post implementation audit report industries.pdf · client name bureau of energy efficiency (bee)...

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore (Food)

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Prepared by: DESL Date: 31-01-2017 of 39

POST IMPLEMENTATION AUDIT REPORT “SUPPORTING NATIONAL PROGRAM ON ENERGY EFFICIENCY IN SMES FOR INDORE (FOOD) CLUSTER”

Dharmesh Industries

36, D&F, Maxi Road Industrial Area Ujjain

Madhya Pradesh

January 2017

Submitted to

BUREAU OF ENERGY EFFICIENCY

4th Floor, Sewa Bhawan, R K Puram, Sector-I, New Delhi -110066

Submitted by

DEVELOPMENT ENVIRONERGY SERVICES LTD 819, Antriksh Bhawan, 22 Kasturba Gandhi Marg, New Delhi -110001 Tel.: +91 11 4079 1100 Fax : +91 11 4079 1101; www.deslenergy.com

http://www.deslenergy.com/



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DISCLAIMER

This report (including any enclosures and attachments) has been prepared for the exclusive use and benefit of

the addressee(s) and solely for the purpose for which it is provided. Unless we provide express prior written

consent, no part of this report should be reproduced, distributed or communicated to any third party. We do

not accept any liability if this report is used for an alternative purpose from which it is intended, nor to any

third party in respect of this report.



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ACKNOWLEDGEMENT

DESL places on record its sincere thanks to Bureau of Energy Efficiency (BEE) for vesting confidence in

DESL to carry out the assignment “Conducting Post implementation audit Post implementation audit

in Indore SME food clusters” under their national project “Supporting national program on Energy

Efficiency in SMEs for Indore(Food) cluster”.

As a part of this assignment, work in Indore and Ujjain food cluster was awarded to DESL and DESL is

grateful to BEE for their full-fledged coordination and support throughout the study.

The study team is indebted to Mr. Dharmesh Jain, Owner for showing keen interest in the energy

audit and also thankful to the management of Dharmesh Industries for their wholehearted support

and cooperation for the preparation of this Base line energy audit report, without which the study

would not have steered to its successful completion. Special thanks to other members of the unit for

their diligent involvement and cooperation.

It is well worthy to mention that the efforts being taken and the enthusiasm shown by all the plant

personnel towards energy conservation and sustainable growth are really admirable.

Last but not the least, the interaction and deliberation with Mr. Mayank Patel, Secretary, Poha

Parmal, Nirmata Sangh, Ujjain, technology providers, and all those who were directly or indirectly

involved throughout the study were exemplary. The entire exercise was thoroughly a rewarding

experience for DESL.

DESL Team



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DESL Team

Project Head Mr. R. Rajmohan Chief Executive Officer

Team leader and co-coordinator Mr. Suparno R Majumdar Consultant

Team Members Mr. Abhisheka Nand Jha Analyst

Mr. Amit Kumar Yadav Analyst



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CONTENTS

EXECUTIVE SUMMARY ............................................................................................................................................ 9

Replacement of existing roaster motor with EE motor .................................................................................... 10

1 INTRODUCTION ............................................................................................................................................ 12

1.1 Background and Project objective ...................................................................................................... 12

1.2 Methodology ....................................................................................................................................... 12

1.2.1 Boundary parameters ..................................................................................................................... 12

1.2.2 General methodology ..................................................................................................................... 13

1.2.3 Project specific audit methodology ................................................................................................ 14

2 ABOUT THE MSME UNIT ............................................................................................................................... 15

2.1 Particulars of the unit .......................................................................................................................... 15

2.2 Manufacturing process ....................................................................................................................... 16

2.2.1 Process & Energy flow diagram ...................................................................................................... 16

2.2.2 Process description ......................................................................................................................... 16

3 POST IMPLEMENTATION ENERGY AUDIT OUTCOME AND RESULT .............................................................. 17

3.1 Installation of IE3 induction motors .................................................................................................... 17

3.1.1 Baseline Scenario ............................................................................................................................ 17

3.2 ENERGY SAVING AND COST ECONOMIC ANALYSIS ............................................................................. 19

