ENERGY CONSERVATION & MANAGEMENT Utilities Supply ENERGY MANAGEMENT SYSTEM 1 P.F.MANAGMENT DSM TOD Benchmark Analyasis Energy consumption Measurments Energy.

ENERGY CONSERVATION & MANAGEMENT

Utilities Supply

ENERGY MANAGEMENT

SYSTEM

1

P .F.MANAGMENT

DSM

TOD

Benchmark

Analyasis

Energy consumption Measurments

Energy cons.projects

Electric bill

Load Factor

Power Factor

Demand management

T.O.D. terrif

Energy Management system

ENERGY CONSERVATION

Real time measurement of consumption of

Electric power through SCADA system

2

Extruder

Mixing

Compressed air system

Various production group

Others

socketing

Rework

Utilityes

Vaccum system

Chilled Water System

Energy Management System

3

The entire manufacturing activity has been divided into different sub activities depending on nature of operations.

Each power consuming equipment has been provided with multifunctional meter and at present approximately 200 multifunctional meter are deployed.

Thus equipment wise and shift wise power consumption data is available at SCADA station.

The energy balance is also checked at various levels of power distribution system.

With this system it is possible to measure losses at various levels of power distribution system.

The equipment wise power consumption data helps in evaluating the specific energy consumption of each equipment thus enabling the user to under take gap analysis and formulating improvement plans.

Maximum demand controller helps in monitoring and controlling the bill demand.

Energy Management System

4

132 kv MDController

C & P (11kv)HDPE/PPR (11kv)PVC Pipe (11 kv)

UtilityGrinderExtruder

CanteenHMFROTOCPVCPVC

LTPCC

Grinder/ Pulveriser

MixerExtruder

SparesCapacitorsUtilitySocketing Grinder/ Pulveriser

MixerExtruder

Energy Management

System (E.M.S.)

Statistical Analysis

Objective :- Energy conservation

LTPCC LTPCC

Energy Management Report

  PVC CPVC

  Units Production Units / Kg Units Production Units / Kg

For the day

Cumulative

  HDPE PPR

  Units Production Units / Kg Units Production Units / Kg

For the day

Cumulative

Roto Moulding HMF C&P XF

Total Units Total Units Total Units Total Units

For the day

Cumulative5

Daily Power Consumption

Energy Management Report 

Areawise Power Consumption Allocation

S N Sub sections PVC CPVC HDPE PPR ROTO HMF C&P XF

1 Extruders

2 Mixer

3 Utility

4 Socketing

5 G/P

6 Others

  a) Plant Lighting

  b) Yard Lighting

  c) .Offices

 d) Common Facility

e) 11 KV Transformer Losses

  Total

6

Energy Management Report

1 Areawise allocationDaily Variance

Cumulative Variance

2 MSEDCL units

3 MD Controller Units

4 132 KV I/C ( 1 OR 2)

5 11 KV O/G # 1    

6 11 KV O/G # 2    

7 11 KV O/G # 3    

8 MSEDCL MD    

9 MSEDCL (PF for Day)    

7

Energy Management Report

8

PVC ------ Performance of Specific Energy Consumption

Sr No.   U/Kg (Target) U/Kg (For the day) U/Kg (Cumulative)

1 Extrusion

2 Mixer

3 Utility

4 Socketing

5 G/P

6 Other

  Total         

ENERGY CONSUMPTION FOR THREE YEAR

2008-09 2009-10 2010-110.200

0.400

0.600

0.800

1.000

1.200

1.400

PPRC

C/P

HDPE

CPVC

UPVC

9

PROJECTS FOR ENERGY CONSERVATION 2010-11

S.N. Energy Saving ProposalInvestment in

RsRemark

1Use of PIR sensor for material conveying blowers room to switch off lights

5000  

2

Control hot water flow in mixer and cooling water flow in cooler jackets to optimize cycle time and optimize Specific power - hot water from air compressors discharge / solar water system

378000

Trial conducted on Heater mixer, HM-111 insulated on dated 10/5/2010. Saving observed 0.002 units/kg.

