Custom Capsules Pvt. Ltd

8/6/2019 Custom Capsules Pvt. Ltd

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Energy AuditReportFor

Custom Capsules privateLimited, BoisarThe report presents finding of the energyaudit study at Custom Capsules privatelimited, Boisar. The overall potential forimprovement in the facility is Rs. 34.65Lakhs per annum for an investment of Rs31.50 Lac.

April2009

Prepared by:

A.R.S. ENERGY AUDITORS, VIRAR


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ACKNOWLEDGEMENT

M/s A.R.S. Energy audi tors . team has carr ied out energy audi t s tudy

at M/s . Custom Capsules Pvt . Ltd. , Boisar dur ing the month of Apri l

2009. We hereby express our special thanks to

Mr. J.N Vyas CEO, Custom Capsules Pvt. Ltd.

And a l l o ther employees fo r thei r p roac tive support and cour tesy

extended to the visit ing energy audit team during the study.

For Team ARS:1. Mr.Sachin Deshpande, BE(Mech); BEE Certified

Energy Auditor.

Experience : 18 years

2. Mr. Sunil Apte, B.Tech (Civil); BEE Certified EnergyAuditor.

Experience : 30 years.

3. Mr. Atul Vartak, BE (EXTC); P.W.D Certified ElectricalSupervisor

Experience: 18 years.

4. Mr. Parag Nerurkar ,Dipl(Etrx), AMIE; AdvancedCertificate in Power Distribution and Management(ACPDM)


5. Mr. J .V. Kade, Dipl (Mech), Dipl (Elex)


Prepa red By : ARS Energy Aud i to r s


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Energy Audit

Report|April 2009

6. TABLE OF CONTENTS

1. E X E C U T I V E S U M M A RY ........................................................................................................ 71.1 P R E L U D E : ............................................................................................................... 71.2 C U R R E N T E N E R G Y S C E N A R I O : ................................................................................... 7

1.3 T H E AU D I T AC T I V I T Y: ............................................................................................... 8

1.4 E N E R G Y S AV I N G ME A S U R E S : ...................................................................................... 91.5 P O T E N T I A L F OR E N E R G Y S AVINGS : ........................................................................... 10

B A C K G R O U N D ....................................................................................................................... 11P R E S E N T E N E R G Y S C E N A R I O .................................................................................................. 12

O V E RV I E W O F THE B U I L D I N G E N E R G Y U S A G E : .................................................................... 12H I S T O R I C A L D AT A AN A LY S I S ........................................................................................... 12

ME T H O D O L O G Y ..................................................................................................................... 16E L E C T R I C A L D I S T R I B U T I O N S YS T E M : ............................................................................... 16IN D O O R LI G H T I N G : ............................................................................................... ......... 16W I N D O W /S P L I T A IR C O N D I T I O N E R S ................................................................................ 17P U M P S : ........................................................................................................................ 18

4 .2UPS: ........................................................................................................... ......... 19C O M P R E S S E D A IR S YS T EM : ............................................................................................. 203H I S T O R I C A L D A T A AN A LY S I S ............................................................................................... 21

MO N T H LY E L E C T R I C I T Y B I L L S .......................................................................................... 21LOA D D I S T R I B U T I O N .......................................................................................... ............ 22LOA D P R O F I L E : ............................................................................................................. 23

T A R I F F AN A LY S I S : ......................................................................................................... 27ME A S U R E M E N T S , O B S E RVAT I O N S , AN D D AT A AN A LY S I S ............................................................. 28

B I L L I N G AN A LY S I S , E L E C T R I C A L D E M A N D AN D P O W E R F A C T O R : .......................................... 28C A PA C I T O R B ANKS : ..................................................................................................... .. 30L I G H T I N G : .............................................................................................................. ...... 31W I N D O W A I R C O N D I T I O N E R S : .................................................................................... ..... 34DX C H I L L E R S ............................................................................................................... 36C O M P R E S S E D A IR S YS T EM : ............................................................................................. 38P U M P S : ........................................................................................................................ 39UPS 40

7 E N E R G Y C O N S E RVAT I O N O P P O RT U N I T I E S .............................................................................. 42C A PA C I T O R B ANKS : ..................................................................................................... .. 42L I G H T I N G ...................................................................................................................... 42W I N D O W / S P L I T A IR C O N D I T I O N E R S : .............................................................................. 46C H I L L E R S ...................................................................................................................... 48C O M P R E S S E D A IR S YS T EM : ............................................................................................. 53P U M P S : ........................................................................................................................ 53

R E N E WA B L E E N E R G Y ............................................................................................................ 54S OLAR PV S Y S T E M : ....................................................................................................... 54S OLAR AN D W IN D E N E R G Y H YBRID S Y S T E M : ..................................................................... 57P A S S I V E D E S I G N T E C H N I Q U E S ......................................................................................... 5910. 1 EL ECTRO NIC BAL LAS TS ............................................................................... 63VO LTA GE CO NT RO LL ER FO R LI GH TI NG ............................................................. 6410. 3 T5 TU BE LI GH TS (2 8 WA TTS ) .................................................................... 6510.4 L I G H T I N G S E N S O R S ......................................................................................... ..... 66

Prepa red By : ARS Energy Aud i to r s .


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10.5 C H I L L E R S ............................................................................................................ 67



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Energy Audit

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List of Tables

TA BLE NO .1 : HA RM ON IC S:............................................................................26

TABLE NO. 2: MONTHLY ENERGY BILLS......................................................28

TA BLE NO .3 : LI GH TI NG .................................................................................31

TABLE NO.4: COMPA RISON OF L PD VA LUE WITH ECBC NORMS.... .. .. .. .. .. .33

TABLE NO.5: COMPA RISON OF P RESE NT L UX L EVEL WITH NBC... ... .. .. .. .. .33

TABLE NO.6: MEAS UREME NTS AT W INDO W AI R-CON DITI ONERS ... .. .. .. .. .. .34

TAB LE NO. 7: DAT A A NAL YSI S WIN DOW AIR CON DIT ION ER.......................35

TABLE NO.8: DX CHILLER INPUT DATA.......................................................36

TABLE NO.9: DX CHILLER PERFORMANCE ANALYSIS.................................36

TAB LE NO.1 0: AIR COM PRE SSO R PUM P UP TES T RESUL TS.....................39

TA BL E NO .1 1: PU MP PE RF OR MA NC E...........................................................39

TABLE NO.12: UPS.........................................................................................40

TAB LE NO. 13 : BY MAI NTA INI NG POW ER FAC TOR UNI TY...........................42

TABLE NO. 14: SAVING BY REPLACEMENT OF CONVENTIONAL BALLASTSWI TH EL EC TRO NI C BA LLA STS .......................................................................43

TABLE NO. 15: SAVING BY INSTALLATION OF VOLTAGE REDUCTIONDEVICE............................................................................................................44

TABLE NO. 16: SAVING BY RETROFITTING PRESENT LIGHTING FIXTURESWITH ENERGY EFFICIENT LIGHTING FIXTURES T5:....................................45

TABLE NO. 17: SAVINGS BY INSTALLING ENERGY SERVER.......................46

TABLE NO. 18: SAVINGS DUE TO INSTALLATION OF CENTRAL AIRCO ND IT ION IN G SY ST EM................................................................................47

TABLE NO. 19: SAVING BY INSTALLING CENTRAL AIR CONDITIONINGSYSTEM .........................................................................................................48

TABLE NO. 20: SAVINGS BY INSTALLATION OF THERMAL STORAGESYSTEM...........................................................................................................52

TA BL E NO . 21 SA VI NG S BY AV OI DI NG LE AK AG E........................................53

TAB LE NO. 22 : S AVI NG BY INS TAL LIN G S OLA R P V S YST EM .......................57

TABLE NO.23: SAVING BY INSTALLING SOLAR AND WIND ENERGY HYBRIDSYSTEM...........................................................................................................59



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List of Figures

FIG URE 1 : SEA SON AL PO WER C ONS UMP TI ON PAT TER N..........................13

FIGURE 2: DAILY POWER CONSUMPTION PATTERN...................................14

FIG URE 3: DAT E-W ISE POW ER CON SUM PTI ON PAT TER N...........................15

FIGURE 4: HISTORICAL DATA ANALYSIS.....................................................21

FI GU RE 6: LO AD DI ST RI BU TI ON BA SE D ON KW H.......................................22

FIGURE 7 LOAD PROFILE POWER..............................................................23

FIGURE 8: LOAD PROFILE - VOLTAGE..........................................................24

FIGURE 9 LOAD PROFILE POWER FACTOR................................................24

FIGURE 10 LOAD PROFILE DEMAND..........................................................25

FIGURE 11: LOAD PROFILE VOLTAGE HARMONICS...................................25

FIGURE 12: LOAD PROFILE CURRENT HARMONICS...................................26



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Energy Audit

Report|April 2009

1.Executive Summary

1.1 Prelude :

M/s. ARS Energy Audi tors , Virar, conducted an energy audi t s tudy

at M/s . Custom Capsules Pvt . Ltd. , Boisar. The company is in the

f ie ld o f manufac tur ing empty hard ge la t in capsu les . The CCPL,

Boisar Plant was inaugurated in the year 1980.

