate t*e t*and $t*order *armonics,


61


64/119

'BSE0.A)I'( (o+

0EDC)I'( '= DIS)0IB)I'( A(D CABLE L'SSES

uring t*e course of detailed energy audit at Asian Paints, Patanherunit. t*e distri/ution system of t*e plant was studied for possi/le identificationof voltage drops and ca/le losses,

Simultaneous measurements were carried out at t*e P(( and #((, 2*e valuesmeasured are as indicated /elow

Loation .oltage atPCC 8.9

.oltage at/CC 8.9

Dro* 8.9

S&D 1 -4$,% -44,>3 -,$

S&D - -4",3% -43,3% 3,%%

B&D 1 -44,13 -43,"$ %,4$

B&D - -43,3% -3),%% 4,3%

1 -44,>3 -41,%% 3,>3

- -4>,>4 -44,3% 4,4

IPD 1 -4-,$3 -41,%% 1,$3

IPD - -43,-% -4-,%% 1,-%

2*e voltage drop is recommended to /e less t*an 4 ' ! from maindistri/ution /oard to eac* su/'distri/ution per p*ase as per ;E(, 2*e voltagedrop is /elow t*e permissi/le limits

2*e voltage drop /etween t*e origin of t*e installation and t*e fixed current

using e


65/119

1-% m lengt*

-% m underground :open trenc*8

1%% m in air ? ca/le tray

2*e current carrying capacity of t*e compressor ca/le is

(urrent carrying capacity 3>1 A

e'rating factor of %,$1 for %%(a/ove ground

-$%,1 A

e'rating factor of %,>) for 3%%( 3%%(soil temp

33),%) A

2*e motor full load current is 1) A, It is in t*e permissi/le limits,


63


66/119

'BSE0.A)I'( (o+ %

0EC'.E0 >EA) =0'/ 0ESI( >'SE C'(DE(SA)E ='0P0E>EA)I(G )>E B'ILE0 =EED @A)E0

uring t*e detailed energy audit atAsian Paints Limited, Patanheru,t*eresin *ouse /oiler and condensate recovery system was studied in details toidentify any possi/le energy savings,

2*e revomax /oiler are used to provide steam to t*e industrial resin reactorsand t*e condensate from t*e reactor disc*arge is /een collected in condensatetank, 2*e (ondensate was o/served to /e at a temperature of a/ove "% eg (at all t*e time, 2*e condensate at present is not /eing utili9ed /ack to /oilerdue to *ig*er 2S levels and is /een sent to softening plant,

As t*e 2S levels of t*e condensate is very *ig*er cause of intermixing ofcooling water and steam /eing passed t*oug* t*e same reactor coils it is notpossi/le to recycle t*e same condensate t*oug* t*e /oiler feed water pumpdue to increased c*ances of scaling in /oiler coils,

2*is condensate at over "% eg ( can /e used for pre *eater t*e /oiler feedwater to reduce t*e /oiler fuel consumption, 2*e *eat availa/le in condensateat "% eg ( can /e used for *eating up t*e /oiler feed water w*ic* is at 3%eg (,

&y pre*eating t*e /oiler feed water to /oiler /y 3% eg ( would result in fuelsavings of %,"$ kg of LP6 per *our,

Pre*eating t*e /oiler feed water would increase t*e feed water vapourpressure w*ic* again can effect t*e ;PS of t*e /oiler feed water pump, Afterinstallation of *eat exc*anger for pre*eating /oiler feed water from processcondensate would increase t*e water temperature to around 4 eg (, 2*evapour pressure of t*e water at 4 eg ( is %,1 /ar. so at all t*e time apositive *ead of over %,1 /ar *as to /e maintained for smoot* operation of/oiler feed water pump,

2*e water vapour pressure curve is as /elow


64


67/119

Additionally after installation of a *eat exc*anger would lead to pressure dropacross t*e feed water side and t*e pump inlet pressure would get reduced andt*e ;PS would get compromised,

ence. to maintain t*e re


68/119

U %,"$ kg of LP6

unning *ours U 3%%% oursKAnnumAnnual savings U %,"$ kg x 3%%% *rsKannum x s,

"%Kkg of LP6

U s, 1. -%. %%%

Say 0s+ $+"# La4hs

Investment considered includes

1, or s*ifting t*e tank to t*e top of t*e /uilding

-, or installation of *eat exc*anger :PE8 of flow %," m3K*r of /ot* fluids

3, or laying of new pipeline for /ot* condensate and /oiler feed water

Investment re


69/119

Chapter V

Management Aspets an! Conl"sions


67


70/119

C>AP)E0 & .

/A(AGE/E() ASPEC)S C'(CLSI'(S

E 'B!EC)I.ES '= ASIA( PAI()S LI/I)ED, PA)A(C>E0S>'LD BE

2o make energy conservation a permanent activity at t*e plant

2o ac*ieve power consumption possi/le in t*e unit

2o reduce t*e electrical energy consumption to t*e minimum

2o *ave a firm top management commitment. so t*at. t*e company

ac*ieves energy conservation on a time /ound /asis,

2o implement t*e recommended proposals and reap t*e maximum

/enefits


71/119


72/119


73/119

Anne#"re


71


74/119

Anneure&A

SPPLIE0 ADD0ESS

.=D and other dri5es

1, 0o46ell Automation India P5t+Ltd+ 8Allen-Bradley India Ltd+9( ' 11. Industrial AreaSite ' 4. Sa*i/a/ad

6*a9ia/ad ' -%1 %1%

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Amalgamated Indl+ Com*osites P+ Ltd+

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86/119

Gaso Energy Systems 8I9 P5t+ Limited2'1-- . #,I,,(,. &*osari. Pune ' 411 %-"2el, F )1 -% -$1- >>-3 K 3%"> -"

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Dryteh EngineersS*, ;o, 1-'1. Sapana (o,op, sg, Soc,.

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ax )1'44'-3'--%Email nadiairHvsnl,net

Be/site www,nadiindia,com

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88/119

Com*utational =luid Dynamis Study

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89/119

Com*ressed Air Audit and Control Systems

1. Godrej Boye /anufaturing Com*any Limited+

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