dea report - krpp

8/10/2019 Dea Report - Krpp

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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

K R Pulp Papers !i"itedShahjahanpur

#une $%&'

Confederation of Indian IndustryCII(Sohrabji Godrej Green Business Centre


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C)*+E*+S

Chapter

*o,

DesriptionPage

*o,

Executive Summary 1

I Introduction 3

II Acknowledgment 4

III List of Energy Saving Proposals

I! Energy Saving Proposals "

! #anagement Aspects And $onclusions %

Annexure 3

&ackup $alculations '

Total No of Pages: 117



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E.EC/+I0E S/11AR2

K R Pulp Papers !i"ited is among India(s leading manufacturers of eco)friendly paper enric*ed wit* t*e expertise and experience of around twodecades in making paper from non conventional raw material i+e+ &agasse, aresidue of sugar cane+

Incorporated in 1--, t*e company *as two fully integrated pulp and papermanufacturing facilities situated in S*a*.a*anpur district in t*e state of /ttarPrades* in India+ 0*e /nit)1 is used to manufacture raft paper w*ile /nit)2 isused to manufacture *ite paper+

$II *as conducted t*e etailed Energy Audit at K R Pulp Papers !i"ited,S*a*.a*anpur Plant from 1%t*to 1't*April, 2%14+ A detailed presentation wasmade to t*e plant team covering various energy conservation opportunities on

1't*

April, 2%14+ 0*e com5ined efforts of K R Pulp Papers !i"ited and $II)6odre. 6&$ team *ave toget*er identified, annual energy saving potential ofRs, '3',&% !a4hs, 5ased on present energy cost+7

Details*o, of

Proposals

Annualsa5ings in

!a4hs

0otal Annual savings 89s+ Lak*s: $3 '3',&%

Annual savings wit*out investment89s+ Lak*s:

' &%6,3%

Annual savings wit* investment 89s+ Lak*s: &7 3$8,9%

Investment 9e;uired &7 &93,7%

Average pay5ack period for capital proposals 1onths 6



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SPECI:IC AC+I)* P!A*

a: Specific target date for implementation of proposals s*ould 5e made wit*in3% days from su5mission of t*is report+

5: 0*e plant s*ould prioritise t*e a5ove proposals and implement t*em in ap*ased manner+

c: In our opinion t*e following proposals can 5e implemented wit*in nextt*ree mont*s straig*taway and s*ould 5e on top priority+

8ESP :

0*e a5ove proposals do not re;uire any investment and no detailedverification+

As a second priority and after detailed verification t*e following proposalss*ould 5e implemented+

8ESP


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C;AP+ER - I

I*+R)D/C+I)*

K R Pulp Papers !i"ited< Shahjahanpurevinced interest in availing t*eservices of $onfederation of Indian Industry for conducting a detailed energyaudit in t*eir factory+

0*is report on t*e detailed energy audit carried out at K R Pulp Papers!i"ited< Shahjahanpur< is in accordance wit* $II(s proposal, agreed 5y K RPulp Papers !i"ited< Shahjahanpur vide t*eir work order


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C;AP+ER - II

ACK*)=!EDG1E*+

$II acknowledges wit* t*anks t*e co)operation and t*e *ospitality extended to

t*e $II energy audit team during t*e detailed energy audit at K R Pulp

Papers !i"ited< Shahjahanpur,

0*e interactions and deli5erations wit* K R Pulp Papers !i"ited teamwere exemplary and t*e w*ole exercise was t*oroug*ly a rewardingexperience for $II+

0*e arrangements and support during t*e energy audit were excellent+ edeeply appreciate t*e interest, ent*usiasm and commitment of K R Pulp Papers !i"ited< Shahjahanpur team towards t*e energy conservation+

e would also like to place on record our sincere t*anks and appreciation for

all t*e senior plant executives+



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C;AP+ER - III

!IS+ ): E*ERG2 SA0I*G PR)P)SA!S

Sl,*o

Energy Sa5ing PropsalsAnnnual Sa5ings

>Rs,!a4hs?

In5est"entRe@uired

>Rs,!a4hs?

Payba4Period

>1onths?

1 9educe t*e @re;uency of 0ur5o 6enerator 1 to 4- B 1%%+%% % %

2 9educe Cne 0ap Setting of 0ransformer 2+1% % %

3 CptimiBe t*e Lig*ting !oltage in t*e Plant +%% 2+%%

4Install !aria5le @re;uency rives in Identified Pumps InPulp #ill

>+"% 4'+4% 1%

Install !aria5le @re;uency rives in $entricleaner

Pumps in Pulp #ill "+"% "+% 11

>Install !aria5le @re;uency rives in Identified Pumps inPaper #ac*ine

"+4% 1%+%% 1



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'Install !aria5le @re;uency rives in $entricleanerPumps in Paper #ac*ine

43+%% 1-+% >

"Avoid t*e Pressure rop Across @eed $ontrol !alve &yCperating &fp it* !fd in /nit 1

4+%% 4+% 14

-Avoid Passing 0*roug* #inimum 9ecirculation Line &yInstalling #ultistage rag !alves @or &oiler @eed Pumpin /nit 1

-+%% +%% '

1%Avoid t*e Pressure rop Across @eed $ontrol !alve &yCperating &fp in Auto it* !fd in /nit 2

2'+%% 1+%% 1

11Avoid Passing 0*roug* #inimum 9ecirculation Line &yInstalling #ultistage rag !alves @or &oiler @eed Pumpin /nit 2

4+"% "+% 2%

12Avoid 9ecirculation of $ondensate &y Installing !fd And9educing Speed of $ondensate Extraction Pump

2+4% 1+%%

13 9educe Air Ingress in /nit)1 &oiler @lue 6as Pat* 2+% % %

14Cperate All t*e $ooling 0ower @ans And 9educe t*eSpeed &y Installing !fd @or All @ans in /nit)2 PowerPlant

4+%% 3+%% -

19educe Excess @low 0*roug* eat Exc*angers in /nit)2Power Plant

32+%% "+%% 3



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1>Switc* off Cne $ondensate Extraction Pump $ompletelyin /nit)2 Power Plant

3+2% % %

1'Avoid Pressure rop Across ot ell Level $ontrol!alve And #aintain ot ell Level irectly &y Installing!fd

2+%% 1+% -

1"Avoid Cperating Cne Pump &y Pumping m aterirectly to eaerator After Passing 0*roug* t*e @las*Steam eat Exc*anger in Paper #ill Section

3+2% 1+%% 4

1-CptimiBe t*e Cperation of Instrument Air $ompressorsin /nit )2

1>+4% 1%+%% '

2%CptimiBe t*e Cperation of Instrument Air $ompressorsin /nit )1

>+%% +%% 1

21 CptimiBe !acuum Pump Cperation in /nit)2 +2% 2+%% >

229eplace ! &elt it* $ogged @lat &elt in IdentifiedE;uipments

34+4% 2%+%% '

23CptimiBe t*e $ondensate 9ecovery $ircuit in Paper AndEvaporator Section

4+4% 4+%% 11

+otal '3',&% &93,7% '



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Chapter IV

Energy Saving Proposals

Confederation of Indian IndustryCII ( Sohrabji Godrej Green Business Centre


12/157

E*ERG2 SA0I*G PR)P)SA! *), &

RED/CE +;E :RE/E*C2 ): +/RB) GE*ERA+)R &+) '7 ;

uring t*e detailed energy audit at K R Pulp and Papers !i"ited,energy conservation 5y reducing fre;uency of t*e tur5o generator wasexplored in detail as t*e alternator was isolated from t*e grid+

uring t*e detailed energy audit at K R Pulp and Papers !i"ited,energy conservation 5y reducing fre;uency was explored in detail+ Inorder to look at t*is possi5ility a detailed study was carried out for t*eloading of t*e motors along wit* t*e plant team+

Present Status

0*e rating of t*e 0ur5o generator is given 5elow for reference+

9ating of t*e alternator 1%%% k!A


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0*e current operatingCperated at a fre;uency of t*e 061 is % B+ Adetailed load study was carried out in t*e plant to explore t*e possi5ilityof reducing fre;uency of alternator+ 0*roug* motor study, it was foundt*at t*e motors in t*e plant are operating mostly in t*e range of >% D "%+

#a.ority of t*e process e;uipment will not 5e affected in production asmost of t*e process e;uipment *asveve a !@sinstalled and reducingt*eir speed will not *amper production+ +

#a.ority of t*e process e;uipment also *ad margin in e;uipmentre;uirement and operating conditions+ @or example t*e pumps in t*eplant were t*rottled wit* valves significantly to meet t*e operatingre;uirements+0*e pumps also delivers energy to cater t*e pressure lossacross t*e valve+9educing t*e fre;uency of t*e alternator will avoid t*ispressure loss across t*e valve and reduce t*e energy consumed 5ypumps+

Proposed syste"

ue to t*is availa5le margin 5etween operation and re;uirement, t*ere isa good potential to optimiBe t*e fre;uency of t*e plant+A detailed studywas carried out along wit* t*e plant team to understand t*e loading oft*e motors to explore opportunity of fre;uency rediuction+ As mentionedearlier in t*e proposal t*e loading of t*e motors in t*e plant are found to5e in t*e range of >% D "%+ &ased on t*e loading of t*e motors t*efre;uency can 5e reduced to 4- B safely wit*out overloading t*e motors.