T he un it i s sp re ad ov er a n ~5 a cr e a rea a nd c on ta in s a

manufacturing block and administrative unit connected together.

T he b ui ld in g i s p ro vi de d w it h u ti li ti es l ik e a ir c on di ti on in g,

l ig ht in g, p um pi n g e tc . A D X t y pe a ir c on di ti on in g s ys te m w it h

package un it s i s p rov ided fo r the manufac tur ing b lock and theadminis t ra t ive block contains a mixture of Window and Spl i t type

Air condi tioners. Approximate ly 150 persons a re p resent a t any

given point of t ime. The building operates from 9.00 AM to 6.00 PM

and a n igh t sh if t i s insta ted when the p roduc t ion demands a re

higher.

The focus o f the s tudy was on to iden t ify and eva luate energy

conservation opportunities in the facil i ty.

1.2 Current Energy Scenario:

M/s Custom Capsules Pvt . Ltd. (CCPL) has an annual bi l l of Rs.

56.27 Lac for the e lectric i ty consumed. Total annual e lectric i ty

usage a between the months Apri l 2008 t i l l March 2009 is shown

as under:

Annual Electricity usage:

Electricity bill kWh/year 576144

Rs. /year 5627196

Contract demand kVA 500

Billing Demand kVA 203



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Power Factor 0.99 (in past 5 months)

Energy Charges Rs. /kWh 6.20

1.3 The Audit Act ivi ty:

In order to conduct the comprehensive energy audi t s tudy, ARS

Energy Auditor evaluated performance of individual equipments

l ik e C hi ll er s, w at er p um pi ng s ys te ms , l ig ht in g, m ot or s, A ir

c om pre ss ors e tc . a s p er Bu re au o f En erg y E ff ici en cy ( BEE)

guidelines.



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Energy Audit

Report|April 2009

1.4 Energy Saving Measures:

Power Factor Improvement:

Improve the power factor by install ing capacitors at suitable load

centers

Lighting:

Replace the conventiona l ba ll ast s wi th e lec t ron ic ba ll ast s . Af te r

insta ll ing e lec t ron ic chokes, insta ll vo ltage reduc ing device fo r

lighting feeder.

OR

Replace the present 52 W and 48 W tube lights with energy efficient

T-5 tube lights having electronic ballast

Window Air Conditioners:

Install ing energy saving devices l ike t imer based ON-OFF system for

present window/split air-conditioners

OR

Replace present air conditioner system with central air conditioner

system

DX type Package Air Conditioners:

Replace present air conditioner system with central air conditioner

system

OR

Replace present air conditioner system with Thermal storage system

Air Compressor:

Avoid the leakage present at receiver.



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1.5 Potentia l for Energy Savings:

Sr.No Section Scheme

Powersaving

kWh/Annum

EnergySaving

Lac Rs. / Year

Investment

Lac Rs.

SimplePay

Back,

MonthsElectric Energy:

Capacitorbank Improvement of power factor Unity 1.01 1.13 13

1 InteriorLighting

Option I : Step I -Replacement of Convention ballastwith electronicballast

6772 0.66 0.57 10

Option I: Step II-installation of reducing operatingvoltage from 235 Vto 210 V

6235 0.61 1.10 22

Option II:By retrofittingpresent lightingfixtures withenergy efficientlighting fixtures (T-5)

13628 1.33 2.00 18

2

Window /Split airConditioner

Option I:Installing EnergySaver

21542 2.10 1.20 7

Option II:Installing Centralair conditioner

152064 14.84 15.20 12

Chillers

Option I:Installing Centralair conditioner

177408 17.32 13.50 9

3Option II:Installing thermalstorage system

368640 32.72 230.40 85

4 AirCompressor

By avoidingleakage at receiver

2323 0.22

5 Total : 345013 34.65 31.50



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Energy Audit

Report|April 2009

BackgroundM SEB has init iated sev eral demand side management

p ro gr am me s w it h t he o bj ec ti ve o f p e ak c li pp in g, s tr at e gi c

e ne rg y c on se rv at io n, v all ey f il li ng a nd l oa d sh if ti ng i n

accordance with direct ive issued by the MERC. The consumers

included for such study have contract demand of 1000 KVA and

above, both in commercial and industrial sectors.

As a par t of th is in i t ia t ive , ARS Energy Audi tors , Virar carr ied

out energy audit activity at M/s. Custom Capsules Pvt. Ltd. This

report relates to the findings of the energy audit activit ies.



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Energy Audit

Report|April 2009

Seasonal Variations:

Figure 1: Seasonal Power Consumption Pattern

Seasonal variation

42000

44000

46000

48000

50000

52000

A p r - 0

8

M a y - 0

8 J u

n - 0 8

J u l - 0

8

A u g - 0

8

S e p - 0

8

O c t - 0

8 N o

v - 0 8

D e c - 0

8 J a

n - 0 9

F e b - 0

9

M a r - 0

9

Months

U n

i t

C o n s u m p

t i o

0

0.2

0.4

0.6

0.8

1

1.2

P o w e r

F a c t o

Unitconsumptionkwh

P.F.

T he S ea so na l v ar ia ti on s ho ws t ha t t he m ax im um e le ct ri ci ty

consumption was in the month of February and minimum

elect r ic i ty consumpt ion in the month o f September due to l ess

usage of machinery.

The CCPL, Boisar operates between 10.00 hours to 18:00 hours.

The laboratory equipments and l ight ing, computers contr ibute to

regular loads; while space condit ioning sy ste ms like air

conditioners, fans etc. contribute to t ime-bound / seasonal loads.

To u nd er st an d t he p ow er c on su mp ti on p at te rn , t he e le ct ri ca l

measurements for the period of 5 days at incoming LT meter were

carried out to capture the loading pattern of the facil i ty.



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Figure 2: Daily Power Consumption Pattern

180.00

Daily power consumption pattern from 16 t h Apri l 2009 to 21 s t April

2009 is as shown above. Being weekly OFF, the power consumption

was less on 18 t h and 19 t h April .

T he ab ov e g rap h s how s t ha t t he p ow er c ons ump ti on i s i n

incre asing tre nd from 8: 50 AM onward and reaches peak

consumption of 130 kW at around 9:50 AM. It remains stable in the

range of 120 kW to 140 kW between 9:50 AM to 5:50 PM and af ter

that , i t shows receding t rend upto 11.00 PM (30 kW) and remains

s ta bl e u pt o 6 :0 0 A M. F ro m 6 : 00 A M o nw ar ds t he c on su mp ti on

s ta r t s inc reas ing and reaches 48 kW and remains cons tan t up to

8 .5 0 A M. Ni ght l oad i s 3 0 k W, wh ich i s ma in ly du e t o p lan t

machinery.



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Energy Audit

Report|April 2009

Figure 3: Date-wise power Consumption Pattern

Power Consumption, kWh/day

0.00

500.00

1000.00

1500.00

2000.00

2500.00

16-Apr 17-Apr 18-Apr 19-Apr 20-AprDate

k W h / d a

Power Consumption, kWh/ day

The power consumption pattern for five days is represented above,

it may be important to note that, 18th and 19th April being weekly

OFF, the power consumpt ion on Monday, 20 t h Apr i l i s more than

normal working day, due to high start-up load.



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Methodology

Electrical Distribution System:

Scope of Work:

Measure/Record the 24 hrs. Load distribution.

To suggest various energy efficient measures with first order

cost benefit analysis

Methodology:

A . Census:

Find out the electrical normal & emergency loading.