3

Change the layout such that air is blown at the bottom & behind all root blowers (auto mixer conveyor blower room) so as to carry the heat out through the other diagonally opposite opening at the top of the room. 1 blower can be removed and VFD for one bl

100000Work in progress to be completed in last week of May-10.

4Use of ADSC (Auto Delta Star Converter) for Mixer-2/10/11/15/211 cooler motor

65000Trial of auto start delta conducted at cooler mixer no-11 on dated 12/5/10

5Optimization of Higher Specific power of mixers -2, 8,11,15 & 17 by maintenance etc

1100000Work in progress, blade set to be ordered.

6 Power analyzer for energy conservation purpose. 80000 For in-house energy audit.

7 Ultrasonic air Leak Detector 300000For in-house checking of all air Leakages in the plant.

8Stop use of blowers or optimize blower air flow used on heaters of Extrusion machines

525000

Implemented on 35 nos machine with controller setting. Saving 0.004 units/kg , remaining extruder requires temperature controller of make "SELECTRON"

9Install close loop VFD on Vacuum pumps of vacuum tank at Extrusion machines PVC plant

2080000Implemented on machine no-11. Saving 1.86 units/hr observed.

10

ENERGY CONSUMPTION FOR FOUR YEAR

2008-2009 2009-2010 2010-2011 2011-20120

0.5

1

1.5

2

2.5

3

3.5

PPRHDPECPVCUPVC

11

10 Use of Automatic Voltage Regulator (AVR) at Lighting feeder-PVC plant

4000001 no. unit for hall # 1 to 5 , 1 no. unit for hall # 7 to 12 of PVC / CPVC plant.

11Insulation of chilled water lines & Calibrator vacuum tank to save surface cooling losses

160000Implemented on M/C no-10 on dated 11/5/2010. To be implemented on balance vacuum tanks.

12 Use of Genie energy saver with timer controller 11000To be tried on one A.C., then implement on balance A.C.'s

13 Use of VFD for Air compressors at PVC rework division. 110000  

14Use of VFD for ventilation blower at PVC grinder plant and open discharge damper fully

75000  

15Use of VFD for Dust collection blower -1 at PVC grinder plant and open discharge damper fully

90000  

16 Use of VFD for Air compressors E-45 / E-22 110000  

17 Use of VFD for Air compressors E-15 110000  

12

18 Use of VFD for Air compressors at ROTO/HMF division. 110000 Implemented in June-10

19Use of photo sensors / timer controller for street light feeders-12 locations

10000To be tried on one location, then implement on balance locations.

20Use of VFD for Aspirator blowers - 1 & 2 at PVC mixer plant and suction damper fully opened.

180000 Trial conducted.

21

Installation of Sandwich Energy Efficient Flat belt transmission system on main motor at Extrusion machines or Direct coupling of main motor to gear box and avoid belt system to save power as extruder is operated with VFD.

43077To be tried on one machine then implement on balance extruders.

22Replace motor and gear box for vertical screw feeder motors with PMSM at extrusion machines (13 nos)-PVC plant.

10154To be tried on one machine then may be implemented on balance extruders.

23Replace motor and gear box for Haul off motors with PMSM at extrusion machines (13 nos)-PVC plant.

11692To be tried on one machine then implemented on balance extruders.

24Modifications to present raw water system at Raw water treatment plant at PVC plant.

75000  

25 Use of Energy Efficient Vac blow air guns for cleaning. 275000  

26Thyristorized control system for electrical heaters at extrusion machines - PVC plant.

70000To be implemented on M/C no-10, after successful results it can be implemented on balance extruders.

27 Use of premafrost for Air conditioners. --- Offer awaited

28Installation of flat belt transmission system on Pulveriser motors to save power consumption.

150000  

29Installation of cogged belt transmission system on Grinder motors to save power consumption

210000  

TOTAL 6843923 13

ENERGY SAVING PROJECTS 2011-12

1MODIFICATION IN CALIBRATOR TO REDUCE AIR CONSUMPTION(5 EXTRUSIO LINE)

1.5Monitoring the energy saving on continuous basis.