Proposed syste"

e recommend to reduce t*e fre;uency and operate it at 4- B+ 0*ereduction in fre;uency will ma.orly reduce t*e power consumed 5ycentrifugal e;uipment+ 0*e power consumed 5y centrifugal e;uipment areis proportional to cu5e of speed and t*e power consumed 5y positivedisplacement e;uipment arepower consumed 5y positive displacemente;uipment isproportional to t*e speed+ it*Also, 5y reducing t*e t*e

reduction in fre;uency t*e power consumed 5y individual motors alsoreduce, due to t*e reduction in no load losses of t*e motor+ In order too5tain t*e savings on a conservative 5asis only 4% of centrifugale;uipment are considered for calculation of energy savings+

Since t*e alternator 061 is operating isolated from t*e grid and also dueto t*e margin availa5le in t*e e;uipment, t*ere is a good potential tooptimiBe t*e fre;uency of t*e plant to 4- B+

A small variation in speed will lead to apprecia5le reduction in t*e powerconsumption of t*e plant+ 0*e fre;uency reduction is only possi5le for t*e

situation w*en plant is running wit*out sync*roniBation wit* grid+

Steps involved in fre;uency reduction



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1

2

30*e fre;uency of t*e alternator can 5e reduced 5y reducing t*e tur5inespeed+ In 9 Pulp and Paper a trial was taken along wit* t*e plant teamand t*e fre;uency was reduced to 4-+ B+ $II congratulates t*e plantteam on t*e excellent effort+

=ith the redution in fre@ueny the poer onsu"ed by indi5idual"otors also redue< due to the redution in no load losses of the"otor , +he turbine rp" an be redued to &%' rp" to "aintainthe alternator fre@ueny as '7 ;,

Abstrat of +rial +a4en at site +rial to redu e alternator fre@uenyto '7, ;

A trial was taken wit* discussions from t*e plant team and t*e fre;uencywas reduced to 4-+ B from % B+ $II t*anks t*e plant team for *elpingextending all t*e support in taking t*e trial+ us take t*e trial+

0*e speed of t*e prime mover corresponding to % B of operation is1%'>% rpm, w*ic* in turn corresponds to 1%% rpm of t*e alternator+ 0*isrpm was reduced from 1%'>% rpm to 1%>3 rpm+ 0*e speed of t*e primemover and correspondingly t*e fre;uency of t*e alternator was reducedfrom % B from 4-+ B+

*en t*e fre;uency of t*e alternator was reduced from 1%'>% % to

1%>3 4-+ rpmB, t*e power produced 5y t*e alternator s*owed animmediate reduction of 1"% k+ 0*is reduction of 1"% k ofreductiono5servedis instantaneous,as t*e fre;uencies of !@s read.ustitself to t*e re;uired fre;uency of operation wit*in few cycles+ Also, duringt*is reduction in power produced 5y t*e alternator, a reduction of 1+0P of steam consumption was also o5served+

0*e immediate c*ange of values o5served during t*e trial arec*ange ofvalues?results o5served during t*e trial ismentioned in t*e ta5le 5elow7

Parameter Before +rial %;

After trial '7,;

@re;uency of t*eAlternator

% B 4-+ B

Cperating 9P# of t*etur5ine

1%'>% rpm 1%>3 rpm

6eneration # 1%+-' # 1%+'- #

$apacity 0P '-+42 ''+"'



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0*e value mentioned a5ove is an instantaneous value and cannot 5econsidered for energy savings directly+ In order to monitor t*e reductionin energy produced 5y t*e alternator t*e monitoring of powerconsumption *as to 5e monitored for a longer duration to realiBe t*eenergy savings ac*ieved+

0*e !@s will ad.ust t*e voltage and fre;uency to operate at t*e desiredvalues 5ased on t*e feed5ack given to t*e !@+ ue to t*is t*e effect offre;uency reduction will *ave no effect on t*e e;uipment w*ic* *ave!@s+ In t*e future t*e plant team may plan on installing !@s fore;uipment in t*e plant for energy savings+ Cverall t*e effect of fre;uencyreduction may 5e reduced 5y installing !@s and t*e margin of energysavings may reduce 5y installing more !@s+ Event*oug* t*e margin ofenergy savings reduces it is still recommended to reduce t*e fre;uency oft*e alternator and operate at 4- B+

Reo""endation

e recommend

to 0o reduce t*e fre;uency of 061 to 4- B from 4-+ B in steps of

%+2 B+ +

Cn a $conservatively 5asis4% of load is assumed as centrifugal+

Atleast 2% k can 5e saved 5y implementing t*is proposal+

Benefits

Annual energy savings of Rs &%%,%% !a4hscan 5e ac*ieved 5y reducingt*e energy savings+ 0*e investment re;uired for t*e pro.ect is


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E*ERG2 SA0I*G PR)P)SA! *), $

RED/CE )*E +AP SE++I*G ): +RA*S:)R1ER

uring t*e etailed Energy Audit conducted at KR Pulp and Papers!i"ited< Shahjahanpurt*e opportunity to optimiBe t*e voltage of plantwas studied+

Present Status

0*e induction motors in t*e plant are rated for 41!+ 0*e tap settingswere maintained to o5tain a voltage 42'! for 0ransformer + 0*e loadingof motors in t*e plant were ranging from '%)"+

0*e grap* s*own in @ig 5elow is drawn for an induction motor on a pu5asis+ It s*ows t*e effect of stator terminal voltage to total motor lossesfor various per unit loading for an induction motor+ 0*e no load curve ont*e grap* s*ows t*at t*e no load loss reduces as t*e stator terminalvoltage reduces+ 0*e pu? 5s total "otor losses

0*e grap* s*own a5ove is drawn for loading at F, G, H and full load+ @oreac* loading of t*e motor t*ere is an optimum voltage point w*ere t*e

total motor loss is at minimum for t*at condition of loading+ 9educing t*evoltage 5elow t*e optimum point, t*e motor capacity gets derated andt*e current flowing t*roug* t*e motor increases i+e+ voltage 5elow t*eoptimum point derates t*e motor+



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0*e motor *as to draw a fixed amount of power to satisfy t*e s*aft powerfor specific loading conditions+ Since, t*e terminal voltage of t*e motorreduces t*e current is increased to meet t*e s*aft power+ 0*is causes anincrease in current and *ence increases copper losses in t*e stator andt*e rotor and during t*is condition of low voltage t*e no load loss is lower

as compared to t*e *ig*er voltage applied to t*e motor+

0*e voltage drop at t*e motor terminals s*ould 5e seen 5ased on t*elengt* of t*e ca5le, siBe of t*e ca5le installed, 5ased on t*e power factorof t*e motor and also due to any loose connections in lugs or t*e wiring oft*e motor+ According to IE$ >%%3" a 41! motor can 5e safely operatedwit* a range 23%?4%%! 1% and )> at t*e #$$ and also 4 voltagedrop is allowed at t*e supply terminals+ 0*e motors are generallydesigned to *andle a voltage variation of J 1% from t*e rated value+

#otors consuming low power factor may *ave *ig*er voltage drop andcan 5e compensated 5y installing capacitor 5anks at t*e motor terminalsor motor &s+ $are s*ould 5e taken w*ile installing capacitor 5anks at t*emotor terminals, t*at t*e installed k!A9 of t*e capacitance s*ould notexceed t*e no load k!A9 of t*e motor+

Since t*e voltage maintained at t*e motor terminals may lie 5elow t*eoptimum voltage point as explained a5ove, t*e current consumed 5y t*emotors may increase, w*ic* may increase t*e copper losses in t*e motor+&ut t*e reduction of voltage reduces t*e magnetiBation losses of t*emotor and can 5e significantly reduce t*e energy consumed in t*e plant+0*e loading of t*e motors in t*e plant *as 5een o5served to 5e '% D ",t*e current consumed 5y t*e motors will not exceed t*e full load currentof t*e motor, due to t*e reduction in voltage and t*e motor can 5e safelyoperated+

Proposed syste"

In general for an A$ induction motor operating at a *ig*er voltage t*anrated, t*e no load losses can 5e reduced 5y reducing t*e voltage to t*erated value+ As a t*um5 rule t*ere is 1 reduction in power consumption

for every 4 reduction in voltage+ &ased on t*is t*e t*um5 rule of 1reduction in power consumption for every 4 reduction in voltage, powersavings of > k can 5e ac*ieved in t*e plant 5y reducing one tap settingof t*e distri5ution transformers811k!?433!:+

+aps setting of the +ransfor"ers and orresponding ;+ and !+0oltages

+ap Position ;+ 0oltage >0? !+ 0oltage >0?