Type of tariff

Rating of installed transformer

General hygiene as per standard maintenance practices

D at a o n o pe ra ti ng h ou rs d at a w as c ol le ct ed f ro m t he

operating staff

B. Performance audi t:

Electric load recording with: Vol ta ge , c ur re nt , k W, k Wh , P.F., H ar mo ni c Vol ta ge a nd

Current

Indoor Lighting:

Scope of Work:

To s tudy exis t ing l ight ing scenar io of faci l i ty and ver i fy the

building data

To find out the performance of l ighting fixtures

To calculate the ILER (Lux/wat t /m 2 ) and compare lux wi th

the bench mark/prevailing standard in the facil i ty



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Energy Audit

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Methodology:

A. Census: U pt o 8 0 % o f t he l ig hti ng f ix tu re s w er e in sp ec te d f or

following:

No. of l ights installed and no. of l ights working

Type of l ights


D at a o n o pe ra ti ng h ou rs d at a w as co ll ect ed f ro m t he

operating staff

B . P er fo rm an ce au di t:

10 % of the to ta l connec ted l igh t ing load f rom the Census wasstudied in detail as per following:

Measurement of lux level

Measurement of room dimensions

Power drawn by the l ighting system

Window /Split Air Conditioners

Scope of Work: To s tu dy e xi st in g w in do w a ir c on di ti on er s o f f ac il it y a nd

verify the building data

To find out the performance of air conditioners

To compare the specif ic energy consumption with the benchmark/prevailing standard in the facil i ty

To ident i fy the causes of deviat ion in the performance and

suggest recommendations for corrective actions



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Methodology:

A. Census: Upto 10 % of the window a i r condi t ioners were inspec ted fo r

following:

N o. o f w in do w a ir c on di ti on er s i ns ta ll ed a nd n o. o f a ir

conditioners working

Type of window air conditioners



operating staff

B. Performance audit:

10 % of the to ta l connec ted window a i r condi t ioners f rom the

Census was studied in detail as per following:

Measurement of air f low quantity across ev aporator

Measurement of temperatures of the supply air and room

Power drawn by the air conditioner

Pumps:

Scope of Work: To s tudy ex i st ing pumping system of faci l ity and veri fy the

building data

To carry out analysis

To find out the performance of pumping system

To compare the operating efficiency with the bench

mark/prevailing standard in the facil i ty



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Energy Audit

Report|April 2009

To i de nt if y t he c au se s o f d ev ia ti on i n t he p e rf or ma nc e a nd


To suggest var ious energy eff ic ient measures with f i rs t order


Methodology:

A. Census: All water pumps were audited for following:

Total no. of pumps installed

Total no. of pumps working

Pressure gauge working

Ammeter working

General hygiene conditions


operating staff

B. Performance audit:

All working pumps from the Census were s tudied in detai l as perfollowing:

Water flow rate m 3 /hr

Head generated mWC

Power drawn by thepump kW

4.2 UPS:

Input and output power consumption of UPS was carried out



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Compressed Air System:

Scope of Work: To s tudy exis t ing Compressed Air system of faci l i ty and ver i fy

the building data

To carry out analysis

To find out the performance of Compressed Air system

To compare the operating efficiency with the bench

mark/prevailing standard in the facil i ty

To i de nt if y t he c au se s o f d ev ia ti on i n t he p e rf or ma nc e a nd


Methodology:

F ol lo wi ng p ar am et er s w ou ld b e m ea su re d f or e va lu at in g t he

performance of the air compressors:

Load pressure kg/cm 2

Unload pressure kg/cm 2

Average load time Sec

Average unload time Sec

Suction fi l ter area M 2

Temperature of inle t air C

Load power consumption kW

Unload power consumption kW

Energy consumption per hour kWh/hr

Volume of the receiver andpiping

m 3



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Energy Audit

Report|April 2009

3 Historical Data Analysis

Monthly Electricity Bills

MSEB i s d i s t r ibu tor o f the e lec t r i ca l power fo r CCPL, Boisa r. The

monthly e lectr ical bi l l analysis for CCPL Boisar i s a s pe r under.

T he a nn ua l e le ct ri ca l u ni t c on su mp ti on d ur in g A pr il , 2 00 8 t o

M ar ch , 2 00 9 w as 56 27 19 2 k Wh . T he a nnu al e le ct ri ca l u ni t

consumption with month wise break-up is as under.

Figure 4: Historical Data Analysis

Monthly Bill analysi

42000

4300044000

45000

4600047000

48000

49000

5000051000

52000

A p r - 0

8

M a y - 0

8 J u n

- 0 8 J u l - 0 8

A u g - 0

8 S e p

- 0 8 O c

t - 0 8 N o

v - 0 8 D e

c - 0 8

J a n - 0 9

F e b - 0 9

M a r - 0

9

Month

U n i

t C o n s u m p t

i o n

k W h

0

100000

200000

300000

400000

500000

600000

B i l l a m o u n t R s .

Consumption kwh Bill am ount Rs .

T he h is to ri ca l d at a s ho ws t ha t t he m ax im um e le ct ri ca l u ni t

consumption was in the month of February and minimum electrical

unit consumption in the month of September.



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Load Distribution

Load Distribution based on kWh:

Figure 6: Load Distribution based on kWh

Power Consumption, kWh/day

Lighting9%

Window/Split AC24%

Computers

6%Chillers20%

Equipments37%

Compressor4%

As the energy aud i t was conduc ted in the month o f Apr i l , 2009 ,

t he re w as m ax i mu m r eq ui re me nt o f a ir c on di ti on in g s ys te m,

l igh t ing . The rest o f energy was consumed by P lan t machinery,

pumps, computers, printers etc. The load dis t r ibut ion based on uni ts is 2160 kWh/day. The major

contributors are Plant Machinery (37%), window air condi tioners

(24%), Chillers (20%), l ighting (9%),), Computer (6%), Compressor

(4%).

In order to calculate kWh/day i t was assumed that the equipment

load is 100 kW and working hours of all loads is 8 hour.



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Energy Audit

Report|April 2009

Load Profile:

During study load profile recorded for five days, Load profile given

below is dated 21 s t April 2009

Power:

Figure 7 Load Profile Power

Power

0.00

20.00

40.00

60.00

80.00100.00

120.00

140.00

160.00

180.00

3 : 2 0 : 0

0 A M

4 : 5 0 : 0

0 A M

6 : 2 0 : 0

0 A M

7 : 5 0 : 0

0 A M

9 : 2 0 : 0

0 A M

1 0 : 5 0 :

0 0 A M

1 2 : 2 0 :

0 0 P M

1 : 5 0 : 0

0 P M

3 : 2 0 : 0

0 P M

4 : 5 0 : 0

0 P M

6 : 2 0 : 0

0 P M

7 : 5 0 : 0

0 P M

9 : 2 0 : 0

0 P M

1 0 : 5 0 :

0 0 P M

1 2 : 2 0 :

0 0 A M

2 : 0 0 : 0

0 A M

Time

k W

The maximum power consumption during data logging was 152 kW

a nd t he m in im um p ow er c on su mp ti on w as 3 1 k W. T he a ve ra ge

power consumption was 82 kW.



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Voltage Variation

Figure 8: Load Profile - Voltage

Voltage Variation

390.00

400.00

410.00

420.00

430.00

440.00

450.00

3 : 2 0 : 0 0

A M

5 : 4 0 : 0 0

A M

8 : 0 0 : 0 0

A M

1 0 : 2

0 : 0 0 A M

1 2 : 4

0 : 0 0 P

M

3 : 0 0 : 0 0

P M

5 : 2 0 : 0 0

P M

7 : 4 0 : 0 0

P M

1 0 : 0

0 : 0 0 P

M

1 2 : 2

0 : 0 0 A M

3 : 0 0 : 0 0

A M

Time

V o l t a g

The average Voltage recorded during data logging was 430V.

Power factor:

Figure 9 Load Profile Power Factor

Power Factor

0.00

0.20

0.40

0.60

0.80

1.00

1.20

3 : 2 0 : 0

0 A M

5 : 2 0 : 0

0 A M

7 : 2 0 : 0

0 A M

9 : 2 0 : 0

0 A M

1 1 : 2 0

: 0 0 A M

1 : 2 0 : 0

0 P M

3 : 2 0 : 0

0 P M

5 : 2 0 : 0

0 P M

7 : 2 0 : 0

0 P M

9 : 2 0 : 0

0 P M

1 1 : 2 0

: 0 0 P M

1 : 3 0 : 0

0 A M

Time

P . F

The average power factor recorded during data logging was

0.93.



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Energy Audit

Report|April 2009

Demand:

Figure 10 Load Profile Demand

20.00E+3

40.00E+3

60.00E+3

80.00E+3

100.0E+3

120.0E+3

140.0E+3

160.0E+3

180.0E+3

VA

1:25:00.000 PM4/20/2009

3:20:00.000 PM4/21/2009

5 Hours/Div1:01:55:00 (D:H:M:S)

20.00E+3

40.00E+3

60.00E+3

80.00E+3

100.0E+3

120.0E+3

140.0E+3

160.0E+3

180.0E+3

VA

1:25:00.000 PM4/20/2009

3:20:00.000 PM4/21/2009

5 Hours/Div1:01:55:00 (D:H:M:S)

The maximum demand recorded during data logging was 164

kVA.