3.2.1 EPIA 1 Replacement of motors of material handling section (conveyor motors) with Energy efficient

motors and gearbox ......................................................................................................................................... 19

3.2.2 EPIA 2: Replacement of press (poha) machine motors with EE motors ............................................. 27

3.2.3 EPIA 8: Replacement of existing roaster motor with EE motor .......................................................... 30

4 Unit Photo graphs ......................................................................................................................................... 32

ANNEXURE-1 ......................................................................................................................................................... 33

ANNEXURE-2 ......................................................................................................................................................... 34

ANNEXURE-3 ......................................................................................................................................................... 38

ANNEXURE-4 ......................................................................................................................................................... 39



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List of figures

Figure 1 General Methodology ............................................................................................................................. 13

Figure 2 Project implementation methodology ................................................................................................... 14

Figure 3: Production flow diagram ....................................................................................................................... 16

Figure 4 New efficiency classes of motors ............................................................................................................ 18

Figure 5 Poha elevator motor 1 HP ...................................................................................................................... 20

Figure 6 Dhaan chalna motor ............................................................................................................................... 22

Figure 7 FD fan blower .......................................................................................................................................... 23

Figure 8 Dhaan elevator motor 1 HP .................................................................................................................... 24

Figure 9Poha chalna ............................................................................................................................................. 26

Figure 10 Poha M/C-1 ........................................................................................................................................... 28

Figure 11 Poha M/C-1 ........................................................................................................................................... 28

Figure 12 Poha M/C-2 ........................................................................................................................................... 29

Figure 13 Poha M/C-2 ........................................................................................................................................... 29

Figure 14 Roaster motor ....................................................................................................................................... 31

Figure 15 Roaster motor ....................................................................................................................................... 31

Figure 16 Roaster .................................................................................................................................................. 32

Figure 17 Dusted poha .......................................................................................................................................... 32

Figure 18: Flaker machine..................................................................................................................................... 32

Figure 19 Poha elevator ........................................................................................................................................ 32

Figure 20 Poha Machine ....................................................................................................................................... 32

Figure 21 Roasted Dhaan ...................................................................................................................................... 32



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List of Tables

Table 1: Details of Unit ........................................................................................................................................... 9

Table 2 Energy audit instruments ......................................................................................................................... 13

Table 3: General particulars of the unit ................................................................................................................ 15

Table 4 Poha elevator motor 1 HP ........................................................................................................................ 19

Table 5 Dhaan chalna motor 5 HP ........................................................................................................................ 20

Table 6 FD fan blower motor 1 HP........................................................................................................................ 22

Table 7 Dhaan elevator motor .............................................................................................................................. 23

Table 8 Poha chalna motor ................................................................................................................................... 24



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ABBREVIATIONS

Abbreviations Expansions

APFC Automatic Power Factor Correction

BEE Bureau of Energy Efficiency

CEA Comprehensive Energy Audit

CFL Compact Fluorescent Lamp

CRV Chromium Vanadium

DESL Development Environergy Services Limited

DG Diesel Generator

EE Energy Efficiency/ Energy efficient

EPIA Energy Performance Improvement Action

FO Furnace Oil

GEF Global Environment Facility

HSD High Speed Diesel

HVAC Heating Ventilation and Air Conditioning

LED Light Emitting Diode

LT Low Tension

MD Maximum Demand

MS Mild Steel

MSME Micro, Small and Medium Enterprises

MT Metric Tons

MTOE Million Tons of Oil Equivalent

MV Mercury Vapor

No. Number

PF Power Factor

PID Proportional-Integral-Derivative

PNG Piped Natural Gas

PSPCL Punjab State Power Corporation Limited

R & C Radiation & Convection

RE Renewable Energy

SEC Specific Energy Consumption

SEGR Specific Energy Generation Ratio

SLD Single Line Diagram

SME Small and Medium Enterprises

UNIDO United Nations Industrial Development Organization

VFD Variable Frequency Drives



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EXECUTIVE SUMMARY

Bureau of Energy Efficiency (BEE) is implementing a project titled “Supporting National program on

Energy Efficiency in SMEs for Indore (Food) cluster” The objective of the project is to provide

impetus to energy efficiency initiatives in, small and medium enterprises (SMEs) for Indore food

Cluster in India.