1 11>%

$>Reo""ended? &&$6

3>Current? &&%%%



18/157

433

4 1%'2

1%4%

> 1%1'

' --%%

Proposed syste"

In general for an A$ induction motor operating at a *ig*er voltage t*anrated, t*e no load losses can 5e reduced 5y reducing t*e voltage to t*erated value+ As a t*um5 rule t*ere is 1 reduction in power consumptionfor every 4 reduction in voltage+ &ased on t*is t*e t*um5 rule of 1reduction in power consumption for every 4 reduction in voltage, power

savings of > k can 5e ac*ieved in t*e plant 5y reducing one tap settingof t*e distri5ution transformers811k!?433!:+

0*e tap settings of 0ransformer are mentioned in t*e ta5le a5ove+ 0*ecurrent tap setting of t*e transformer is at 3 rd tap+ 0*e current tap settingmaintains a voltage of 42' !+ 0*is voltage can 5e reduced closer to 41 !,at w*ic* t*e motors in t*e plant are designed+ 0*is gives us a goodopportunity to reduce t*e plant voltage to 41 !+

0*e tap settings of 0ransformer are mentioned in t*e ta5le 5elow+ 0*ecurrent tap setting of t*e transformer is at 3 rdtap+ 0*e current tap settingmaintains a voltage of 42' !+ 0*is voltage can 5e reduced closer to 41 !,at w*ic* t*e motors in t*e plant are designed+ 0*is gives us a goodopportunity to reduce t*e plant voltage to 41 !+

Reo""endation

$urrently all t*e distri5ution transformers are rated for 11k!?433!+ 0*etap position is in t*e normal tap of 43+ It is recommended to reduce t*etap settings of 0ransformer 4t* to 3rd tap in order to7

#aintain 41 D 42% ! as t*e distri5ution transformer output voltage

9educes magnetiBation losses in t*e motors

Atleast > k can 5e saved 5y reducing one tap setting in t*e

transformers

Benefits

CptimiBing t*e voltage in distri5ution transformers will result in an annualenergy saving of Rs, $,&% !a4hs+ 0*ere is no investment re;uired fort*is proposal+



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E*ERG2 SA0I*G PR)P)SA! *), 3

I1PR)0E +;E P)=ER :AC+)R ): P)=ER

P/RC;ASED :R)1 E!EC+RICI+2 B)ARD

uring t*e etailed Energy Audit conducted at KR Pulp and Papers!i"ited< Shahjahanpurt*e opportunity to improve t*e E& power factorwas explored in detail+

Ba4ground

0*e grid power in 9 Pulp and Papers is used mainly for operating t*eplant during t*e failure of any power generation sources in t*e plant8Emergency conditions:+ 0*e power is used to c*arge t*e transformers forno load condition only+ 0*e 5illing system used is in terms of k!A* and t*eload utiliBed was very low maintaining a power factor of %+-' at t*e grid+0*e k!A* consumed in t*e grid was around 2, 4", %%% k!A*, t*e k*consumption is 2, 3>, %%% k*, leading t*e power factor of operation to5e %+-+

0*ere is a good potential to optimiBe t*e power factor of operation to 5e%+--+0*e power factor of E& can 5e improved 5y installing capacitor5anks+&ased on t*e E& consumption t*e re;uired amount of capacitor5anks re;uired to maintain %+-- pf is also calculated.

Reo""endation

It is recommended to improve t*e E& power factor to reduce t*e k!A*c*arges+ Approximately ->%% k!A* can 5e saved per mont*+erecommend

0o install capacitor 5anks and improve t*e E& power factor to %+--

Around ->%% k!A* can 5e saved

Benefits

Annual energy savings of Rs ,%% !a4hs can 5e ac*ieved+ 0*einvestment re;uired for t*e capacitor 5anks are Rs $,%% !a4hs, w*ic* ispaid 5ack in "onths+



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E*ERG2 SA0I*G PR)P)SA! *), '

I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I*IDE*+I:IED P/1PS I* P/!P 1I!!

uring t*e etailed Energy Audit conducted at K R Pulp Papers !td,% 11 44%

$ontinuous igester

ilution Pump

P/ '4 4" 3 14 '2+"



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et ilution Pump )&S1

P/ 11- >% 12 1" 4%%

&ack S*ower Pump )&S1

P/ 1%% 1' % 12%

et ilution Pump )&S 2

P/ -> >> 2 1-+ %%

&ack S*ower Pump )&S 2

P/ 1%1 1' % 13%

as*ed 0owerPump

P/ 11> '1 "% ' )

ilution Pump P/ 12> 4 % 1>

Secondary ScreenPump

P/ 132 21 3% >

Screened 0owerPump

P/ 14> 24 % '

L$ $*est Pump P/ 1% 24 1 '

Screened 0ower

ilution Pump

P/ 1> 4 2, 14 1>

ECP !A0 ilutionPump

P/ 1>- 1 2" 4+

ECP as*er ilutionPump

P/ 1'1 4 >% 1%+

0*us t*ere is excellent potential to save energy 5y installing !@(s for t*e

pumps and varying flow as per re;uirement+

Reo""endation

e recommend t*e following7

Install !aria5le @re;uency rives for t*e identified pumps

Cperate t*ese pumps wit* suggested !@ feed5ack

!ary speed of pump to maintain re;uired flowCptimiBe t*e power

consumption

Benefits



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0*e annual savings of Rs, 9,8% !a4hscan 5e ac*ieved 5y implementingt*is pro.ect+ 0*e investment re;uired is Rs, '6,'% !a4hs w*ic* is paid5ack in &% "onths+



23/157

E*ERG2 SA0I*G PR)P)SA! *),

I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I*CE*+RIC!EA*ER P/1PS I* P/!P 1I!!

uring t*e etailed Energy Audit conducted at K R Pulp Papers !td, 2 21

#ac*ine $*est PumpP#1"

4 % 13+ )



26/157

0*us t*ere is excellent potential to save energy 5y installing !@(s for t*epumps and varying flow as per re;uirement+

Reo""endation

e recommend t*e following7

Install !aria5le @re;uency rives for t*e identified pumps

!ary speed of pump to maintain re;uired flow as per t*e process

re;uirement

CptimiBe t*e power consumption of t*e pumping system

Benefits

0*e annual savings of Rs, 9,'% !a4hscan 5e ac*ieved 5y implementingt*is pro.ect+ 0*e investment re;uired is Rs, &%,%% !a4hs w*ic* is paid5ack in & "onths+



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I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I*CE*+RIC!EA*ER P/1PS I* PAPER 1AC;I*E

uring t*e etailed Energy Audit conducted at K R Pulp Papers !td,+ >+-% + 1+> 2"

Actual orking pressure re;uired for different applications

@or control valve operations, t*e instrument air re;uirement is in

5etween 1+ D 3+ 5ar

@or press roll mac*ine D t*e pressure re;uirement is > 5ar

0*ere exists a good saving potential to optimiBe t*e pressure settings oft*e instrument air compressors+



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E*ERG2 SA0I*G PR)P)SA! *), $%

)P+I1IE +;E )PERA+I)* ): I*S+R/1E*+ AIRC)1PRESS)RS I* /*I+ -&

uring t*e detailed energy audit at 9 Pulp and Paper t*e compressorswere studied in detail and t*e following o5servations *ave 5een made+

Installed apaity

2 x 3"% $@# screw compressor

o 2 nos wit* k rated motor

In operation ( Paper plant

1 nos of k compressor

0*e pressure setting of all t*e identified compressors is as follows7

$apacity

Actual

re;uirement

Pressure

Suggested

Pr

reduction

9eduction

k Savings

8Pr reduction =

/nloading:$@#

/nloading Loading /nloading

$ompressor)

13"%

24 2"-+2 >+3 " + 2%+2 1+%


@or control valve operations, t*e instrument air re;uirement is in

5etween 1+ D 3+ 5ar


0*ere exists a good saving potential to optimiBe t*e pressure settings oft*e instrument air compressors+

Reo""endation

Install !@ and reduce t*e operating pressure setpoint to + 5ar+

0*is would *ave two 5enefits

o It would reduce t*e operating pressure t*ere5y reducing t*e

operating power

o

It would completely avoid t*e loss due to unloading

Press roll user re;uires > 5ar pressure, *ence to cater its need, a

small 5ooster compressor needs to 5e installed near t*e user



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Benefits

0*e annual energy saving potential is 9s+ +%% Lak*s+ 0*is will re;uire aninvestment of 9s+ >+%% Lak*s, w*ic* will *ave a simple pay5ack period of1 mont*s+



55/157

E*ERG2 SA0I*G PR)P)SA! *), $&

)P+I1IE 0AC//1 P/1P )PERA+I)* I* /*I+-$

0*e vacuum system in /nit)2 was studied in detail and t*e followingo5servations were made+

Current Syste"

0*ere are 11 num5ers of vacuum pumps installed in paper mac*ine tocater its needs+ All are connected to a common *eader 5ut are isolatedfrom eac* ot*er wit* t*e *elp of valves+ 0*e vacuum pump connected towire mes* user is t*rottled at t*e user ends 5ut all ot*er vacuum arecompletely open+

)bser5ations

0*e vacuum re;uirement of various sections of paper mac*ines are ass*own 5elow7

!acuumPump %

' Pickup 9oll %% 34% 1>%

" Suction Press 8low Bone: 3-%

-Pickup felt, 3 press felt, /*le5ox 3"% 32%

>%

1%1=4 press felt, u*le 5ox

44% 31% 13%

11 44% 31% 13%



56/157

As seen in t*e ta5le a5ove, t*e pressure drop 5etween t*e user and t*epump in eac* area is *ugevery *ig*+ 0*e possi5le reason for t*e samecould 5e

Improper line siBing

#oisture carryover to t*e vacuum pump due to non)availa5ility of

separators

Improper water evacuation from separators leading to moisture

carryover

Reo""endation

As it is o5served t*at t*ere is a *uge *ig* pressure drop 5etween t*e userand t*e pump, it is evided t*at t*e line siBing in eac* user is not proper+ Itis *ig*ly recommended to call a t*ird party to conduct a detailedengineering study only for t*e pipe siBing so t*at it could 5e 5roug*tdown to accepta5le limits+ *ile conducting t*e study t*e following pointsneeds to 5e kept in mind

0*e pressure drop across t*e separator s*ould 5e a maximum of

%mmg

0*e pressure drop across t*e complete pipeline s*ould not 5e more

t*an 2% mmg

A detailed study on t*e pipe siBing alone s*ould 5e done and t*e

pressure drop s*ould 5e 5roug*t down to accepta5le limits

Also !@ needs to 5e installed for all vacuum pumps and vacuum needsto 5e maintained 5ased on t*e user re;uirement from $S+

Sa5ings

0*e saving potential is calculated only for t*ose pumps as s*own in t*eta5le 5elow w*ere t*e pressure drop 5etween t*e source and t*e user is

*ig*+

VacuumPump No

UserSource Pr in

mmHgUser Pr in

mmHgDelta P in

mmHg

1 Wire bivac 300 Max 180 50

5Suction Press (high zone)