Voltage and Current Harmonics:

Figure 11: Load Profile Voltage Harmonics

0.60

0.80

1.000

1.200

1.400

1.600

%

1:25:00.000 PM4/20/2009

3:20:00.000 PM4/21/2009

5 Hours/Div1:01:55:00 (D:H:M:S)

0.60

0.80

1.000

1.200

1.400

1.600

%

1:25:00.000 PM4/20/2009

3:20:00.000 PM4/21/2009

5 Hours/Div1:01:55:00 (D:H:M:S)



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Figure 12: Load Profile Current Harmonics

5.000

10.00

15.00

20.00

25.00

30.00

%

1:25:00.000 PM4/20/2009

3:20:00.000 PM4/21/2009

5 Hours/Div1:01:55:00 (D:H:M:S)

5.000

10.00

15.00

20.00

25.00

30.00

%

1:25:00.000 PM4/20/2009

3:20:00.000 PM4/21/2009

5 Hours/Div1:01:55:00 (D:H:M:S)

Table No.1: Harmonics:

Area MaximumV T H D %

Maximum I T H D %

R Phase 1.5 26

Y Phase 1.4 29

B Phase 1.6 31

IEEE standard 519-1992 defines the l imits of various parameters

are shown as under:

PARAMETER LIMIT

%Voltage variation Upto 5%

% V THD 1.5 5%

% I THD Upto 10%

% Frequencyvariation Upto 3%

% Unbalanced V Upto 2%



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Measurements, Observations, and Data Analysis

Billing Analysis, Electrical Demand and Power Factor:

Billing Analysis:

The 12 months electricity bil l data is tabulated and analyzed from

which average electrical unit cost is calculated.

Table No. 2: Monthly Energy Bills

Bill analysis December 2007 to November 2008

Month

Unitconsumpti

on

kWH

Billamou

nt

Rs.

Rs./kWH

P.F.

Demand

Charg

es

P.F.Incentive

/Penalty

Rs.

Billedmaximu

mdemand

KVA

Recorded

maximum

demandKVAApr-08 47366

457787 9.66

0.85 30000 22805 200 209

May-08 48337

493618 10.21

0.79 30000 46412 200 233

Jun-08 50377 525208 10.430.79 30000 49307 200 220

Jul-08 47110 479511 10.180.78 30000 48355 200 210

Aug-08 47298

505574 10.69

0.78 30000 51040 200 226

Sep-08 45192

438538 9.70 0.9 30000 0 200 226

Oct-08 46158

428495 9.28

0.99 30000 -19346 200 188

Nov-08 45355

413464 9.12 1 30000 -26615 200 167

Dec-08 50087

477503 9.53

0.99 30000 -21573 200 168

Jan-09 48806 457561 9.38 1 30000 -29474 200 183

Feb-09 51421

485195 9.44

0.99 30000 -22110 200 193

Mar-09 48637

464742 9.56

0.99 30000 -20998 200 208

Total 57614456271

96 9.760.90 202.58

From the above table i t is observed that maximum unit

consumpt ion was in the month o f Feb 2009 . From Apr i l 2008 to



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Energy Audit

Report|April 2009

August 2008 power factor penal ty was added in the bi l l and af ter

Se pt . 2009 power factor was maintai n ne ar to unity . For

maintaining power factor above 0.95 during this per iod, Recorded

demand was never exceeding sanct ioned demand of 500 kVA and

the facil i ty received incentive of total Rs. 1.4 Lac.



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Capacitor Banks :

Observation:

I t w a s o b s e r v e d t h a t 2 n o s . o f 5 0 k VA R a n d 1 n o . o f 2 5 k VA Rcapac ito rs were p rov ided fo r power facto r correct ion which was

operated manually by operator.

Analysis:

Following data were measured for evaluating performance of capacitors:

Sr.No. Particular

Capacitor

Rating(kVAR)

Actual Current(A)

Required

Current(A)

Remark R Y B

1 Capacitor C1 50 63.9 63.4 64.1 65 Ok

2 Capacitor C2 50 46.9 45.4 46.1 65 De-rated

3 Capacitor C3 25 32.5 32.2 32.4 32.5 Ok

It was found that actual current of capacitor 2 was low as compared

t o t he r at ed c ur re nt , w hi ch i nd ic at ed t ha t t he c ap ac it or w as

derated.



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Energy Audit

Report|April 2009

Lighting:

Observations:

The faci l i ty is having 172 nos. of 52 wat ts tube l ights , 113 nos.of 48 tube lights, 81 nos. of 36 watts PLC.

The office l ighting remains ON during 10 AM to 6.00 PM

Following is the measured data of l ighting system of CCPL, Boisar

at various floors:

Table No.3: Lighting

Name of DepartmentArea,

m 2Lux

level

Total

watts

W/m2

Lux/W/m 2

Lux/m 2

Lux/W

Ground floor

Conference Room 38.44 230 1535 40 6 5.97 0.15

Manager's Room IGR-16 7.68 94 340 44.3 2 12.24 0.28De-dusting IGR-10 6.96 226 104 15 15 32.40 2.17Stores IGR-18 33.64 125 416 12 10 3.72 0.30AC Storage 5.22 123 104 20 6 23.47 1.18Documentation & Executive

Area IGR-1722.94 143 736 32 4 6.24 0.19

Library IGR-14 18.6 177 628 34 5 9.53 0.28Product Development IGR-15 4.21 152 96 23 7 35.95 1.58

Product Development IGR-15 24.79 397 624 25 16 15.99 0.64

Lounge 57.66 103 1061 18 6 1.78 0.10

Pantry IGR-12 31.19 56 192 6 9 1.78 0.29Electrical Panel Room 8.19 123 52 6 19 15.06 2.37Entry Lobby 7.69 296 208 27 11 38.47 1.42

Female Change 10.25 248 208 20 12 24.16 1.19Male Change 10.53 229 208 20 12 21.75 1.10Air Lock IGR-26 4.3 227 104 24 9 52.67 2.18Over gowning 8.19 189 104 13 15 23.04 1.81Dispensing Area IGR-41 10 296 416 42 7 29.63 0.71Air Lock 5.76 307 104 18 17 53.21 2.95



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Name of Department

Area,m 2

luxlevel

Total

watts

W/m 2 Lux/W/m 2Lux/m

2Lux/

W

Ground floorAerosol 10.92 59 80 7 8 5.37 0.73Air Lock-1 3.64 486 104 29 17 133.52 4.67Granulation IGR-30 24.07 102 160 7 15 4.25 0.64Blending igr-31 11.27 259 208 18 14 22.94 1.24Capsulation IGR-39 10.56 335 208 20 17 31.74 1.61Washing IGR-32 3.00 218 208 69 3 72.59 1.05Clean Hold 3.44 195 104 30 6 56.69 1.88Compression - II IGR-33 11.4 154 208 18 8 13.49 0.74

Compression - I IGR-34 10.26 97 208 20 5 9.41 0.46IPQC IGR-35 7.6 362 208 27 13 47.66 1.74Coating IGR-36 12.36 102 80 6 16 8.21 1.27Blister Packing IGR-37 23.28 418 624 27 16 17.97 0.67Quarantine IGR-38 6.66 404 624 94 4 60.62 0.65Corridor 1 21.83 347 416 19 18 15.87 0.83Corridor 2 28.35 123 416 15 8 4.32 0.29Staircase - 75 416 - - - 0.18First Floor

Manager Cabin-1 IFR-5 8.75 174 288 33 5 19.83 0.60Manager Cabin-3 IFR-7 8.75 143 375 43 3 16.31 0.38

Passage-1 21 172 1236 59 3 8.18 0.14

Cabin-1 IFR-10 12.25 173 314 26 7 14.12 0.55Director's Cabin IFR-9 19.25 91 192 10 9 4.71 0.47Changing Room IFR-14 12 191 528 44 4 15.92 0.36Instrument Room IFR-17 81 198

3028 37 5 2.45 0.07

Passage 45 164 984 22 8 3.64 0.17

Instrument room- 27 295 1392 52 6 10.93 0.21

UPS Room IFR-25 6 59 144 24 2 9.79 0.41Documentation RoomIFR-20 18 170 192 11 16 9.44 0.89

Wet Chemistry IFR-29 36 229 471 13 18 6.37 0.49

Wet Chemistry IFR-32 36 211 2522 70 3 5.87 0.08



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Energy Audit

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Instrument room-3 17.87 92 436 24 4 5.13 0.21

Following table indicates norm of ECBC Norm (w/m 2 ) for LPD:

Table No.4: Comparison of LPD value with ECBC Norms

Typical RoomsECBC LPD

ValuesW/m 2

PresentLPDValuesW/m 2

%Increa

se

Office Enclosed 11.84 26 119Conference rooms 13.99 40 185

Toilet and Restrooms 9.69 20 106Staircase 6.46 7 8Equipment room 12.92 33 155Electrical/ MechanicalRoom 16.15 20 23

Following table indicates Lux level required as per National

Building Code:

Table No.5: Comparison of present lux level with NBC

Typical Rooms Illumination LuxPresent

Lux Level

%Increase

/Decreas

eEntrance and Reception Area 150 155 + 3Conference rooms and ExecutiveOffices 300 230 - 24

General Office 300 122 - 59Staircase 100 75 - 25Corridors and Lift Cars 70 181 + 159

It was observed that the present LPD (w/m 2 ) i s higher than

ECBC norm by 99 % but average i l lumina tion (Lux) l eve l i sgreater by 10 % as compare with National Building Code.