As part of this project, DESL has been engaged to implement the project in the SME food cluster in

Indore and Ujjain in Madhya Pradesh. There are about 200 units scattered over Indore and Ujjain.

The major products processed in these food industries includes poha (rice flakes) and various types

of pulses – toor, masoor, chana, arahar, moong etc.

The project awarded to DESL consists of 18 major tasks:

Conducting pre–activity cluster workshop defining the agenda of this engagement.

Conducting initial walk through energy audit within 8 selected units.

Identifying and proposing two energy efficient process technologies to BEE

Identifying at least 5 local technology/Service providers for above technologies in the cluster

Identifying 20 SME units willing to implement and demonstrate the above two technologies

Assist BEE to enter into a contract with each of 20 shortlisted SME units.

Conducting Comprehensive Energy Audits in 20 SME units

Development of technology specific case studies (Audio, Visual and Print) for each technology.

Developing best operating practices(BOP) document for the top 5 energy equipments/process in industry

cluster

Enumeration of common regularly monitorable parameters at the process level which have impact on

energy performance and listing of appropriate instrumentation for the same.

Conducting post energy audit in each of the above 20 units to verify energy savings.

Verification and Submission of relevant documents (Evidence of implementation and Commissioning of

EE technology )to the BEE

Assisting BEE in conducting five post energy audits

Submission of progress report in hard and soft versions (Word, presentation) to BEE.

Submission of Draft document to BEE within seven days from issue of LOI by BEE

Brief Introduction of the Unit

Table 1: Details of Unit

Name of the Unit Dharmesh Industries Constitution Private Limited MSME Classification Small No. of years in operation NA Address: Registered Office 36, D&F, Maxi Road Industrial Area, Ujjain

Administrative Office 36, D&F, Maxi Road Industrial Area, Ujjain Factory

36, D&F, Maxi Road Industrial Area, Ujjain Industry-sector Food Products Manufactured Poha (Rice flakes)



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Name(s) of the Promoters / Directors Mr. Dharmesh Jain

The production process of the unit

The production process description is as follows:

Paddy used as raw material for production of poha is purchased from nearby food grains markets.

The purchased paddy is cleaned in mega and vibro cleaners to remove the large sized and small sized

sand particles which come along with the paddy. The cleaned paddy is then soaked in water for 1

day. The soaked paddy is roasted in rotating tunnel roaster for moisture reduction and to soften it.

The softened paddy is then manually fed into the poha (press) machines where it is flattened and

the husk cover of the paddy is removed by machining. After the husk is removed the rice is process

into flakers that produce rice flakes. These rice flakes are then cleaned in cleaners and finally packed

and dispatched.

Energy efficient technology implemented vis-a-vis baseline energy audit recommendation

Technology recommended as per baseline energy audit( as approved by steering committee)

Technology implementation and cross-verified during post implementation energy audit

Replacement of motors of material handling section

(conveyor motors) with Energy efficient motors and

gearbox(Poha elevator, FD fan blower, Dhaan

elevator motor, Dhaan chalna motor & Poha chalna)

EE motors (1 HP X 4, 5 HP X 1)

Replacement of press (poha) machine motors with EE motors

EE Motors (20 HPX1, 15 HPx1)

Replacement of existing roaster motor with EE motor

EE motor( 3HP X1)

Replacement of Flaker machine motor with EE motor EE motor (20 HPX1) under break down

Cost economic Analysis: Projected (As per baseline) Vs. Actual

EPIA Estimated Energy Savings (%)

Savings (kWh/y)

Investment (Lakh Rs./y)

Simple Payback Period (y)

Replacement of motors of material handling section (conveyor motors) with energy efficient motors and gearbox (Poha elevator, FD fan blower, Dhaan elevator motor, dhaan chalna & poha

chalna)

Baseline Projected (4x1 HP, 1x5 HP)

10% 790 0.21 3.41

Post Implementation Actual 47.16% 7,261.67 0.38 0.66



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(4x1 HP, 1x5 HP)