580 420 90

580 420 90

! Pic"u# $o%% 500 340 90

101&4 #ress 'e%t uh%e box

440 310 0

11 440 310 0



57/157

In t*e a5ove ta5le, t*e pressure drop 8elta)P: is inclusive of %mmgpressure drop across t*e separator and 2%mmg pressure drop in t*epiping+



58/157

Savings calculation

Sample calculation for ire &ivac M 3%%D1"%)%8separator:)2%8piping:

M %mmg

M Pressure drop x Powerconsumption

ead developed

M %mmg x 1%2 k3%% mmg

M 1' k

Similarly, saving for ot*ers is s*own in t*e ta5le 5elow

VacuumPump

NoUser

SourcePr in

mmHg

User Prin

mmHg

DeltaP in

mmHg

Powerconsumption in

kW

savingsin kW

1 Wire bivac 300Max180 50 102 1!

5 Suction Press (highzone)

580 420 90 180 28

580 420 90 14! 23

! Pic"u# $o%% 500 340 90 141 25

10 1&4 #ress 'e%t uh%ebox 440 310 0 1!4 2411 440 310 0 153 21

ota% 138

Benefits

0*e annual energy saving potential is Rs, ,$% !a4hs+ 0*is will re;uirean investment of Rs, $,%% !a4hs, w*ic* will *ave a simple pay5ackperiod of 8 "onths+



59/157

E*ERG2 SA0I*G PR)P)SA! *), $$

REP!ACE 0 BE!+ =I+; C)GGED :!A+ BE!+ I*IDE*+I:IED E/IP1E*+S

Ba4ground

uring t*e detailed Energy Audit conducted at +9+ Pulp and paper,various e;uipments were studied for possi5le energy saving opportunities+

Some of t*e auxiliary 5ag filter fans, pumps, compressors and 5lowersusesconventional !)5elt drives for power transmission+ /se of ! 5eltscauses some energy losses+ 0*ere is a power transmission loss of a5out' ) ", w*en t*e !)5elts NE6E I


60/157

@rom t*e a5ove grap* it is clear indication t*at t*e flat 5elt is operating at-" efficiency w*en t*e drive is 1%% loaded, 5ut !)5elt is operating att*e -4 efficiency only+ 0*ere exists good potential to replace !)5elt wit*t*e flat 5elt drives+

0*ese drives are ideal for steady load applications, suc* as fans,compressors, and 5lowers+ owever, it s*ould 5e ensured t*at t*e areaaround t*e e;uipment is free from oil or water spillage+

Also, proper preventive care must 5e taken to ensure proper alignment5etween t*e drive and driven e;uipment+

Reo""endation

e recommend converting t*e identified !)5elt drives into flat 5elt drivesfor t*e ma.or auxiliary 5ag filter fans+ 0*e list of identified fans is given5elow+ Ensure t*at t*e area around t*e e;uipment is free from oil orwater spillage 8cover could 5e used for protection:

S*+o ,-ui#.ent /#erating "W Saving Potentia%

1 Mixing hest 33 1*32

2 Machine hest 15 0*

3 Pu%# u.# chest 33 1*32

4 gro #u%# chest 30 1*2

5 acuu. #u.# cautisizing #%ant 130 5*2

,P rain #u.# 45 1*8

! agass chest agitator 55 2*28 acuu. #u.#s 11 nos 1398 55*92

9 6nit1 oi%er !P7 an 28 1*12

10 6nit1 oi%er !P7 : an 23 0*92

11 acuu. #u.#s 5 nos 3 14*4

ota% 215 8*24

Sa5ings

Cn a conservative 5asis 4 saving is calculated for t*e identifiede;uipments

Benefits

0*e annual energy saving potential is Rs, 3','% !a4hs+ 0*is will re;uirean investment of Rs, $%,%% !a4hs, w*ic* will *ave a simple pay5ackperiod of 6 "onths+



61/157

E*ERG2 SA0I*G PR)P)SA! *), $3

)P+I1IE +;E C)*DE*SA+E REC)0ER2 CIRC/I+ I*PAPER A*D E0AP)RA+)R SEC+I)*

uring t*e detailed energy audit at 9 Pulp and Paper, t*e sondensaterecovery circuit was studied in detail and t*e following o5servations weremade+

Present status

0*e following o5servations were made in t*e evaporator and papersection

Stea" onsu"ption in e5aporator setion

Average ) 13 0P

9ecovery ) , '0P

Stea" onsu"ption in paper "ahine

Average ) 22 0P

9ecovery ) ', 1> 0P

0*e condensate levels in flas* tank and vacuum tank at paper mac*inesection is maintained 5y individual pumps associated wit* eac* tank wit*t*e *elp of control valves+ 0*e condensate collected in eac* tank is



62/157

pumped into a recovery tank t*roug* a common *eader, w*ic* is againpumped into t*e deaerator wit* t*e *elp of a pump as s*own in t*e figurea5ove+

0*e condensate from t*e recovery section is also sent to t*e recovery

tank w*ic* is at 1%" deg $+

)bser5ation

Paper 1ahineAt paper mac*ine section, t*e individual controls valvesare *eavily t*rottled to t*e tune of 2> and 4-, w*ic* is due tomismatc* 5etween t*e design and operating condition+

E5aporator SetionAs t*e condensate w*ic* is entering t*e recoverytank from t*e evaporator section is at 1%" deg $, some portion of t*econdensate flas*es into steam w*ic* is vented into t*e atmosp*ere

Reo""endation

It is recommended to connect t*e condensate line from 5ot* evaporatorsection as well as from paper mac*ine section directly into t*e deaeratoras indicated 5y dotted line in t*e figure 5elow+

Install !@ in pumps associated wit* @las* tank and vacuum tank and t*elogic to !@ would 5e to maintain t*e tank level+

Stop t*e pump t*at transfers condensate from t*e recovery tank to t*edeaerator

0*e savings wit* t*is modification is as follows



63/157

0*e energy loss associated wit* t*e pressure drop across t*e control

valves in @las* tank and vacuum tank pumps can 5e completelyeliminated+

As t*e new operating parameters will 5e matc*ing wit* t*e design

values, t*e pump will 5e working wit* 5etter efficiency

Stopping of t*e recovery tank pump will 5e saving power to t*e

tune of 11 k 8operating power:

@las* steam generated from 1%0P of condensate would 5e

M 12 kg? *r

ence 12 kg? *r of flas* steam could 5e avoided if directly introduced todeaerator, t*is would inturn reducest*e extraction steam to t*e deaeratorfrom t*e tur5ine+

Install new pump at t*e evaporator section, t*e new pump will *ave aspecification w*ic* will aid t*e condensate to 5e sent directly into t*edeaerator+ 0*e new specification will 5e as follows

$apacity )2% m3? *r

ead ) % mtr

#otor ) kSa5ings

Stoppage of recovery tank pump M 11 k

Benefits

0*e annual energy saving potential is Rs, ','% !a4hs+ 0*is will re;uirean investment of Rs, ',%% !a4hs, w*ic* will *ave a simple pay5ackperiod of && "onths,



64/157

)bser5ation



65/157

)BSER0A+I)* *), &

REP!ACE +&$ A*D +9 !A1PS =I+; E*ERG2E::ICIE*+ + !A1PS

uring t*e detailed energy audit at KR Pulp and Papers=?

Effiay

>!u"ens=att?

!a"p !ife

>hours?

39"" dia+&$?

3" >" 12%%%

$8"" dia+9?3> ' 1%%%

&8"" dia+?2" 1%3 1>%%%

Reo""endation



66/157

0*ere is a good potential to replace existing 012 and 0" lamps wit* 0lamps+ It is recommended to replace 012 and 0" lamps wit* energyefficient 0 lamps+ 0*e savings 5y replacing 0" and 012 lamps wit*electronic 5allasts wit* 0 will 5e around " and 12 respectively+



67/157

)BSER0A+I)* *), $

REP!ACE E.IS+I*G ;PS0 A*D ;P10 !A1PS =I+;E*ERG2 E::ICIE*+ !ED !A1PS

!atest Design +rend in !ighting

0*e latest trend in lig*ting is to utiliBe t*e rig*t amount of pupil lumens+0*e pupil lumens also considerst*e variation in sensitivity of t*e eye inrelation to t*e environment+ 0*e sensitivity of t*e eye varies 5etweendaytime lig*ting and nig*t time lig*ting as s*own in t*e figure 5elow+

0*e scotopic curve and p*otopic curve mention t*e day D time lig*tingand nig*t time lig*ting respectively+ 0*e eye colour is more sensitivetowards t*e green colour for p*otopic curve and is correspondingly for5lue colour in t*e case of scotpic vision+ 0*is data of relative sensitivity ofeye *elps us in designing t*e correct colour of t*e lamp re;uired fordifferent lig*ting conditions+ 0*e scotopic vision is well suited for nig*tenvironment suc* as street lig*ts, 5asements, closed rooms w*eresunlig*t is not availa5le+ 0*e p*otopic on t*e ot*er *and will 5e closer today D time environment+

0*e earlier system of lig*ting w*erein t*e ;uantity of lig*t delivered wasmentioned in lumens and not in pupil lumens considered only t*e p*otopiccurve+

Co"parison of !a"ps

0*e ta5le 5elow s*ows a 5rief comparison of all t*e lamps+ 0*e latesttrend is to go for LE lamps+ 0*ese LE lamps *ave very *ig* scotopic top*otopic ratio of 2+4+ 0*is is very well suited for street lig*ting andlig*ting in dark surroundings+