T he m ai n r ea so ns o f t hi s l ow er l ux l ev el s a nd h ig he r p ow er

consumption are:

Poor house-keeping, and



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Improper layout and selection of improper luminaries

Window Air Conditioners:

Observations:

At CCPL,Boisar, the ins tal led a i r-condi t ioners ( to ta l 40

nos. ) of 1 ton, 1.5 ton and 2 ton configuration.

At the t ime of aud i t , mos t o f the a i r condi t ion ing machines

were in operation, being Summer season

Maximum nos . o f the a i r condi tioners i s insta ll ed on F i rs t

Floor.

For evaluat ing window air condi t ioner performance, fol lowing ai rconditioners were selected on sample basis.

The fol lowing paramete rs were measured for evaluati ng

performance of window air conditioners:

Table No.6: Measurements at Window Air-Conditioners

LocationDuctArea(m 2 )

AirVelocity (m/s)

SupplyTemperature

(C)

RoomTemperature

(C)

Powerconsumptio

n

(kW)DBT WBT DBT WBTUPS Room 0.04 3.78 10.00 9.00 19.00 18.00 2.01Controlsample room 0.40 3.36 16.00 14.50 21.00 15.50 1.91

Change room 0.04 3.45 18.00 17.00 24.00 23.00Measurement of powerwas notpossible

1 st floorpassage 0.04 0.93 20.00 15.00 28.00 22.00

Managercabin 0.03 3.03 14.00 12.00 21.00 19.00

Server room 0.05 3.38 9.00 8.00 15.00 13.00 1.8



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Energy Audit

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Following is the analysis of window air conditioners:

Table No.7: Data analysis Window air conditioner

Location Rated

TRTR KW/T

RUPS Room 2 1.40 1.44Control sample room 1.5 1.26 1.52Change room 1.5 0.99 0.001st floor passage 1.5 0.37 0.00Manager cabin 1 0.67 0.00Server room 2 0.95 1.86

Air condi t ioners for UPS room, Control sample Room and Change

r oo m a re d el iv e ri ng a cc ep ta bl e c oo li n g ( TR ), h ow ev e r, t he a ir

conditioner installed at the first f loor passage, and at server Room

are no t pe rforming as desi red and need c r i t i ca l overhau l ing or

Refrigerant re-charging.



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DX Chillers

Observations:

Apart f rom Window Air-condi t ioners , 9 nos . DX type Chi l l e rof different capacities have been installed

At the t ime of audit Chiller no. 5 and 8 were not working

All chillers are installed on Ground Floor

Table No.8: DX Chiller input data

Identificati

on

DuctArea(m 2 )

AirVelocit

ym/s

SupplyTemperature

(C)

RoomTemperatu

re (C)Power

consumption(kW)

DBT WBT DBT WBT

AHU 1 0.38 1.91 14.00 10.00 25.5021.0

0 17.70

AHU 2 0.43 1.15 18.00 16.50 23.5021.0

0 4.68

AHU 3 0.44 2.83 25.00 20.50 29.5024.0

0 9.98

AHU 4 0.38 1.42 19.00 15.00 23.0020.0

0 5.03

AHU 6 0.41 1.05 19.0

016.50 23.00 20.5

04.54

AHU 7 0.49 2.05 19.00 16.00 24.0020.5

0 9.70

AHU 9 0.43 0.86 19.00 16.00 23.0021.0

0 4.82

Table No.9: DX Chiller performance Analysis

Location RatedTRMeasured

, TR kW/TR

AHU 1 12 7.80 2.27

AHU 2 3 2.44 1.92AHU 3 7 5.41 1.84AHU 4 3 2.82 1.79AHU 6 5 1.93 2.35AHU 7 7 4.80 2.02AHU 9 5 2.00 2.40



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Energy Audit

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The SEC of chillers is high as compared to the norm of 1.2 kW/TR .



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Observations:

Compressed ai r i s required for var ious machines l ike for packing,for operat ing pneumatic tools, e tc . Compressed ai r i s suppl ied by

Compressor #1 . Compressor #1 opera tes be tween pressures o f

6 .4 bar to 6 .0 bar. Compressed a i r f rom rece iver i s supp l ied to

plant via air cooler.

During the f ie ld s tudy, Pump-up tes t was carr ied out to determine

c om pr es so r a ct ua l f re e a ir d el iv er y a nd c om pr es se d a ir l in e

l ea ka ge t es t t o de te rm in e t ot al q ua nt it y of a ir l ea ka ge i n

compressed air l ine.

I t was observed tha t Leakage was observed a t the Rece iver and

the same was notified to the coordinator.

Analysis:

Pump Up test:

Pump up test on the compressor shows that compressor i s no t

w or ki ng e ff ic ie nt l y, h av in g t he i r s pe ci fi c p ow er c on su mp ti on( 28.14 kW/100 cfm ) h igh compare to the s tandard va lue o f 16

kW/100 cfm . The specif ic power consumption of compressor and

its actual free air delivery (cfm) is shown in the following table:



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Energy Audit

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Table No.10: Air Compressor Pump Up test results

Parameters UoMAir

Compressor

Compressor type Reciprocati

ngCapacity CFM

Capacity Measurement

By Pump Up Test

Air generation rate Cfm 41Power consumption during

generation kWh 11.7

Specific Energy Consumption,SEC

kW/100scfm 28.14

% leakage % 29.82

Leakage quantity m3

/hr 18.74

T he co mp re ss ed a ir l ea ka ge r at e i s 3 0% w hi ch c an b e

further reduced by improving ro uti ne maintenance

practices.

Pumps:

Observations:

2 nos. x 3 HP monobloc pumps have been installed and only one

pump is operated for transferring water to overhead tank, while

other pump is stand-by.

The ra ted Head of the ins ta l l ed pump i s ve ry h igh , whi le the

operating Head is very low; s t i l l pump does not offer excessive

flow and at the same time consumes full power.

Table No.11: Pump performance

PumpIdentification

Flow, m 3 /hr Head, m Power, kW Efficiency, %Rated Actual

Rated

Actual

Rated Actual

Rated Actual

Water pump no.2for overhead

tank

14.00 12.00 25 -20 15 2.20 2.10 40% 23%



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50

Water pump no.1for overhead

tank

14.00 13.00 25 -20 15 2.20 2.30 40% 23%

The pump eff ic iency is poor but as these pumps are operated foronly 20 minutes in a day, i t is not feasible to replace these pumps

with energy efficient pumps.

UPS

Observations:

2 nos. x 10 kVA and 1 no. x 40kAV UPS have been installed

UPS no 3 (40 kVA rating) was observed to be overloaded

W hi le m ap pi ng t he l oa d- pr of il e, i t w as o bs er ve d t ha t, t he

current Harmonics were p redominan t during the n igh t hours,

when other motive loads were at minimum. There is a possibili ty

of UPS might be generat ing Harmonics and there is a need for

separate study to assess the Harmonics issue.

Table No.12: UPS

UPS InputIdentification

Phase

Voltage Current

Power

PowerFactor

%Loading

UPS MainR 432 26.3 18.3 0.91

Y 433 21.9 14.5 0.88B 433 22.3 14.9 0.89

UPS 1(10kVA)

R 433 7.29 5.45 172.63 Y 433 2.05 1.45 0.95

B No Current

UPS 2(10 kVA)

R 434 3.31 2.25 0.983.78 Y 432 3.61 2.46 0.9

B 432 4.07 2.83 0.93

UPS 3 R 433 21.4 14.3 0.89 119.10



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Energy Audit

Report|April 2009

(40 kVA) Y 433 20.3 13.6 0.89B 431 22.3 14.5 0.87

UPS OutputIdentificatio

nPhase

Voltage Current Power

PowerFactor

UPS 1 R 405 8.59 5.81 0.96(10 kVA) No Current

UPS 2 231 5.17 1.04 0.87(10 kVA)

UPS 3 R 232 11.4 2.11 0.8(40 kVA) Y 232 10.2 1.91 0.81

B 231 9.63 1.98 0.89



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7 Energy Conservation Opportunities

Capacitor Banks:

I t i s r ec om me nd ed t o r ep la ce t he f au lt y c ap ac it or w it h n ew

capaci tor. Also, as present capaci tors are operated manual ly, i t i s

recommended to install automatic power factor sensing device.