2 COOL MIXER JACKET INSULATION 0.40 Reduce Heat load of Chiller.

3 VFD FOR COOLER MIXRE MOTOR- Qty-14 Nos 7.00Energy saving by reducing speed of motor during idle run.

4INSTALLATION OF FLAT BELT SYSTEM ON Extruder no--2 &10

1.33 to 4% Power saving due to improved transmission effeciency.

5RESCHEDULING OF CAPACITOR BANK IN CRTAEs &PALLET(25 KVAR-2000T/25 KVAR-2400 T

0.1 IMPROVE P.F AT LOAD END

6FIXED CAPACITOR BANK-50 KVAR ON CRATE &PALLET TRANSFORMER

0.1 REDUCED TRANSFORMER LOSS

7APFC PANEL WITH HARMONIC FILTERATION-100 KVAR(ROTO)

1.5 ROTO MOULDING-improve P.f at load end;

8APFC PANEL -150 KVAR GRINDING SECTION(Grinder/Pulvariser)

1.0Grinder / Pulvariser dept -improve P.f at load end;

14

11USE OF PMSM MOTOR HAUL OFF EXTRUSION MACHINE-No-02 & 10

0.2 2 MACHINE

12USE OF PMSM MOTOR EXTRUDER FEEDER MOTOR. MACHINE no2 &-10

0.18 2 MACHINE

13 USE SYNTHETIC OIL FOR SCREW COMPRESSOR 0.15

Monitoring the Benefite as well as life of consumables(oil filter & separatos) for six month period & then decide for other compressors.

14CONTROL OF WATER PRESSURE FOR SEC.CHILLER & SEC PROCESS CENTRALLISIED EATER SYSTEM BY USING VFD & PLC

5.5Order to be released in the first week of Nov 2011.

15CONTROL OF HINGNA PUMPING STATION (Man Less Operation)

6.5  

16WATER TREATMENT SYSTEM WATER PUMP -7.5 H.P (EEC SERIES)- 04NOS

1.32 Using of Energy efficient water pumps.

17600KVR HT CAPACITOR FILTER BANK FOR 132KV SUBSTATION

5.251) Improve P.F of sub station.2)Quotation & technical discussion with supplier in progress.

18OPTIMIZE THE TRANSFORMER LOSSES 132 KV BY LOAD SHARING

--- Minimse No load losses.

19USE VFD FOR DUST COLLECTION SYSTEM FOR HALL NO-07 TO 11 & MIXER AUTOMATION HALL NO-02 TO-03 - Qty - 03 nos.

6.0Energy saving due to speed control during low output requirment.

20OFF LINE SOCKETING MACHINE (HEATING LOSS MINIMISATION)- Qty - 09 nos

0.36Energy saving due to reduction in heat losses

21GLAND TYPE PUMP CONVERTED INTO MECH SHAFT SEAL -QTY-25NOS

0.75 3% energy saving.

22INCREASE SUN LIGHT TO REDUCE LIGHTING IN DAY TIME FOR ALL MIXER HALL

---Energy saving by eliminating the use of lights during late evening hours. 15

23REDUCE THE HEIGHT OF STREET LIGHT ON BOUNDARY Qty - 30 nos.

0.15Improve the lux level & reduce the no. of lamps.

24INSULATION FOR DIE ZONE HEATERS TO REDUCE THE HEAT LOSSES. Qty - 64 lines UPVC

3.2Energy saving due to reduction in heat losses

25INSTALLED DEMAND CONTROLLER IN CRATE &H.D.P.E DIVISION

0.8Control of Individual division max,demand

26Alluminium Fins provided to BZ3 zone for control friction heat. Qty - 02 nos.

0.54 Save energy & Improve productivity.

B

AWARENESS OF T.O.D UTILZATION FOR FOLLWING SECTIONS 1)Roto Moulding division- Extruder, Grinder & Pulveriser 2) UPVC & CPVC,HDPE/PPR divisionGrinder & Pulveriser Total Qty - 25 nos.

2.00

Energy & Hour meter providing for indivdual equipment for assessing specific energy consumption during various time slots.