S+


68/157

1 Life %%%%ours

1%,%%%)12,%%%ours

1,%%%)2%,%%%ours

>%%%)"%%%ours

12%%%)1%%%ours

"%%%%ours

2 Lamp

Efficacy

-%)1%% > to

-%

-%)14% >%)> '%)1%4 >%)"%

3 Lumenepreciation

3% O%,%%%ours

/pto4% O12%%%ours

/pto4% O1%%%ours

1)2%

till endof life

1)2% tillend of

life

1)2% tillend of life

4 $9I '%)-% >)-% 22) 2 >)" >%)- "%

$olor !ariety *ite Qellow *ite *ite w*ite

> colortemperature

21%%)1%%%%

4%%%k)%%%k

21%%)3%%%

3%%%)>%%%

3%%%)>%%

2'%%)>%%

' S?P 9atio upto2+4

1+> %+>2 1+3)2+2

1+3)2+2 1+"

" arm uptime -%Lumens

Instant minutes

4minutes

1minute

1%)%Seconds

Instant

- @licker free yes


69/157

Advantages of LEs

Lower energy consumption

1?LE Longer lifetime 8%,%%% to 1%%,%%% *rs:

ig* Scotopic to p*otopic ratio

Smaller siBe

@aster switc*ing

6reater dura5ility and relia5ility

6ood $9I "%

0*e PS! lamps used for lig*ting *ave very low scotopic to p*otopic ratioof %+>2 and even t*oug* t*e lamp efficacy is *ig*, -% D 14% lumens?watt,

considering only lumen levels and not pupil lumens+ #ultiplying t*isefficacy wit* t*e scotopic to p*otopic ratio from t*e ta5le will give us t*epupil lumens?watt w*ic* is > D "' pupil lumens?watt+ $omparing wit*LE t*e actual pupil lumen?watt will 5e around 21> D 24% pupillumens?watt, w*ic* gives us a good opportunity to replace t*e existingPS! lamps wit* LEs+ In order to ac*ieve t*e same amount of pupillumens t*e power consumed 5y LE is atleast % lesser in comparisonto PS! lamps+

Similarly P#! lamps can also 5e replaced wit* LEs+ 9eplacement of

sodium vapour and mercury vapour lamps wit* LEs are mentioned in t*eta5le 5elow+

Sodiu" 0apour 1erury 0apour !ED

' 12 33

1% 2% '%

2% 4%% 12%

Reo""endation

It is recommended to replace PS! and P#! lamps wit* LEs+ 0*erecommended values for standard lamp siBes are mentioned in t*e ta5lea5ove+



70/157

)BSER0A+I)* *), 3

;AR1)*ICS 1EAS/RE1E*+S

Ba4ground

As a part of t*euring t*e detailed energy audit detailed energy audit ata*armonic survey was conducted at K R Pulp and Papers !i"ited

#ercury &lended lamps Power input ecreases 5y 2%

#etal alide lamps Power input ecreases 5y 2%

PS! lamps Power input ecreases 5y 2%

LPS! lamps Power input ecreases 5y "


77/157



78/157

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)11, 9oad >

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!ED !A1PS

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!td,

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EHess >EHellene In EnergySa5ing Solutions?

2nd Street, ot*ari Layout, 41 %%, 0amil>24CAPACI+)RS

&, 1o"aya Capaitors4%1, #ad*av ApartmentsRawa*ar 9oad, Cpp+ 9ly+ Stn+6*atkopar 8East:#um5ai ) 4%% %''0el7 %22 ) 21>"2"1?"2,>'4%%1?%2@ax7 %22 ) 21> %'"

$, Baron Poer 3"

3, 1eher Capaitors

#r+ Cmer aiser8&usiness evelopment#anager:1eher Capaitors >P? !td,T2?1, &asappa 9d+,&angalorearnataka, India ) >%%2'P*7 %"%)''%4->2#o57 %-"4%1-2%%@ax7 %"%)222232

', EPC)S India Pri5ate !td,14?2, &runton 9oad&angalore >% %20el 7 -1 "% 4%3-%>1,4%3-%>4%@ax 7 -1 "% 4%3-%>%3sales+inOepcos+com

, EPC)S India Pri5ate !td,#e*ta Industrial Estate#at*uradas !asan.i 9oad$*akala, An*eri 8East:#um5ai 4%%%-30el7 -1 22 2> "3 2> % -1 22 2> "3 2> 1@ax7 -1 22 2> "3 2> 4

8, EPC)S India Pri5ate !td,11t*@loor2" r+ 6opal as 0owers&arak*am5a 9oad


88/157


89/157

Cogged flat Belts

K, K, Rubber Co"pany >India? P5t, !td,1, 9ani R*ansi 9oad1--42, 233121 23>12%'2, 23>'-%4@ax7 -1 11 23>21">2Email7 [email protected]

:enner India !td*ivra. $omplex II! @loor, 4"%, Anna Salai%% %3India

0el7 -1)44)243124% to '@ax7 -1)44)2434-%1>, 2432%1-3ptdVm*;Ofennermail+com

Agitators

1+ :luidy"e +ehnologiesE)2?4, Popular Prestige,India? P5t, !td,Cld 3"

Cffice #o5ile7 -3"1% 4'2348#arketing:, -3"2" 2114380ec*nical:Email7 5aronpowerOvsnl+net

5aronpowerOsatyam+net+incorporateO5aronpower+com

Cro"pton Grea5es !i"ited,$6 ouse, >t* @loorr+ Annie &esant 9oadorli, #um5ai ) 4%% %3%

India0el7 -1 %22 2423 ''''@ax7 -1 %22 2423 ''""

mailto:[email protected]:[email protected]:[email protected]://www.indiamart.com/pinnacleequipmentshttp://www.indiamart.com/indofabindustrieshttp://emailto:[email protected]%20/http://emailto:[email protected]%20/http://emailto:[email protected]/mailto:[email protected]:[email protected]:[email protected]://www.indiamart.com/pinnacleequipmentshttp://www.indiamart.com/indofabindustrieshttp://emailto:[email protected]%20/http://emailto:[email protected]%20/http://emailto:[email protected]/


90/157

Cu""ins India !i"itedPower 6eneration &usiness /nit3 A?1?2 ErandawanaPune D 411 %3"P*7 %2% D >>%2 '2

@ax7 %2% D >>%2 "%-%Contat Person

1r, S Ra5ihandran6eneral #anager#o57 %-"22% -3'"Email7su5ramaniam+ravic*andranOcummins+com

*eel ControlsT112, #inerva Industrial EstateP 9oad, , 9ow ouse, 6oyal Inter $ity&e*ind rive in cinema, 0*alte.9oad, 0*alte.A*meda5ad, 6u.arat 3"% %4IndiaP*7 8%'-: 2>"4 %124? 324

APCT , Lake Avenue,%, 24--"21%Email7npsl+corporateOnumericups+com

E"erson *etor4 PoerPlot '2%"%%%?"%%2?'"%%@ax7 %22 ) 2"2"3", 2"%%"2-,2"242">

Consul Consolidated Pri5ate !i"ited

-?>, Ist Street, !enkates*wara %% %2%, 0amil

@ax7 8-1:)844:)244%34'%

E)mail7 consulOvsnl+com, npkris*nanOconsulindia+com

mailto:[email protected]:[email protected]:[email protected]:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected]:[email protected]:[email protected]:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.commailto:[email protected],[email protected],[email protected]?subject=Consul%20Consolidated%20Private%20Limited%20Mail%20Through%20consulindia.com


91/157

=aste ;eat Reo5ery

+her"aH !td,*anra. #a*al, 2nd @loor$*atrapati S*iva.i #a*ara. #arg

)3)>4-,

@ax8s:7 -1)%4%)23%-'433

infoOt*ermalindia+com

1egather" DNteh P5t !td

Plot 1%, Perungudi Industrial Estate

Perungudi, $*ennai ) >%%%->+ I4'-2 ? 42>2-%%"

Email I 7 govinmegaOsify+com?

govinmegaOgmail+com

)I! :IRED +;ER1)PACA/A+;ER1 S2S+E1

+her"aH Babo4 =iloH

!i"ited

Energy &uilding, 1 &lock, Plot 14?3"?"

@ax7 %44 D 24-" '>3"

mailto:[email protected]:[email protected]:%C2%[email protected]:[email protected]:[email protected]:[email protected]:%C2%[email protected]:[email protected]


92/157

:urnae

+her"al Syste"sPlot 2'>2, 2>2'-%@ax7 %44 ) 4214%-''Email7 t*ermalsystemsOya*oo+com t*ermalsystemsOairtel5road5and+in

Radiant Reuperati5e ;eaters

+her"aH Babo4 =iloH !i"ited

Energy &uilding, 1 &lock, Plot '"

@ax7 -1 22 2431 %--2 ? 2432 1-2-Email7 enconindiaOvsnl+comEmail7 akraiOencongroups+com

A"alga"ated Indl, Co"posites P, !td,

/nit -'

Atlas Copo Co"pressor Sales>)3)11-1, 2nd @loor, &ri. 0arang6reenlands, &egumpetydera5ad ) %%%1>

0el7 -1 4% 32-4-%-%@ax7 -1 4% 2341'-23

8#r+ *anan.ay esai9egional #anager:Atlas Copo Co"pressor Sales2nd @loor, 0ellus 0ec*nologies PvtLtd, 2%-?1&?1A, 9ange ill, Pune411%2%, P*7 -1 2% 32-4-%-%@ax7 -1 2% 2'14''"#o57 -1 -"23%141"Email7 d+desaiOin+atlascopco

mailto:[email protected]:[email protected]:[email protected][email protected]&subject=Inquiry%20from%20www.encongroups.commailto:[email protected][email protected]&subject=Inquiry%20from%20www.encongroups.commailto:[email protected]:[email protected]:[email protected]:[email protected][email protected]&subject=Inquiry%20from%20www.encongroups.commailto:[email protected][email protected]&subject=Inquiry%20from%20www.encongroups.commailto:[email protected]