Table No.13: By maintaining power factor unity

Improving Power Factor to unity:Particulars UoM ValuePresent power factor 0.99Propose power factor 1Present Demand kVA 200

Propose Demand kVA 198Demand charges Rs./kVA 150

Saving in demand chargesRs./month 300

Annual saving in demand chargesRs./annum 3600

Present average bill charges (of past 12 months)Rs./annum

5026826

Propose P.F. incentive due to improve in power factor tounity

Rs./annum

100537

Cost of 50 kVAR and real time power factor improvement

panel Rs.

11250

0Payback Period Months 13.0

Lighting

7.2.11 For inter ior light ing:

I . O pt ion I:

Step I:

By replacing conventional ballasts with electronic

ballasts:

At present 285 nos. l igh t ing f ixtu res a re f i t ted wi th magne t ic

bal las ts and consume 12 W of power per bal las t . Also, l ight ing

f ix tu re s c on su me 4 0 Wat ts p ow er p er f it ti ng . T hu s, p ow er



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Energy Audit

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c on su mp ti on o f s in gl e l ig ht in g f ix tu re i nc lu di ng m ag ne ti c

b al l as ts i s 5 2 W p er f i tt in g. I t i s p ro po se d t o r ep la ce t he se

lighting fixtures with electronic ballasts which consume 2 W per

ballast . The expected savings shall be as under:

Table No. 14: Saving by replacement of conventional ballasts with electronic ballasts

Parameters UoM ValuePresent Status

No. of magnetic ballast installed no. 285Power consumption of magneticballast W 12Operating duration hr/day 9

days/month 20

Electrical unit cost Rs./kWh 9.76Present electrical energyconsumption kWh/year 7387

Status after replacement with Electronicballast

No. of electronic ballast required no. 143Power consumption of electronicballast W 2Propose electrical energyconsumption kWh/year 616Savings kWh/year 6772

Rs/year 66091Implementation cost Rs./unit 400Rs. 57000

Simple payback period Months 10

Step II:

After replacing with e lectronic bal las ts , ins ta l l vol tage reducing

device that shal l reduce operat ing vol tage f rom 235 V to 210 V.

The savings shall be as under:



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Table No. 15: Saving by installation of voltage reductiondevice

Present Status UoM ValueNo. of 52 W Tube fittings No. 172Power consumption W 42No. of 48 W Tube fittings No. 113Power consumption W 38No. of 36 W Tube fittings No. 81Power consumption W 36Operating duration hr./day 9

days/month 20Electrical unit cost Rs./kWh 9.76Electrical unit consumption kWh/year 31177

Status after installation of lighting

transformerElectrical unit consumption kWh/year 24942Savings kWh/year 6235

Rs./year 60858Size of lighting transformer kVA 21Investment Rs. 110000Simple Payback period Month 22

Step III:

By installing motion / occupancy sensors

Feature of motion sensors:

Motion sensor is a ful ly automatic indoor and out door l ight ing

controller. Capable of controlling up to 1000 W incandescent or

30x 10 fluorescent of l ighting.

At night , bui l t in passive infrared (PIR) motion sensor turns on

connect ion l ight ing system, when i t detects motion in i ts cover

a re a. D uri ng t he d ay i n b ui lt i n p ho to ce ll se ns or s av es

electricity by deactivating the l ight.

The adjustable t imer lets you select how long the l ights stay on

activation the l ights.



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Energy Audit

Report|April 2009

Lux ad jus tment de termine a t what l eve l l igh t ing system wi ll

start operating when you set motion sensor to automatic mode.

I t i s not pos sibl e t o quant i fy s av ing a ch i eve by i ns ta ll i ng

motion sensor.

II . Option II:

By retrofit t ing 172 nos. l ighting fixtures with 52 watts T-5

and 113 nos. l ight ing f ix tu re s o f 48 wat t s w ith ene rg y

efficient l ighting fixtures T-5:

The present 285 nos. l ight ing f ixtures consume 52W power per

f i t t ing. I t i s proposed to re t rof i t these l ight ing f ixtures with T-5

tube l ights which consume 30 W power per f i t t ing. The savings

shall be as under:

Table No. 16: Saving By retrofit t ing present Lightingfixtures with energy efficient l ighting fixtures T5:

Parameters UoM ValuePresent status:No. of 52 W Tube fittings No. 172Power consumption W 52

No. of 48 W Tube fittings No. 113Power consumption W 48Operating duration hr./day 9.76

days/month 20Electrical unit consumption kWh/year 33655Status after replacement with T5Power consumption W 30Electrical unit consumption kWh/year 20027Savings kWh/year 13628Electrical unit cost Rs./kWh 9.76Total savings kWh/year 13628

Rs./year 133010Investment Rs. 199500Simple payback period Months 18



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Window/ Split Air Conditioners:

Option I:

By installing Energy Saver device: The power consumption of present compressor is about 1.7 kW per

TR. The power consumption af ter ins ta l l ing the energy saver will

reduce upto 15%. The savings shall be as under:

Table No. 17: Savings by installing energy server

Installing Energy Saver:UOM Value

ParametersQuantity of Window Air Conditioner Nos. 40

Present power consumption per unit kW 1.70Proposed Power consumption afterinstalling Energy Saver device @ 15%Saving

kW 1.45

Saving by Installing Energy Saver kW 0.26Operating hours per annum Hour 2112

Total Units Saved by Energy Saver kWh/annum 21542

Cost of Energy Saver Device Rs./Unit 3000 Total Cost of Energy Saver devices Rs. 120000

Cost Per unit Rs./kWh 9.76Total Saving per annum Rs./annum 210254

Simple Payback Period Months 7

Option II:

Replace present Sp li t Ai r condi tioners a t f i rs t f loor wi th

central air conditioning system

Speci f ic power consumpt ion of p resent sp il t AC i s 1.7 kW/TR

which is very high when compared with the central ai r

condi tioning system, (Water cooled Screw Chil ler) . The Specific

energy Consumption (SEC) of the proposed system shal l be 0.80

kW/TR ; resulting in saving of 0.9 kW/TR.



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Energy Audit

Report|April 2009

Table No. 18: Savings due to installation of central air conditioning system

Installing Central Air Conditioning Plant:Parameters UoM Value

Requirement of TR TR 80Present specific energy consumption per unit kW/TR 1.70

Proposed specific energy consumption afterinstalling Central Air Conditioning Plant kW/TR 0.80

Saving by Installing Central Air ConditioningPlant kW/TR 0.90

Operating hours per annum Hour 2112 Total Units Saved by Central Air ConditioningPlant

kWh/annum

152064

Cost Per unit Rs./kWh 9.76

Total Saving per annumRs./annum

1484145

Cost of Central Air Conditioning Plant Rs. 1520000Simple Payback Period Months 12



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Chillers

Option I:

The power consumpt ion of p resent DX type ch il l e r insta ll ed a tground f loor is about 1.85 kW /TR . The power consumption af ter

insta ll ing the Centra l a i r condi tioning system shal l be 0 .80 kW

/TR . The savings shall be as under:

Table No. 19: Saving by installing central air conditioningsystem

Installing Central Air Conditioning Plant:Parameters UoM Value

Requirement of TR TR 80Present specific energy consumption per unit kW/TR 1.85

Proposed specific energy consumption afterinstalling Central Air Conditioning Plant kW/TR 0.80

Present power Consumption 312576Saving by Installing Central Air ConditioningPlant kW/TR 1.05

Operating hours per annum Hour 2112

Propose power Consumption kWh/annum13516

8

Total Units Saved by Central Air ConditioningPlant kWh/annum 177408Cost Per unit Rs./kWh 9.76

Total Saving per annum Rs./annum17315

02

Cost of Central Air Conditioning Plant Rs. 1350000Simple Payback Period Months 9

Option II:

In o rder to op timize the performance of a i r-condit ion ing system

and to av ai l be ne fits of Time of the day ( TOD ) tari ff , it i s

recommended to install Thermal Storage System , which would

opera te (charge) during lean t a ri ff t ime a t fu ll load and would

discharge during the peak tariff hours.



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Energy Audit

Report|April 2009

Demand Management through Thermal Storage System:

In most of the s ta tes in India , industr ia l consumers pay separate

charges for electricity consumed and maximum kVA or kW demand.