Replacement of press (poha) machine motors with EE motors

Baseline Projected (25 HPx1, 15x1 HP)

20% 13492 1.45 1.4

Post Implementation Actual (20 HPx1, 15x1 HP)

35% 25206.3 0.74 0.4

Replacement of existing roaster motor with EE motor

Baseline Projected (3 HPx1) 8% 394 0.12 3.96

Post Implementation Actual (3 HPx1)

31% 1585.03 0.10 0.8

`



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1 INTRODUCTION

1.1 Background and Project objective

Bureau of Energy Efficiency (BEE) is implementing a project titled “Supporting National program on

Energy Efficiency in SMEs for Indore (Food) cluster”. The objective of the project is to provide

impetus to energy efficiency initiatives in micro small and medium enterprises (MSMEs) sector in

Indore and Ujjain food cluster in India.

The objectives of this project are as under:

Identifying energy efficient process and technologies that can be implementable by units in

the Indore food cluster;

Identifying 20 MSME units within the cluster that are willing to implement and demonstrate

the above technologies in their units;

Facilitate Bureau of Energy Efficiency (BEE), New Delhi to sign tri-partite Memorandum of

Understanding (MOUs) with the 20 MSME units of Indore food cluster (that are willing to

implement the energy efficient technologies) and their cluster association

Conduct Baseline Energy Audits in 20 MSME food units of the Indore food cluster who have

signed MOUs with BEE;

Establish baseline energy efficiency scenario for the 20 units against which energy savings

shall be computed post implementation

Facilitate the 20 MSME units to implement the proposed energy efficient technologies in

their units.

Conduct post implementation energy audits in the 20 MSME units to establish the actual

energy savings in those units

Development of technology specific case studies (audio-visual and print) for each technology

(during pre-implementation, implementation and post implementation stages).

1.2 Methodology

1.2.1 Boundary parameters

Following boundary parameters were set for the baseline audit:

Audit covered all the identified energy intensive areas and equipments for which energy

efficiency improvement measures were proposed

All appropriate measuring systems including portable instruments were used

The identified measures normally fall under short, medium and long-term measures



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1.2.2 General methodology

Following flow chart illustrates the methodology followed for carrying out the project:

Figure 1 General Methodology

The study was conducted in fallowing stages:

Stage 1: Identification of units and conducting walk through energy audit in 5 units to understand

the process and its energy intensiveness, identification of energy saving technologies, assessment of

the measurement system, proposing energy efficient technologies to BEE and units for acceptance,

Stage 2: Identification of vendors for implementation of energy efficient technologies and facilitate

BEE to sign tripartite MOUs with the units that is willing to implement the EE technology and its

cluster association

Stage 3: Formation of project team for conducting baseline energy audits (DEA) in the units that

have signed MOUs with BEE; and conduct DEA in those units – carry out on-site measurement of

energy parameters, collection of historical energy use data for analysis.

Stage 4: Data analysis, quantification of energy savings (in the processes / equipment) post

measurements, and preparation of baseline energy audit report.

The energy instrument used in post implementation audit is tabulated below :

Table 2 Energy audit instruments

Sl. No. Instruments Make Model Parameters Measured

01 Power Analyzer – 3

Phase (for balance load)

with 1 CT and 2 PT

Elcontrol

Energy

Nanovip plus

mem

AC Current, Voltage, Power Factor,

Power, Energy, Frequency, Harmonics

and data recording for minimum 2 sec

interval



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1.2.3 Project specific audit methodology

The BEE’s national program on energy efficiency and technology up gradation at Indore food cluster followed

the following implementation methodology:

Figure 2 Project implementation methodology



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2 ABOUT THE MSME UNIT

2.1 Particulars of the unit Table 3: General particulars of the unit

S. No Particulars Details 1 Name of the unit Dharmesh Industries 2 Constitution Private Limited 3 Date of incorporation / commencement of

business NA

4 Name of the contact person Mobile/Phone No. E-mail ID

Mr. Dharmesh Jain +91 – 9425092998 [email protected]

5 Address of the unit 36, D&F, Maxi Road Industrial Area,Ujjain 6 Industry / sector Food 7 Products manufactured Poha (Rice flakes) 8 No. of operational hours 8 9 No. of shifts / day 1 10 No. of days of operation / year 300



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2.2 Manufacturing process

The following flow chart shows the typical process employed at manufacturing of rice flakes in Dharmesh

industries.