93/157

Ingersoll-Rand >India? !td)Air $enterSolitaire $orporate Park I!/nit 411)412, 1st @loorAnd*eri)6*atkopar Link 9oad

#um5ai 4%%%-3$*akala, And*eri 8East:P*7 %22)>>-')@ax7 %22)>>-' >>

Godrej Group ( EE ser5ies#r < aruwala6odre. = &oyce #fg+ $o+ Ltd+Piro.s*anagar, !ik*roli,#um5ai ) 4%%%'-,

#a*aras*tra,India+P*7 -1)22)>'-> >> ? >'->--@ax '-> 11"

Den5i4 +ehnology Pri5ate !i"ited 11?, Arundale &eac* 9oadalaks*etra $olony&esant %%%-%*ttp7??www+denvik+in

Contat Person!i.ay ris*na, irector, &usiness evelopmentP*7 %-"4%"1"%% Email7 vi.ayOdenvik+in

;)C Dryers

Gaso Energy Syste"s >I? P5t, !i"ited0)122 , #+I++$+, &*osari, Pune ) 411 %2>0el+ 7 -1 2% 2'12 ""23 ? 3%>" 2>@ax7 %2% ) 2'11-'3

Email7kgiramOgasoenergysystems+com

Dryteh EngineersS*+ %1@ax 7 -1)2%)243'>'"-Email7 drytec*engineersOet*+net, v5kVdrytec*Oya*oo+co+in,.mdVdrytec*Oya*oo+co+in, responseOdrytec*engineers+com

mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.mailto:[email protected],%[email protected],%[email protected][email protected]&body=This%20Mail%20has%20delivered%20to%20you%20thorugh%20Maharashtra%20Industries%20Directory.


94/157

Energy Effiient Pu"ps

Suler Pu"ps India !td,- #I$, 0*ane &elapur 9oadig*a, % >"14E)mail7 spisalesOsulBer+com

Grundfos Pu"ps India Pri5ate!td,11" Cld #a*a5alipuram 9oad0*oraipakkam, $*ennai >%% %-'0el7 -1 44 24-> >"%%@ax7 -1 44 24-> >->-

@ax7 -12% 2444)%"24,2444)

41-",2444)%1>Email7 k5linOk5l+co+in


Kirlos4ar Brothers !td,/dyog &*avan, 0ilak 9oad,Pune 411 %%2 8India:P*7 -1 2% 2444%''%
mailto:[email protected]:[email protected]%20mailto:[email protected]:[email protected]%20


95/157

Energy effiient fans

Dusteh Engineers P5t !td$ontact Person 7 #r 9 6upta WirXAddress 7 P)2' 2nd @lr malviya ?4321

@ax7 -1)44)2434'""'email7 salesOswitBerinstrument+com

Chanda4 Instru"ents P5t, !td,6)%%4, Smruti, Cpp+ *anwatey


96/157

Air onditioning syste"

/nited Engineering Corporation14', 9 P 9oad, Secundera5ad)%% %%30elefax7 2'4)%1, 1113, 3-, 2'3)"->

Email7 ueca.ayOgmail+com= *yd2Vueca.ayOsanc*arnet+in!isit7 www+smartcool+co+in

Stea" +urbines >1ini "iro?

+ri5eni Engineering Industries !i"ited12 D A, Peenya Industrial Area &angalore >% %",0el7 %"%)2"3-4'21@ax7 %"%)2"--211)-4-1r S * Prasad24#o57 -"41"-4'2Email7 snprasadOt5g+trivenigroup+com

+urbo+eh Preision Engineering >P? !td,


97/157

Insulations

1egha Insulations P5t !td,A)11?>t*@loor, ada Sa*e5 @latsalanala, &*avnagar D 3>4%%1

P*7 %2'")3%%423?2>@ax7 %2'")3%%4'2"Email7 miplOmeg*ainsulation+com

Contat Person#r ! S*a* )-"22)%''23 = -42>2)12"23#rs+ #ad*u7 -"'-)4>23

Energy 1anage"ent Softare

1anoj +elrandhe

#anager D nowledge &ased &usinesses = I0esSEE-+eh Solutions P5t, !td,11?, Lets $onserve, #I$ Info0ec* Park'-> 1'%% ? 1"%%@ax7 -1 22 >'-> 12

Contat Details#r+ omi+ '-> 22%1Email7 *ndOgodre.+com

1r, /"esh 0, Shah8$*ief 6eneral #anager:Industrial Electronics = Automation0el+7 -1 22 >'-> 2211Email7 uvsOgodre.+com

mailto:[email protected]://www.letsconserve.org/mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]://www.letsconserve.org/mailto:[email protected]:[email protected]:[email protected]:[email protected]


98/157

$, Ingersoll-Rand >India? !i"ited,Plot 2 1%-0el7 -1 "% 221> >%%%@ax7 -1 "% 221> >%22

3 )rhid Industrial E@ui"ents Energy /tility Ser5ies 14' ) A, Cld Ani.rwadi, #aBgaon#um5ai ) 4%% %1%0el7 -1 ) 22 ) 23'3 '4 4

-1 ) 22 ) 23'4 23 4@ax7 -1 ) 22 ) 23'1 -4 4>

P! Engineering !i"ited8A Pun. Lloyd 6roup $ompany:'> Institutional Area, Sector 326urgaon ) 122%%1, India

Contat Person

#r Priya 9an.an umar6# ) &usiness evelopment1ob %6'&&%$&7$%< Bangalore

mailto:[email protected]:[email protected]:[email protected]:[email protected]


99/157

Supplier for Paddle 1iHers

B;S-Sonthofen >India? P5t, !td,>)3)22?1?'?&, 3rd floorCpp+ IIP#, ErramanBil

&an.ara ills, ydera5ad) %% %340el7 -1)4%)2331341 ?4@ax7 -1)4%)233134>

Contat Person

1r *eelesh Desai"%

Sangha5i Engineering121, $+I+E, 5alanagar Expansion

6and*inagar, ydera5ad )%% %3'And*ra Prades*P* %4%)23%">>31?33E mail seOsang*avigroup+com

Con5eyor Belts

1r 0ijay Ku"ar K9egional #anager)Sout*PhoeniH 2ule >P? !i"ited1st @loor, P # #odi, $ommercial $omplex

ar5ala #aidan, )4)1"'?>#a*atma 6and*i 9oadSecundera5ad D %% %%3P*7 %4%)>>32442, >>31442#o57 %)-3-32 23112Email7 pyl*ydOya*oo+co+in kandukurivi.ayOya*oo+com

Dislai"er

=hile e5ery are has been ta4en in o"piling this list< Confederation

of Indian Industry does not aepts any lai" for o"pensation< if anyentry is found to be rong< abbre5iated< o"itted or insertedinorretly either as to the ording spae or position in the list, =hileatte"pts are being "ade ontinuously to "a4e the list as elaborateRs,!a4hs?

Payba4Period

>1onths?

PersonDepart"entResponsible

+argetDate

Re"ar4s

19educe t*e @re;uency of 0ur5o 6enerator1 to 4- B

1%%+%% % %

2 9educe Cne 0ap Setting of 0ransformer 2+1% % %

3 CptimiBe t*e Lig*ting !oltage in t*e Plant +%% 2+%%

4Install !aria5le @re;uency rives inIdentified Pumps In Pulp #ill

>+"% 4'+4% 1%

Install !aria5le @re;uency rives in$entricleaner Pumps in Pulp #ill

"+"% "+% 11

>Install !aria5le @re;uency rives inIdentified Pumps in Paper #ac*ine

"+4% 1%+%% 1

'Install !aria5le @re;uency rives in$entricleaner Pumps in Paper #ac*ine

43+%% 1-+% >



101/157

"Avoid t*e Pressure rop Across @eed$ontrol !alve &y Cperating &fp it* !fd in/nit 1

4+%% 4+% 14

-

Avoid Passing 0*roug* #inimum9ecirculation Line &y Installing #ultistagerag !alves @or &oiler @eed Pump in /nit1

-+%% +%% '

1%Avoid t*e Pressure rop Across @eed$ontrol !alve &y Cperating &fp in Auto

it* !fd in /nit 2

2'+%% 1+%% 1

11

Avoid Passing 0*roug* #inimum9ecirculation Line &y Installing #ultistagerag !alves @or &oiler @eed Pump in /nit2

4+"% "+% 2%

12Avoid 9ecirculation of $ondensate &yInstalling !fd And 9educing Speed of$ondensate Extraction Pump

2+4% 1+%%

139educe Air Ingress in /nit)1 &oiler @lue6as Pat*

2+% % %

14Cperate All t*e $ooling 0ower @ans And9educe t*e Speed &y Installing !fd @or All

@ans in /nit)2 Power Plant

4+%% 3+%% -

19educe Excess @low 0*roug* eatExc*angers in /nit)2 Power Plant

32+%% "+%% 3

1>Switc* off Cne $ondensate ExtractionPump $ompletely in /nit)2 Power Plant

3+2% % %



102/157

1'Avoid Pressure rop Across ot ell Level$ontrol !alve And #aintain ot ell Levelirectly &y Installing !fd

2+%% 1+% -

1"

Avoid Cperating Cne Pump &y Pumpingm ater irectly to eaerator AfterPassing 0*roug* t*e @las* Steam eatExc*anger in Paper #ill Section

3+2% 1+%% 4

1-CptimiBe t*e Cperation of Instrument Air$ompressors in /nit )2

1>+4% 1%+%% '