At Boisa r, MSEB a ls o h as a n a tt ra c ti ve l ow n ig ht - ti me t ar if f between 24.00 hrs . to 8 .00 hrs . Fol lowing is the TOD tar i ff deta i ls

schedule at CCPL,Boisar :

Hours Paise / kW2200 hrs - 0600 hrs - 750600 hrs - 0900hrs 00900 hrs 1200 hrs 501200 hrs 1800 hrs 01800 hrs 2200 hrs 100

Consumers with large refr igerat ion and ai r-condi t ioning load can

u se t he c on ce pt o f t he rm al s to ra ge t o r ed uc e t he i r m ax i mu m

demand, reduce peak t ime energy consumpt ion and avai l t a ri ff

rebates.

Thermal S torage impl ies s tor ing the cool ing e ffec t in the l a ten t

h e at o f i ce b an ks ( re fe r t o t he f ig ur e b el ow ) o r e ut e ct i c s al t s

(which undergo a phase change) and using i t when required. Ice

b an ks a re b ei ng u se d i n d ai ri es f or t he p as t m an y y ea rs t o

overcome their peak cooling loads. The same concept can be used

to reduce energy cost by opera ting the ch il l er s during off-peak

hours and storing chilled for use during peak hours. This reduces

the number o f ch i l l e r s tha t may have to run to sa t i s fy the peak-

cooling load.

One thing worth mentioning here is that Thermal Storage system is

no t an energy conservat ion system. I t i s energy cost reduc tion

t ec hn iq ue b y w ay o f D em an d M an ag em en t. T he e ne rg y c os t

sav ings accrue due to reduc t ion in the reg i s te red Maximum KVA

a nd P e ak - ti me e ne rg y c ha rg es a nd r eb at e s ( if a pp li ca bl e ); t he

quantum of savings would depend on the load profile of the plant.



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Ice banks are a proven technology. A var ie ty of eutect ic sal ts are

available which can change from solid to l iquid phase at

temperatures ranging from 33 to +27C. The sal t hydrates are

enclosed in HDPE (High Density Poly-ethylene) nodules; a number

of such nodules are enclosed in a tank through which chilled wateror brine can be allowed to flow.

Schematic of a typical thermal sto rage tank is shown below:

During charging cycle, l iquid refrigerant is passed through the coil ,

absorbs heat f rom water or eutect ic sal t and evaporates . Sal t or

wate r undergoes a phase change . During the Discharge Cycle ,

br ine or water to be cooled is passed through the system. Ice or

salt nodules absorb latent heat of fusion from the cooling medium.Charging is done during OFF PEAK periods and Discharging is done

during PEAK pe riod thus lowe ring the maximum demand

registered.



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51

Energy Audit

Report|April 2009

T hi s t ec hn ol og y c an b e u se d v er y e ff ec ti ve ly t o r ed uc e a ir -

conditioning costs by way of demand management.

Option I:

I t i s p roposed to opera te bo th ch i l l e r s a t -5 deg . C . The ch i l l e r s

would be operated during off-peak hours i .e. between 24.00 hrs. to

8.00 hrs. to feed the Thermal storage system. This would generate

a bo ut 6 40 T RH o f T he rm al s to ra ge s ys te m d ur in g t he o ff - pe ak

period of 8 hours. Therefore, with the help of the Thermal storage,

i t w oul d be p ossi bl e t o me et t he ai r- co nd it io ni ng n ee ds o f

CCPL,Boisar w it ho ut t he n ee d t o o pe ra te t he c hi ll er s d ur in g

daytime since the entire requirement would be met by the Thermal

storage system.

At the same time, additional pumps would be required to circulate

chilled water from the Thermal storage system to the AHUs. At the

same time, savings due to non-working of chillers during peak and

normal tariff hours shall also be substantial .


Refrigerant

Vapour

Return

Water

Ice

eeeeee

Waterter

LiquidRefrigerant

Chilled Water toLoad

WaterIce


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50

The savings shall be as under:

Table No. 20: Savings by installation of Thermal storagesystem

Thermal Storage System

Thermal Storage System UoMPresent specific energy consumption kW/TR 1.85Present TR generation TR 160.00Present power consumption kW 296.00Present operating hours Hours/day 8.00

Present energy consumption kWh/annum 852480

Proposed specific energy consumption kW/TR 1.05Proposed TR generation TR 160Proposed power consumption kW 168

Proposed operating hours Hours/day 8

Proposed energy consumption kWh/annum 483840

Saving in energy consumption kWh/annum36864

0Cost of power from 9.00 hours to 18.00hours Rs./kWh 6.30

Cost of power from 24.00 hours to 8.00hours Rs./kWh 5.45

Energy savings Rs./annum27336

96

Present demand charges Rs./annum 538182Savings in Demand Charges Rs./annum

538182

Total Savings Rs./annum32718

78

Cost of TSS Rs. 23040000Payback Period Months 85

Thus, by implementing Thermal storage scheme as above, i t would

b e p os si bl e t o m ee t t he a ir -c on di t io ni ng r eq ui re me nt s o f a ny

normal day wi thout runn ing the ch il l er s during normal work ing

hours.



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Energy Audit

Report|April 2009


I t was observed that compressor shif ts on loading without using

compressed ai r because of 29 % leakage is present a t receiver.

Th is has been brought in the no t ice o f co-ord ina tor and CCPL,

B oi sa r h as p ro mi se d t o t ak e i mm ed ia te a ct io n a ga in st t hi s.

Howeve r, i f this l eakage is arrested, then the saving in

compressor power consumption shall be as under:

Table No. 21 Savings by avoiding leakage

Parameters UoM ValueCompressor loading one hour Min 12Compressor loading One hour Hours 0.2Power Consumption duringloading kW 11Power Consumption duringloading kWh/day 2.2

Unit rate Rs/Unit 9.4Operating hours hr/day 4

day/month 22

month/year 12

Total savings kWh/year 2323.2

Total savings Rs./year 21838Investment Rs Nil

Pay Back Period MonthsImmediate

P er fo rm an ce o f A ir C om pr ess or c an b e i mp ro ve d byoverhauling.

Pumps:

Even the efficiency of pump is poor i ts operating hour is less thenone hour. Hence, i t not advisable to replace present pumpswith energy efficient pumps.



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Renewable Energy

Solar PV system:

Sola r PV power generat ion systems cons i st s o f in te rconnec ted

c om po ne nt s, e ac h h av i ng s pe ci fi c f un ct i on . O ne o f t he m aj or

f ea tu re s o f P V s ys te ms i s m od ul ar it y. A s y ou r n ee ds g ro w,

i nd iv id ua l c om po ne nt s c an b e r ep la ce d o r a dd ed t o p ro vi de

increased power demand. Following are the main components of a

typical PV system.

Schematic of Solar PV System:

Solar Array

T he s ol ar a rr ay c om pr is es o f o ne o r m or e P V m od ul e s w hi ch

convert sunl ight in to e lectric energy. The modules are connected

in ser ies and/or paral le l to provide the vol tage and current levels

to mee t your power needs . The a r ray i s normal ly mounted on a

metal structure and inclined to face the sun.



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50

Optimization of Power System Demands

E xa mi ne y ou r p ow er c on su mp ti on a nd r ed uc e y ou r p ow er

needs as much as possible. Identify large and/or variable loads

( su ch a s w at e r p um ps , o ut do or l ig ht s, e le ct ri c r an ge s, A Cr ef ri ge ra to rs , e tc .) a nd t ry t o e li mi na te t he m o r e xa mi ne

a lt er na ti v es a va il ab le . R ep la ce i nc an de sc en t f ix tu re s w it h

f lu or es ce nt l ig ht s w he re ve r p os si bl e. F lu or es ce nt l am ps

provide the same level of i l lumination at lower wattage levels.

I f there i s a l a rge load that you cannot e l imina te, cons ider

using it only during peak sun hours or only during the summer.

Revise your Load Sizing.

Sizing of Battery Bank

Understand characte ri s ti cs o f Ba tte ries and then choose the

appropriate battery for your needs.

Determine the Sun Hours Available Per Day

Following factors influence how much sun power your modules

will be exposed to be:

When you wil l be using your sys tem summer, win ter, or

year-round.

Typ ic al l oc al w ea th er c on di ti on s.

F ix ed mo un ti ng s v s. tr ac ke rs .

L oc at io n a nd an gl e o f P V a rr ay.



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51

Energy Audit

Report|April 2009

Sizing of PV Array

Detailed study of above four factors will decide size of PV

system.