    35.92  

16

Salient features• As policy, we have decided that we will buy efficiency 1 motor

with all new machinery. • we will be replacing the existing motors with efficiency 1

motors at opportune times.• We have introduced conditioning chemicals for water

treatment. The parameters like STD, COC and LSI are being continuously monitored. This has resulted in drastically reducing the frequency of acid descaling of heat exchangers. The better heat transfer at heat exchangers of chillers has resulted in achieving optimum SPC of chillers.

• Waghur river water lifting pumping station is run on MSEB power supply as far as possible despite the fact that power feeder is a rural one having very high load shedding cycles.

this has resulted in minimum use of D.G. power & hence substantial saving in power cost.

• Solar lighting was provided at truck terminus. The performance is being assessed for wider applications.

17

Source :-Values Of Performance Characteristic Of 4 Pole Energy Efficient Induction Motors IEEMA – 19 - 2000

RatingOutput

kW

Full LoadSpeed

Min Rev /Min

Full LoadCurrent Max. Amps.

(415V)

Efficiency(equal or above)

Effi. 2 Effi. 1

0.37 1330 1.4 66.0 73.0

0.75 1360 2.2 73.0 82.5

1.5 1380 3.8 78.5 85.0

3.7 1410 8.1 84.0 88.3

5.5 1420 11.4 85.7 89.2

7.5 1430 15.4 87.0 90.1

11.0 1440 22.0 88.4 91.0

18.5 1440 36.0 90.0 92.2

30.0 1450 56.0 91.4 93.2

45.0 1460 84.0 92.5 93.9

75.0 1470 134.0 93.6 94.7

90.0 1470 164.0 93.9 95.0

110.0 1480 204.0 94.4 95.2

125.0 1480 234.0 94.7 95.5

132.0 1480 247.0 94.7 95.5

160.0 1480 288.0 95.0 95.8

18

19

MSEDCL Power cost Statement-2011 to 2012 Date:- 25/5/2012

MonthUnits

consumedAmount

paid

Billed Max.

demand

Rs/Unit with E.D

Rs/UnitWithout E.D.

Power Factor

Load factor

Power factor

incentive

load factor incentive

prompt payment incentive

JULY 2704500 16282930 6263 6.60 6.02 1.00 48% 1222456 NIL 174637

AUG 4801000 28883420 7850 6.60 6.02 1.00 86% 2162435 NIL 308919

SEPT 3141000 19312780 6263 6.60 6.15 1.00 58% 1450331 NIL 207190

OCT 3436000 21002240 7050 6.70 6.11 1.00 58% 1677082 NIL 225297

NOV 4602000 28637650 7800 6.82 6.22 1.00 73% 2150939 NIL 307277

DEC 4994500 30785730 8350 6.8 6.16 0.99 86% 1757113 2647561 351423

JAN 5203000 32848950 8500 6.95 6.31 0.99 83% 1828044 1945766 365609

FEB 5056200 31872540 8050 6.94 6.30 1.00 80% 2483386 1170752 354769

MAR 4831200 29510780 8366 6.73 6.11 1.00 82% 2332427 1530469 295107

APL 5704800 27795360 8327 5.49 4.87 1.00 87% 2738010 3270357 391144

MAY 5318000 31875250 8154 6.61 5.99 1.00 84% 2557832 2167431 365405

JUN 5409400 31846380 8194 6.51 5.89 1.00 86% 2601472 2777159 371639

TOTAL 55201600 330654010 6.61 5.99 24961527 15509495 3718416

1) POWER FACTOR INCENTIVE RUPEES- 2,23,60,055 /-

2) LOAD FACTOR INCENTIVE RUPEES - 1,81,08,275 /-

3) PROMPT PAYMENT DISCOUNT RUPEES- 33,46,777/-

TOTAL RUPEES- 4,38,15,107 /-

20

The Supreme Ind. Ltd.

Maintenance Dept.(PVC Div.)

Year 2011 - 2012

2006-07 2007-08 2008-09 2009-10 2010-11 2011-120.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

4.384.59

4.80

5.53

5.99

6.61

1.671.94 1.97 2.16 2.25

2.39

0.381 0.430 0.391 0.389 0.376 0.362

Trend of energy consumption

Rs. / Unit Rs./kg. U/kg.