2%CptimiBe t*e Cperation of Instrument Air$ompressors in /nit )1

>+%% +%% 1

21CptimiBe !acuum Pump Cperation in /nit)2

+2% 2+%% >

229eplace ! &elt it* $ogged @lat &elt inIdentified E;uipments

34+4% 2%+%% '

23CptimiBe t*e $ondensate 9ecovery $ircuitin Paper And Evaporator Section

4+4% 4+%% 11

+otal '3',&% &93,7% '



103/157



104/157

a!"up Cal!ulations



105/157

E*ERG2 SA0I*G PR)P)SA! *), &

RED/CE +;E :RE/E*C2 ): +/RB) GE*ERA+)R & +)'7 ;

0*e power produced 5y /nit 061 isM 1%+-' # at %+% B

Cn a conservative 5asis it is assumed t*at around 4% of load is assumedcentrifugal in nature

As per t*e loading of motors t*ere is a good potential to reduce t*e fre;uencyof t*e alternator 061 to 4- B+

Power consumed 5y centrifugal e;uipment 8Speed3

:

3

Power consumed 5y centrifugal e;uipmentM 4% of 1%+- #M 4+3> #

Power consumed 5y t*e centrifugal e;uipment after reduction in fre;uency to4- B M 84-:3 x 4+3>

8%:3

M 4+1% #

9eduction in power consumption M 4+3> D 4+1%Y 2% k

Annual energy savings M 2% k x 9s x "%%% *oursM Rs, &%%,%% !a4hs

0*ere is no investment re;uired for t*is proposal+



106/157

E*ERG2 SA0I*G PR)P)SA! *), $

RED/CE )*E +AP SE++I*G ): +RA*S:)R1ER

0ransformer t*e L0 voltage maintained is 42' !+ 0*ere is a good potential toreduce t*e tap setting of t*e transformer and maintain Z 41!for transformer+

+ap Position ;+ 0oltage >0? !+ 0oltage>0?

1 11>%

433

$>Reo""ended? &&$6

3>Current? &&%%%

4 1%'2

1%4%

> 1%1'

' --%%

9educe t*e tap setting for t*e transformer to tap position 2 from tap position

0otal load of transformers M -' k

Power savings M %+%%>2 x -' k

M > k

Annual Savings M > k x "%%% *rs x 9s+ +%?k*M 9s+2,4%,%%%?)M Rs,$,'% !a4hs

0*ere is no investment re;uired for t*is proposal+



107/157


)P+I1IE E!EC+RICI+2 B)ARD P)=ER :AC+)R

0*e mont*ly average power factor is maintained at %+-' lag+ 0*e E& 5illing isin k!A* so for 5y increasing t*e power factor towards unity t*e consumedk!A* units will decrease resulting in lower 5illing amount+

9ecommend to install auto P@ controller and maintain %+-- P@

0otal average k!A*?mont* M 24"%%% k!A*0otal average k*?mont* M 23>%%% k*Power factor M %+-

Improved Power factor M %+--

Average k!A*?mont* after E%%%?%+--M 23"3"3 k!A*

Savings k!A*?mont* M 24"%%%) 23"3"3M -,>1' k!A*

Annual savings M ->1'k!A* x 9s +%?k!A*x 12 mont*s

M 9s+,'',%2%?)Say Rs,,66 !a4hs

!A9 re;uired7#aximum instantaneous k M >>%k!A x %+-"

M >4' k$apacitor re;uired M 8tan[1D tan[2:

M >4' 8%+2%3:M 12-+4 k!Ar

Say &$% 40Ar

9ecommend to install 12% k!Ar 0 capacitor 5ank

Investment for AP@$ M 12% k!Ar \ 9s+1%%?k!ArM Rs, &


108/157

E*ERG2 SA0I*G PR)P)SA! *), '

I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I* IDE*+I:IEDP/1P S I* P/!P 1I!!

Present Status

#any of t*e pumps in t*e pulp mill in /nit)II were found to 5e controlledt*roug* control valves+ 0*e flow re;uirement in t*e 5elow mentioned pumpsvaries on t*e 5asis of production levels and t*e consistency to 5e maintainedin t*e respective c*ests+

$losing of t*e valve creates an artificial resistance to t*e flow, additional to t*esystem resistance+ 0*is pressure drop across t*e valve is a mec*anical energyloss w*ic* is also included in t*e work done 5y t*e pump+ It is estimated t*at

a5out 1%)4% of t*e pump power consumption is lost across t*e valve+

Sa5ings

*a"e of Pu"p+ag

*a"ePoer

4=

0al5e)pening

F

4=Sa5ing

:lo"3hr

Screw Press $*estPump

P/ '> ' 3)>% 11 44%

$ontinuous igesterilution Pump

P/ '4 4" 3 14 '2+"

et ilution Pump )&S1

P/ 11- >% 12 1" 4%%

&ack S*ower Pump )&S1

P/ 1%% 1' % 12%

et ilution Pump )

&S 2

P/ -> >> 2 1-+ %%

&ack S*ower Pump )&S 2

P/ 1%1 1' % 13%

as*ed 0owerPump

P/ 11> '1 "% ' )

ilution Pump P/ 12> 4 % 1>

Secondary Screen

PumpP/ 132 21 3% >



109/157

Screened 0owerPump

P/ 14> 24 % '

L$ $*est Pump P/ 1% 24 1 '

Screened 0owerilution Pump

P/ 1> 4 2, 14 1>

ECP !A0 ilutionPump

P/ 1>- 1 2" 4+

ECP as*er ilutionPump

P/ 1'1 4 >% 1%+

@or Savings, considering 1% savings for 'D1%% open valve considering2% savings for >%D' open valve 3% savings for 1%D>% open valve

@or Example, consider $ontinuous igester ilution Pump P/ '4

Saving Potential M %+2 x 4" kM 14+4 kSay 14 k

0otal Saving Potential M 14>+ k

Annual Savings M 14>+ k x "%%% *rs?yr x 9s+ ?k*M 9s+ >,"%,%%%

Investment for !@ O Rs, '6,' !a4hs

Pay5ack period M 9s+ 4'+4% Lak*s x 12 mont*s9s+ >+"% Lak*s

M &% "onths

Benefits

0*e annual savings of Rs, 9,8% !a4hscan 5e ac*ieved 5y implementing t*ispro.ect+ 0*e investment re;uired is Rs, '6,'% !a4hs w*ic* is paid 5ack in &%"onths+



110/157

E*ERG2 SA0I*G PR)P)SA! *),

I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I*CE*+RI C!EA*ER P/1PS I* P/!P 1I!!

Present Status

0*e $entricleaner pump in t*e pulp mill in /nit)II was found to 5e controlledt*roug* a control valve+ 0*e flow re;uirement in t*e pump varies on t*e 5asisof production level+

$losing of t*e valve creates an artificial resistance to t*e flow, additional to t*e

system resistance+ 0*is pressure drop across t*e valve is a mec*anical energyloss w*ic* is also included in t*e work done 5y t*e pump+ 0*e necessity forcontrolling t*e valve is due to *ig*er design *ead or design flow+

0*ere is pressure loss of %+" 5ar across t*e valve for primary $etricleanerpump w*ic* accounts to more t*an 3% of t*e pump *ead+ As pump power isdirectly proportional to t*e operating *ead of t*e pump, t*ere is good potentialto save energy+

Sa5ings

Pump isc*arge Pressure M 3+4 5ar

Pump ead M 3+4 D %+4 5arM 3 5ar


+o Sreen =asher

9' 4=P/ &$9

'%F open

Pri"ary Centrileaner

Standpipe

3,' bar

$,8 bar%,8 bar



111/157

Pressure rop across !alve M 3+4 D 2+> 5arM %+" 5ar

Pump Power M "4 k

As pump power is directly proportional to t*e operating *ead of t*e pump

Saving Potential M %+" 5ar x "4 k3 5ar

M 22+4 kSay 22 k

Annual Savings M 22 k x "%%% *rs?yr x 9s+ ?k*M 9s+ ","%,%%%

Investment for !@ O Rs, 9 !a4hs

Pay5ack period M 9s+ "+% Lak*s x 12 mont*s9s+ "+" Lak*s

M && "onths

Benefits

0*e annual savings of Rs, 9,9% !a4hscan 5e ac*ieved 5y implementing t*ispro.ect+ 0*e investment re;uired is Rs, 9,% !a4hs w*ic* is paid 5ack in &&"onths+



112/157


I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I* IDE*+I:IEDP/1PS I* PAPER 1AC;I*E

Present Status

#any of t*e pumps in t*e paper mill in /nit)II were found to 5e controlledt*roug* control valves+ 0*e flow re;uirement in t*e 5elow mentioned pumpsvaries on t*e 5asis of production levels and t*e consistency to 5e maintainedin t*e respective c*ests+ 0*e pumps would *ave 5een designed for maximumproduction and *ence t*e flows are generally controlled t*roug* valves+

$losing of t*e valve creates an artificial resistance to t*e flow, additional to t*esystem resistance+ 0*is pressure drop across t*e valve is a mec*anical energy

loss w*ic* is also included in t*e work done 5y t*e pump+ It is estimated t*ata5out 1%)4% of t*e pump power consumption is lost across t*e valve+

Sa5ings

*a"e of Pu"p +ag*a"e

Poer4=

0al5e)pening

F

4=Sa5ing

:lo"3hr

9efined S $*est PumpP#1"1

1% 2" ) 22

&roke $*est PumpP#1-%

1- 4" + ''

&agasse Pulp $*estPump

P#1-4

24 '> 2 21

#ac*ine $*est PumpP#1"

4 % 13+ )

@or Savings, considering 1% savings for 'D1%% open valve considering2% savings for >%D' open valve 3% savings for 1%D>% open valve