Typical costing of 50 kW Solar PV system:

Table No.22: Saving by installing solar PV system

Installing Solar PV System:Solar PV System UoM Value

Present power consumption kWh/hr 25

Average sunshine hours per day Hours 6 Total no. of days per annum Days/annum 270

Operating hours per annum Hour 1620

Total power consumption kWh/annum 40500Cost of power Rs./kWh 10

Present Cost of power consumption Rs./annum 405000

Total sunshine hours per annum Hours/annum 1620

Propose Solar PV System kWh/hr 25

Power generation by Solar PV System kWh/annum 40500

Cost of Solar PV System Rs. 7500000Total Saving per annum Rs./annum 405000Simple Payback Period Months 222

Solar and Wind energy Hybrid system:

T he h yb ri d s ys te m m ak e s t he u se o f w in d a nd s ol ar e ne rg y t o

produce electr ic i ty. Hybrid system uses a combinat ion of energy

producing components that provide a constant flow of

uninterrupted power. Hybridization ensures that if any part of the

system is not be performing (solar -c loudy days, wind- no wind)

f or a ny r ea so n, y ou wi ll h av e a b ac k u p m ea ns o f p ro du ci ng

electricity.

T he m os t p op ul ar h yb ri d c ho ic e i s t ha t o f s ol ar a nd w in d. I t' s

g en er al ly w in dy t o s om e d eg re e d ur in g o ve rc as t d ay s, w hi ch



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m ak e s w in d t ow er s a nd t ur bi ne s e ff ec ti ve w he n t he s un i sn 't

sh in ing . The wind co llecto rs wi ll a l so work a t n igh t , p rov id ing

there 's wind. Alone, the solar and wind systems both have f laws;

solar can ' t work without sun, and wind can ' t work without wind.

When the two systems are combined, they fa i r ly wel l cover eachothers ' weaknesses.

Hybr id systems work fo r bo th o ff-g rid so lu t ions ( such as using

propane generators to charge bat teries when the sky is overcast)

and for gr id- t ie systems (using wind turbines to supplement the

electricity you produce during in climate weather).

Schematic of Hybrid system:

Examples of Hybrid systems are:

Solar Electric and Wind:

Using wind turbines to supplement the electricity you produce

during in climate weather

Solar Electric and Generator:

Using a propane generator to charge batteries, when the sky is

overcast.



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51

Energy Audit

Report|April 2009

Solar Electric and Hydro:

Water from a running stream generates electricity on cloudy days

Wind and Diesel:

A wind generator can supplement a diesel generator

Table No.23: Saving by installing solar and wind energy hybrid system

Installing Solar Wind+ PV Hybrid System:Solar Wind + PV System UoM ValuePresent power consumption kW 25Average sunshine hours per day Hours 6

Total no. of days per annum Days/annum 270

Operating hours per annum Hour 1620 Total power consumption kWh/annum 40500

Cost of power Rs./kWh 9.76

Present Cost of power consumption Rs./annum 395280

Total sunshine hours per annum Hours/annum 1620

Power Generation by Solar PV + Wind System kWh/day 150Power generation per annum kWh/annum 40500

Cost of Solar PV + Wind Mill Rs. 11250000Total Saving per annum Rs./annum 395280Simple Payback Period Months 341

Passive Design Techniques

Day lighting:

Mumbais climate being humid, the need is to create pleasant day

lighting levels in the interiors for visual comfort while avoiding the

harsh direct solar gains by the use of the shading devices.D ay l ig ht in g i s a c on tr ol l ed a dm is si on t o r ed uc e o r e li mi na te

electric l ighting.



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51

Energy Audit

Report|April 2009

8 Other Techniques to be used to make the

structure a green building:

Rainwater Harvesting:

With the r is ing demand, the r is ing pressure on the exis t ing water

resources has g rown h igh . Ra in wate r ha rves t ing i s the age o ld

concept in reducing the run-off and reducing the por table water

demand.

In areas having ra infal l of considerable intensi ty, spread over alarge per iod in a year with short dry spel ls ra inwater harvest ing

f ro m r oo f t op i s a n i de al o pt io n f or a ug me nt in g w at e r s up pl y.

Ra inwate r i s e ssen tia lly bacte rio log ica l pure , f ree f rom organ ic

matter and sof t in nature . Recharge pi ts can be provided for the

surface water of the open grounds which would help to reduce the

run-off and help increase the ground water table.

Solar Lighting for the common areas:With the high demand of power and shortage of electricity, certain

areas o f the s t ruc ture can be conver ted to so la r energy. P laces

l ike common corr idors, passages , to il e ts , ga rden l igh t s can be

powered by solar energy. As CCPL, Boisar had a large amount of

terrace on top which is unutil ized can take solar panels.



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Application of Reflective coating:

S un E xp os ed p ar t o f t he b ui ld in g l ik e r oo f a nd w al ls c an b e

painted with High albedo means ref lect ive paints to ref lect the

m ax im um i nc id en t s ol ar r ad ia ti on s. I t wi ll r ef le ct t he s ol ar

radia tions up 70-80% which he lps to main tain the roof o r wa ll

surface much cooler than unpainted or coated surface. Final ly i t

implies in reduction in cooling load on HVAC system.



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Energy Audit

Report|April 2009

9 Vendor List

10.1 ELECTRONIC BALLASTS

Elmech Electronics

Lake Palace Building,

Marol Village Road, Marol,

Andheri (E), Mumbai

West Coast Instruments & Devices

1/1, Sahar Tower Parsiwada

Andheri Sahar Road, Mumbai

Philips India Ltd.

Business Group Lamps

P-65 Tarotalla Road

Calcutta 700 088

Euro-light Electricals Ltd.

20 Rahi Chambers, Sadashiv Peth,

L. B. S. Marg, Pune - 411 030

Crompton Greaves Ltd.

Lighting Business Group,

405, Concorde R.C. Dutt Road,Baroda 390 007



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VOLTAGE CONTROLLER FOR LIGHTING

Prithvi Technologies PVT. LTD.

104 Devendra Industrial Estate,

Lokmanya Nagar, Pada No.2,

Yashodhan Nagar, Thane 400606

Contact no-9869059501

E-mail [email protected]

Anupushp Energy & Environmental Services Pvt Ltd.

917/ 19-A shivaji NagarFergusson College Road

Pune - 411 004

Energy Systems

No. 3660, 5th Cross, B- Block

Gayatri Nagar,

Banglore 560021

Beblec India Pvt Ltd

P.B. No 3411, 711, 6th Cross

3rd Block, Koramangala

Banglore --- 560 034

Vijay Energy Product Pvt Ltd

Sp -75 Ambattur Industrial Estates

Chennai 600 058

aceinnov@giasmd01. vsnl. net. in

mailto:[email protected]:[email protected]


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Energy Audit

Report|April 2009

1 0. 3 T5 TUBE LI GHTS (2 8 WATTS)

Philips India Ltd.

Mahakali Caves Road,Chakala Andheri (East)

Mumbai400 093

Tele: 1-22 56912160

Fax: 91-22-56112184

Crompton Greaves Ltd.

Kanjur (East)Mumbai 400 042

Tele 022 - 25782451/ 25791990

Fax 022 - 2579488



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10.4 Lighting Sensors Bajaj Electricals Limited.

15/17, Saint Savta Marg, Reay Road,

Mumbai 400 010

Tele Phone : 022 - 2372 4192, Extn. 402 / 462 / 253 /254

Hand Phone : 098216 94842 / 098704 551 18

Fax : 022 - 2374 0504 / 2373 0505

E-mail : [email protected]

Contact Person : Mr. Nat raj lye r, S r. Marke t ing Manager

GE India Industrial (Private) Ltd.

Address : Aifacs Building, # 1, Rafi Marg, New Delhi

Tele Phone : 011-41551000

Fax : 011 -23355955

E- mail : badal [email protected],

Contact Person : Mr. Bada l Bagri , Count ry Di rec to r Sales

Kaktiya Energy Systems Private Limited

Address : 3-6-272, NVK Towers Himayath Nagar,

Hyderabad- 500 029

Tele Phone : 040 - 2326 2540

Fax : 040 - 2326 2550

E-mail : [email protected],Websi te : www.natureswitch.com,

C on ta ct P e rs on : M r. Su re sh , Ma na ge r



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Thermax Ltd.

Address : 15, Sal Chambers, Pune Mumbai Road,Wakdewadi, Pune - 411 004

Tele Phone : 020-25511010

Fax : 020-25511943

E-mail : [email protected],

Websi te : www.thermaxindia.com,

Contact Person : Mr. Akhil Javagal - Asst Manager

Voltas Ltd.

Address : Electro-mechanical & RefrigerationBusiness Group

Voltas House B I . B. Kadam Marg,Chinchpokli , Mumbai - 400 033

Tele Phone : 022 - 6665 6214

E-mail : [email protected],

Websi te : www.voltas.com,

Contact Person : Mr. A. K. Joshi, EVP & COO

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