21

Sr. Item Specification Qty Benefits

1 Electrical Sub station for PEB hall 10 & 11-1000KVA capacity. 1 No.

To take care for additional load & minimise the breakdown due to

overloading of existing transformer.

2 Errection & commissining of 1000 KVA transformer.

Job Standby transformer against 9 nos

3 Power cable extension for PDB 8/9/10 1 No.Due to additional of load in

Extrusion /mixer area ,to avoid overloading of existing cables.

4DG power back up for X-

film,Crates,Commercial office,HR,main gate & knowledge center etc.

JobProvision for continues Emergency

power supply

5 Street light (Golf area side) monkey ladder provision for maint purpose

Job To improve the safe working condition by 100%

7 Eurotherm make temp.controller for extrusion machines-for 60 machines. 150 Nos

Improvement in 1% of Heating load process with properties & Power

saving purpose.

8 Seperation of Electrical Panel for Herbold Grinder/Pulverisor .

3 Nos To improve the safe working condition by 100%

9 Automatic power factor control panel for controlling power factor of electrical system.

15 Nos

For monitaring unity power factor & benefit of power factor incentive in MSDCL Billing.also Automatic power

factor control.10 Emergency light for PVC,CPVC,Utility area. 1 No. Improved in safe working conditions.

11 Remote monitering & controlling of waghur water lifting pump station at Hingane job

To eliminate operating & human error also reduction in manhours.

12Replacement of Zeplin make PLC ( non

repairable )of vaccum loader by Selectron make

10 Nos. Import substitution & reduction in breakdown.

13 Variable frequncy drive for cooler mixer 8 Nos.Reduction in B/D & energy saving ,also

eliminate kick to reduction in max. demand in peak period

14 To procure of LED lights for plant lighting Job Energy saving by 35 % in plant lighting due to LED illumination.

15 To procure of Green Magic Energy Saver for plant lighting.

JobEnergy saving by 15 % in plant

lighting due to voltage controlling method.

22

S.N. NAME OF ACTIVITYAnnual

SAVING IN (Lacs)

STATUS REMARKS

1Control the maximum demand & maintain power factor at unity on day to day basis.

458.47 …Benefit in MSEDCL monthly bill for 1) Load incentive 2) P.F. incentive.

2Daily Energy Monitaring (KWH) in Utility Area,& Run Optimum Utility to achive the target of - 0.070 U/kg

37.68 …

Energy consumption for utility in year 2010-11 was 0.75 U/kg.Annual saving accrued is 0.005 U/kg as compared to last year. In Rs-(0.005*114000*1000*6.61= 3767700/-)

3

Develope auto control system for centralized chilled & process water system through controling water pressure by using VFD & PLC

2.24Completed on

Dec-2011

Achived 2.5% energy saving against actual consumption 8500 units / day for water pumps i.e.212 units / day.Benefits accrued in annual saving (160*212*Rs-6.61)= Rs-224211/-

4

Low air pressure ckt for Cutter & Barrel Vaccum by using PRV for the same application against actual working air pressure.(i.e.4.8 kg/sq.cm to 3.0 kg/sq.cm ) for cleaning purpose.

1.6Completed on

Oct 2011.

Achived energy saving due to reduction in air pressure.Assumption 180CFM air is utilized for cleaning.reduction in pressure from 4.8 to 3.0 kg/sq.cm i.e 15% CFM is saved ( 27 CFM *0.156 kw=4.2 units/hr saved ). Annual saving 4.2*24*240*6.61=Rs-159909/-

5 Use synthetic oil for screw compressor. 0.67Completed on

Oct 2011.

Achived the energy saving 2% (28kwh/day) of compressor daily running units 1419 Kwh/day;Also got benefit in improved life of consumables.

6Gland type Pump Converted into Mech Shaft Seal -QTY-25 Nos.

1.2Completed on

Dec-2011

2-% energy saving is achived i.e. ( 5.5 kw*80%*25*24*350*6.61=120000/-) & effeciency of pumps improved.