@or Example, consider &roke $*est Pump P# 1-%

Saving Potential M %+3 x 1- kM +' kSay + k

0otal Saving Potential M 21 k

Annual Savings M 21 k x "%%% *rs?yr x 9s+ ?k*M 9s+ ",4%,%%%



113/157

Investment for !@ O Rs, &% !a4hs

Pay5ack period M 9s+ 1%+% Lak*s x 12 mont*s9s+ "+4% Lak*s

M &% "onths

Benefits

0*e annual savings of Rs, 9,'% !a4hscan 5e ac*ieved 5y implementing t*ispro.ect+ 0*e investment re;uired is Rs, &%,%% !a4hs w*ic* is paid 5ack in &"onths+



114/157


I*S+A!! 0ARIAB!E :RE/E*C2 DRI0ES I*CE*+RIC!EA *ER P/1PS I* PAPER 1AC;I*E

Present Status

0*e $entricleaner pumps in t*e paper mill in /nit)II were found to 5econtrolled t*roug* control valves+ 0*e flow re;uirement in t*e pumps varies ont*e 5asis of production levels+

$losing of t*e valve creates an artificial resistance to t*e flow, additional to t*esystem resistance+ 0*is pressure drop across t*e valve is a mec*anical energyloss w*ic* is also included in t*e work done 5y t*e pump+ 0*e necessity forcontrolling t*e valve could 5e due to *ig*er design *ead or design flow+

0*ere is pressure loss of 1+1 5ar across t*e valve for primary $etricleaner

pump w*ic* accounts to more t*an 2 of t*e pump *ead+ Similarly, t*ere isa 1+ 5ar pressure loss across t*e valve for t*e secondary centricleaner pumpw*ic* is more t*an 4% of t*e pump *ead+ As pump power is directlyproportional to t*e operating *ead of t*e pump, t*ere is good potential to saveenergy+

Sa5ings Calulations

$onsidering Primary $entricleaner pump

Pump isc*arge Pressure M 4 5ar

Pump ead M 4 D %+4 5arM 3+> 5ar


+o Pri"ary Sreen

through P1 $3'

$3' 4=P1 &%%

'%F open

:ro" C! BoH

' bar

$,7 bar %,9 bar


6 4=P1 '$

3, bar

$ bar %, bar

'%F open


115/157

Pressure rop across !alve M 4 D 2+- 5arM 1+1 5ar

Pump Power M 234 k

As pump power is directly proportional to t*e operating *ead of t*e pump

Saving Potential for P# 1%% M 1+1 5ar x 234 k3+> 5ar

M '1+ k

Saving Potential for P# 42 M 1+ 5ar x ' k3+1 5ar

M 3> k

0otal Saving Potential M 1%'+ k

Annual Savings M 1%'+ k x "%%% *rs?yr x 9s+ ?k*M 9s+ 43,%%,%%%

Investment for !@ O Rs, &7, !a4hs

Pay5ack period M 9s+ 1-+ Lak*s x 12 mont*s9s+ 43 Lak*s

M 8 "onths

Benefits

0*e annual savings of Rs, '3,% !a4hscan 5e ac*ieved 5y implementing t*ispro.ect+ 0*e investment re;uired is Rs, &7, !a4hs w*ic* is paid 5ack in 8"onths+



116/157


A0)ID +;E PRESS/RE DR)P ACR)SS :EED C)*+R)!0A!0E B2 )PERA+I*G B:P =I+; 0:D I* /*I+ &

uring t*e detailed energy audit at KR Pulp Papers !i"ited%% m

9ated Power 7 -% k

% kg?cm2and t*e drum pressure is around4 kg?cm2+ &ecause of t*e severe t*rottling t*ere is *uge pressure drop acrosst*e feed control valve+ Approximately, 1% kg?cm2is t*e pressure drop is takingplace across t*e control valve+



117/157

&oiler drum level is 5eing controlled 5y t*ree element control valve+ 0*isautomatic flow 5ased control valve operates 5ased on t*e level of t*e 5oilerdrum+ As per t*e drum level t*e open of t*e control valve varies+

@low controlling wit* t*e control valve is not an energy efficient mec*anism+

0*e loss *appening across t*e control valve can 5e minimised ? reduced 5yreducing t*e speed of t*e pump+

As t*e pump is already installed wit* !@ and running in manual mode+ Powerconsumption of t*e pump can 5e optimiBed 5y operating t*e !@ in automode+

Reo""endation

e recommend to

Cperate t*e pump wit* a closed loop feed5ack to t*e !@

o )ption & @eed5ack can 5e same t*at of to t*e valve 83 element

signal:

o )ption $ @eed5ack can 5e pressure difference of 2 kg?cm2across

t*e control valve

Saving $aculations

At least pressure drop of " kg?cm

2

can 5e reduced

reduction in pressure drop M " kg?cm2x 1%%>% kg?cm2

M 13+3

Power consumption of &@P M -% k

9eduction in power consumption M -% k x 13+3M 12 k

$onsidering 1%k savings,Annual Savings M 1% kx "%%%*rs x 9s+?k*M 9s+ 4,%%,%%%?)M Rs, ',% !a4hs

Investment for !@ M Rs ',% !a4hs

Pay5ack Period M 9s+ 4+ % Lak*s x 12 mont*s9s+ 4+% Lak*s

M &' "onths



118/157


A0)ID PASSI*G +;R)/G; 1I*I1/1 RECIRC/!A+I)*!I*E B2 I*S+A!!I*G 1/!+IS+AGE DRAG 0A!0ES :)R

B)I!ER :EED P/1P I* /*I+ &

uring t*e detailed energy audit at KR Pulp Papers !i"ited+"M >" k

Annual Savings M >" kx "%%%*rs x 9s+?k*M 9s+ 2',2%,%%%?)

M Rs, $6,% !a4hs

Investment for automation M Rs &,% !a4hs

Pay5ack Period M 9s+ 1+% Lak*s x 12 mont*s9s+ 2'+% Lak*s

M & "onth



122/157

E*ERG2 SA0I*G PR)P)SA! *), &&

A0)ID PASSI*G +;R)/G; 1I*I1/1 RECIRC/!A+I)*!I*E B2 I*S+A!!I*G 1/!+IS+AGE DRAG 0A!0ES :)R

B)I!ER :EED P/1P I* /*I+ $

uring t*e detailed energy audit at KR Pulp Papers !i"ited+ >+-% + 1+> 2"


@or control valve operations, t*e instrument air re;uirement is in 5etween

1+ D 3+ 5ar


0*ere exists a good saving potential to optimiBe t*e pressure settings of t*einstrument air compressors+



142/157

Reo""endation

Interconnect t*e compressed air pipe lines of 5ot* paper plant and

power plant and stop t*e compressor in power plant

As we can see from t*e a5ove ta5le t*at t*e unloading percentage ofcompressor)3 is very *ig*, it would easily accommodate t*e compressedair re;uirement from power plant+

Install !@ in $ompressor)3 and reduce t*e operating pressure setpoint

to + 5ar+ 0*is would *ave two 5enefits


operating power

o It would completely avoid t*e loss due to unloading

Press roll user re;uires > 5ar pressure, *ence to cater its need, a small

5ooster compressor needs to 5e installed near t*e user

Sa5ings alulation

As a first step, it is recommended to reduce t*e pressure settings and maintaint*e average pressure at + 5ar

Loading pressure 7 >+ 5ar

/nloading pressure 7 >+- 5ar

Average Pressure 7 >+' 5ar

Power saving in t*e compressor 5y reducing t*e operating pressure,

Power saving8IA$ T 1,2 = 3: M >+' D +>+' 1

M 1+"

Poer sa5ing in IAC &< $ 3 by reduing pressure

Average loading of compressor M 1%%

Loading Power of compressor M k

Power saving M k x 1+%% x %+1"M "+>k

@or 3 $ompressors M 3 x "+> k

M 2+>" k

M say 2 k

Poer sa5ing in IAC 3 by a5oiding unloading



143/157


144/157

E*ERG2 SA0I*G PR)P)SA! *), $%

)P+I1IE +;E )PERA+I)* ): I*S+R/1E*+ AIRC)1PRESS)RS I* /*I+ -&

uring t*e detailed energy audit at 9 Pulp and Paper t*e compressors werestudied in detail and t*e following o5servations *ave 5een made+

Installed apaity

2 x 3"% $@# screw compressor

o 2 nos wit* k rated motor

In operation ( Paper plant

1 nos of k compressor

0*e pressure setting of all t*e identified compressors is as follows7

$apacity

Actual

re;uirement

Pressure

Suggested

Pr

reduction

9eduction

k Savings

8Pr reduction =

/nloading:$@#

/nloading Loading /nloading

$ompressor)

13"%

24 2"-+2 >+3 " + 2%+2 1+%


@or control valve operations, t*e instrument air re;uirement is in 5etween

1+ D 3+ 5ar


0*ere exists a good saving potential to optimiBe t*e pressure settings of t*einstrument air compressors+

Reo""endation

Install !@ and reduce t*e operating pressure setpoint to + 5ar+ 0*is

would *ave two 5enefits


operating power

o

It would completely avoid t*e loss due to unloading

Press roll user re;uires > 5ar pressure, *ence to cater its need, a small

5ooster compressor needs to 5e installed near t*e user



145/157

Sa5ings alulation

As a first step, it is recommended to reduce t*e pressure settings and maintaint*e average pressure at + 5ar

Loading pressure 7 >+3 5ar

/nloading pressure 7 " 5ar

Average Pressure 7 '+1 5ar

Power saving in t*e compressor 5y reducing t*e operating pressure,

Power saving8IA$: M '+1 D +'+1 1

M 2%+24

dea report - krpp

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