2.2.1 Process & Energy flow diagram

Figure 3: Production flow diagram

2.2.2 Process description

Dharmesh Industries, Ujjain is rice flakes (poha) manufacturing unit. The process description is as

follows:

Paddy is used as raw material for production of poha. Raw material is purchased from nearby

situated food-grain markets. Purchased raw material is conveyed to mega cleaner to remove huge

sand particles which come along with the paddy from fields. After removal of larger sized sand

particles in the mega cleaner, the smaller sized sand particles are removed from the paddy in a vibro

cleaner. Post cleaning, the paddy is soaked in water for 24 hours. The soaked paddy is heated in a

roaster for removal of moisture and to soften it. The roasted paddy is transferred manually to the

poha machines where the paddy is flattened and the husk is removed from the softened paddy.

After the husk is removed the rice is process into flakers that produce rice flakes Then the material is

processed cleaner to produce poha (rice flakes) which is then packed and dispatched.



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3 POST IMPLEMENTATION ENERGY AUDIT OUTCOME AND RESULT

During DEA of the plant, all energy consuming equipments and processes were studied. The analysis

of all major energy consuming equipments and appliances were carried out. Based on the analysis,

Energy Performance Improvement Actions (EPIA) had been identified in which EE motor

replacement was the major one is explain below:

3.1 Installation of IE3 induction motors

3.1.1 Baseline Scenario

During the baseline energy audit, M/s Dharmesh industries were using less efficient motors which

were installed when plant commissioned. Now these days it is categorized in inefficient motors due

to enhancement in new technology available in the market.

The international organization which prepares & publishes international standards for all electrical,

electronics & related technologies is known as IEC.

The IEC (International Electrotechnical Commission) publishes IS:12615-2011 which is based on IEC

60034-30 (2008) ) which defines New Efficiency Classification for single speed, three phase,

induction motors.

The IS:12615-2011 covers single speed, three-phase, 50Hz, cage induction motors that:

Have rated voltage ≤1000V;

Have a rated output 0.37kW ≤ PN ≤ 375kW;

Have either 2, 4 or 6 poles;

Meet frame size to output relation as stipulated in IS:1231 (for outputs covered by IS:1231);

Are rated on the basis of either duty type S1 (continuous duty) or S3 (intermittent periodic

duty) with rated cyclic duration factor of 80% or higher;

Are capable of operating direct on-line;

Are designed for operation on virtually sinusoidal and balanced voltage conditions as

defined in 7.2.1 of IS/IEC 60034-1;

Designed for an ambient temperature not exceeding 40°C and altitude not exceeding

1000m;

Have degree of protection IP44 or superior;

Have method of cooling IC411 in accordance with IS 6362 / IEC 60034-6;

Have service factor not exceeding 1.0.

The Efficiency classes defined are:

IE1 - Standard Efficiency

IE2 - High Efficiency

IE3 - Premium Efficiency



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The IS: 12615-2011 also stipulates that for motors to be classified as “Energy Efficient”, these must

meet at least IE2 efficiency values.

Figure 4 New efficiency classes of motors

During DEA of the plant, the recommended EE measures & outcome of the implementation i.e.

energy saving & cost economics analysis (Post implementation) is shown below:



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3.2 ENERGY SAVING AND COST ECONOMIC ANALYSIS

During DEA of the plant, all energy consuming equipments and processes were studied. The analysis

of all major energy consuming equipments and appliances were carried out. The energy saving and

cost economic analysis after post implementation audit is discussed below:

3.2.1 EPIA 1 Replacement of motors of material handling section

(conveyor motors) with Energy efficient motors and gearbox

In the material handling section, five numbers of motors were studied during baseline audit, i.e.,

Poha elevator motor, Dhaan chalna motor, Dhaan elevator motor, Poha chalna & FD fan blower.