23

S.N. NAME OF ACTIVITYAnnual SAVING

IN (Lacs)STATUS REMARKS

7Rescheduling capacitor bank in Crate & pallet (25 KVAR- for m/c-2000T, 25 KVAR- for m/c-2400T)

…Completed on Dec-

2011Improved power factor at load end

8Fixed Capacitor bank 50 KVAR at LT side of Transformer of Crates & Pallet division.

…Completed on

Dec-2011Reduced transformer losses during idle condition.

9 VFD for cooler mixer motor Qty-14 Nos 4.27Completed on

Dec-2011

Energy saving from 0.055 to 0.052 U/kg by reducing speed of motor during idle run. (64539MT*0.001*1000*=64539 units*6.61 = Rs 426602/-)

10Use Vfd for dust collrection system for Hall no 7 -11 & Mixer Automation Hall no 2 to 33 - Qty - 03 nos.

0.59Completed on

Dec-2011Energy saving by reducing speed of motor during idle run.(50*180*6.61=Rs-59490/- )

11Installation of Flat belt system to Extruder no - 2 & 10

0.61Completed on

Jan-2012

Observed 3% Power saving due to improved transmission effieciency. (1050 units*3%=31*2*150*6.61=Rs-61473)

12Increase sunlight to reduce the lighting in day time for Mixer hall 7 to 11

0.44Completed on

Feb-2012

Increased day light by installing transperent sheet for hall no.10.Also lighting fixture height minimised, due to this removed 10 nos fixtures (470 watt fixtures * 10 nos *12 hrs working = 55*120*6.61= Rs-43626/-)

13Installed Demand Controller in Crate & HDPE Division..

…Completed on

Feb-2012For Control of Maximum Demand at Individual division. ( Pl. see Sr.no.1 )

  Total Saving Rs in Lacs- 507.27    

24

  Mechanical    

1 To procure of High Jet Pressure Pump. 1 No. Efficient & proper physical descaling of chiller.

2 To procure of Stackers for overhead crane maintenance. 1No.

For improved safety work for maintenance of overhead plant

lighting,street lighting & crane work.

3 To procure & replaced gear coupling for Cooler Gear Box

10 Nos Reduction in breakdown of cooler gear box.

4 Auto chemical dosing with controller for condenser cooling tower water circuit. 1No.

For maintain accurate chemical dosing & benefit in improve the efficiency of

chillersalso reduction in water consumption by 3 % with make up

quantity.

5Indo vacc make oil lubrication vaccum

pump with receiver and piping systemfor hall no 7,8,9

5 Nos. Energy efficient pump & less power consumption.

6 Conversoin of mechanical linkage in to Gear motor for 4 Jaw & 2 Jaw for Haul -of

4 Nos. for reduction in breakdown & achive energy saving upto 2 %

7 Monorail Crane for individual mixer of Hall 10 4 Nos. To attend the breakdown immediately.

8 Dust collection system for manual mixers 3 Nos. Maintain the Houskeeping & Improved human health.

9 Air booster for CPVC 06, Dust cllection , Hall no 1 Haul off 3 Nos.

To minimise the slippages pipes in haul off due to low centralised air pressure.

10 Project on disposal of Cacl2 concentrate effluent (HMF)

1No. To meet the pollution control board noms for trade effueint.

11 Refrigerant Air dryer-125 CFM for HDPE/PPR plant

1No. To minimise the air losses & enegy saving.

12 Inhouse manufacturing of Hypochloride solution.

Job To saving the Rs/-500 per day.

13 Recycle the drain/backwash water of Lamella clarifier /MGF /ACF

JobReuse the water by

recirculation ,through lamella clearifier & reduction in consumption.

14 To develop testing facility for manhole chambers in roto moulding division.

Job To avoid outsider agengy for testing purpose, thus save in time & money .

ENERGY CONSUMPTION FOR FOUR YEAR

252008-2009 2009-2010 2010-2011 2011-2012

0

0.2

0.4

0.6

0.8

1

1.2

1.4

UPVCCPVCHDPEPPR

Thank you 26