These motors were inefficient and were consuming higher power. It was proposed to replace these

motors with high energy efficient motors.

The table below summarizes the post implementation energy consumption figures of the unit vis-à-

vis the baseline energy audit data.

Table 4 Poha elevator motor 1 HP

Parameter Unit Value

Baseline scenario

No. of motor # 1

Rating of poha elevator motor HP 1.00

Present Power consumption by poha elevator motor kW 0.71

Post Implementation Scenario

Rating of dhaan poha motor HP 1.00


Savings

Reduction in power consumption kW 0.21

Percentage reduction in energy consumption % 30%

Running hours / day hrs / day 8

Operating days / year days / y 300

Weighted avg. cost of electricity Rs / kWh 7.94

Annual energy savings kWh / y 508.74

Annual monetary savings Rs. Lacs / y 0.04

Estimated Investment Rs Lacs 0.06

Simple payback period y 1.4

Annual CO2 emission reduction tCO2/y 0.45

Assumption / conversion factors:



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Emission factor kwh has been considered as 0.89kg CO2 per kWh

CO2 emission reduction calculation has been considered based on equivalent reduction in

CO2 emission

Inference

Energy cost saved per year is Rs. 0.04 Lac.

Actual investment made to implement the energy efficient motor is Rs. 0.06 lac.

The investment made will be recovered within 1.4 year.

Picture

Figure 5 Poha elevator motor 1 HP

Table 5 Dhaan chalna motor 5 HP


Baseline scenario

Rating of elevator motor HP 5.00

Present Power consumption by elevator motor kW 3.54


Rating of elevator motor HP 5.00

Present Power consumption by elevator motor kW 1.19



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Savings






Annual energy savings kWh / y 5,646








CO2 emission

Inference




Picture



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Figure 6 Dhaan chalna motor

Table 6 FD fan blower motor 1 HP


Baseline scenario






Savings






Annual energy savings kWh / y 337









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CO2 emission

Inference




Picture

Figure 7 FD fan blower

Table 7 Dhaan elevator motor


Baseline scenario






Savings








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Annual energy savings kWh / y 446








CO2 emission

Inference




Picture

Figure 8 Dhaan elevator motor 1 HP

Table 8 Poha chalna motor


Baseline scenario

Rating of poha chalna motor HP 1.00



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Present Power consumption by poha chalna motor kW 0.75

Post Implementation scenario

Rating of poha chalna motor HP 1.00

Present Power consumption by poha chalna motor kW 0.61

Savings





Weighted avg. cost of electricity Rs / kWh

7.94

Annual energy savings kWh / y 324.20








CO2 emission

Inference






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Figure 9Poha chalna



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3.2.2 EPIA 2: Replacement of press (poha) machine motors with EE

motors




Baseline scenario

No. of motors # 2

Rating of Poha machine motor #1 HP 25.00


Present Power consumption by poha motors kW 30.12


No. of motors # 2.00



Present Power consumption by poha motors kW 19.62

Savings












Emission factor kWh has been considered as 0.89kg CO2 per kWh


CO2 emission

Inference






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Picture

Figure 10 Poha M/C-1




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3.2.3 EPIA 3: Replacement of existing roaster motor with EE motor




Baseline scenario

Rating of roaster motor HP 3.00

Present Power consumption by roaster motor kW 2.13


Rating of roaster motor HP 3.00

Present Power consumption by roaster motor kW 1.47

Savings







Annual monetory savings Rs. Lacs / y 0.13







CO2 emission

Inference




Picture



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Figure 14 Roaster motor

Figure 15 Roaster motor



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4 Unit Photo graphs

Figure 16 Roaster

Figure 17 Dusted poha

Figure 18: Flaker machine

Figure 19 Poha elevator

Figure 20 Poha Machine

Figure 21 Roasted Dhaan



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ANNEXURE-1

Base Executive summary



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ANNEXURE-2

Clearance by CA



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ANNEXURE-3 Completion Letter



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ANNEXURE-4 GHG Emission Factor

post implementation audit report industries.pdf · client name bureau of energy efficiency (bee)...

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