Draft DEA Report Asian Paints LTD, Patancheru1

Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
Detailed Energy Audit

At
Asian Paints Limited,
Patancheru
June 2014June
CIISohrabji Godrej Green Business Centre
CONTENTS
Chapter
No.
Description
Page
No.
Executive Summary
Introduction
II
Acknowledgement
III
List of Energy Saving Proposals
IV
Energy Saving Proposals
Management Aspects and conclusion
56
VI
Annexure
60
VII
Back-up Calculations
79
Total Pages: 114
EXECUTIVE SUMMARY
Asian Paints is one of the India's largest paint companies which
manufacturesmanufacture paints for decorative and industrial use. Since its
foundation in 1942, Asian Paints has come up a long way to become Indias
largest and Asias third largest paint company, with a turnover of Rs. 127.15
billion. Asian Paints operates in 17 countries and has 23 paint manufacturing
facilities in the world servicing consumers in over 65 countries.
Asian Paints has always been a leader in the paint industry, pushing new
concepts in India like Colour Worlds, Home Solutions, Colour Next, and Kids
World.
The plant team has done exceedingly well in incorporating certain energy
efficiency aspects in design stage. Further, plant team has taken many steps
towards the improvement in energy efficiency.
CII has conducted the Detailed Energy Audit at Asian Paints Limited.,
Patancheru Plant from 15 to 21 January, 2014. A detailed presentation was
made to the plant team covering various energy conservation opportunities on
25th January, 2014. The combined efforts of Asian Paints Limited., Patancheru
and CII-Godrej GBC team have together identified, annual energy saving
potential of Rs. 98.81 Lakhs, based on present energy cost.
The summary of the annual energy savings identified is as below:
Total Annual Savings (14 proposals)
: Rs. 98.81 Lakhs
Investment required (10 proposals)
: Rs. 75.0 Lakhs
Average payback period for capital Proposals
: 9 months
SPECIFIC ACTION PLAN

a) Asian Paints Limited, Patancheru should identify specific person or
department to facilitate implementation of the above proposals and
achieve the savings.
b) Specific target date for implementation of proposals should be set and
implementation should be taken up on priority.
c) The plant team should prioritize the above proposals and implement
them in a phased manner.
d) In our opinion the following proposals can be implemented straightaway
and should be on top priority.
(ESP Nos. 5,6,13,14, 6, 13, 14)
The above
investment.
proposals
doesntproposal
doesnt
requiresrequire
any
e) As On a second priority and after verification by the plant team, the

following proposals can be implemented within next six months.
(ESP Nos. 1, 2, 4, 7, 8, 9, 10, 11)
f) As a third priority, due to the higher payback, the following proposal
should be implemented before twelve months.
(ESP Nos. 3, 12)
g) Asian Paints Limited, Patancheru should form an energy conservation
committee. The General Manager should head the committee. The
committee should meet once in a month and review the progress of
implementation activity.
CHAPTER I
INTRODUCTION
Asian Paints Limited, Patancheru evinced keen interest in availing the services
of CII - Godrej Green Business Centre (CII Godrej GBC) of the Confederation
of Indian Industry (CII) for conducting a detailed energy audit at their unit.
The CII-Godrej GBC proposal for conducting a detailed energy audit at Asian
Paints Limited, Patancheru was accepted by management; vide their Reference
P.O. No. 15191843, dated 26th November, 2013.
The field activities of the detailed energy audit were conducted in one visit and
the final presentation to the plant team was made on 25th January, 2013.
The methodology adopted for conducting the detailed energy audit at
Asian Paints Limited, Patancheru is as follows:
Basic data collection on list of power consuming equipments, design
specifications of the major equipments and actual operating parameters
Power measurements of major electrical energy consumers
Measurement of operating parameters of various equipments to estimate
their operating efficiency
Analysis of data collected and measurements, to develop specific energy
saving proposals
Discussion with the plant personnel on the identified proposals
Presentation on the findings of the detailed energy audit to the plant
personnel, with the cost economic analysis
We are pleased to mention that all the identified energy saving proposals have
been discussed with the plant executives before finalizing the ideas.
The contents of the report are based on the data provided by the plant
personnel and actual measurements conducted jointly by the CII-Godrej GBC
and plant team during the detailed energy audit.
The plant personnel should implement the suggestions made in this report,
after verifying the necessary regulatory safety aspects. It is solely the
responsibility of the plant personnel to observe statutory regulations, if any, as
applicable to their plant.
CHAPTER II
ACKNOWLEDGEMENT
CII acknowledges with thanks the co-operation and the support extended to
the CII energy audit team during the detailed energy audit at Asian Paints
Limited, Patancheru.
The interactions and deliberations with Asian Paints Limited, Patancheru
team were exemplary and the whole exercise was thoroughly a rewarding
experience for CII.
The arrangements and support during the energy audit were excellent. We
deeply appreciate the interest, enthusiasm and commitment of Asian Paints
Limited, Patancheru team towards the energy conservation.
We would also like to place on record our sincere thanks and appreciation for
all the senior plant executives.
CHAPTER III
LIST OF ENERGY SAVING PROPOSALS

Sl.
No
1
2
3
7
8
9
10
11
12
13
14

REPLACE THE 1X36W and 2X36W T5
LAMPS WITH 1X20 W LEDs
REPLACE 2 X 36 W CFLS WITH 18 W
LEDS
RENEWABLE ENERGY FOR LIGHTING
(LONG TERM)
OPTIMIZE THE EXCESS AIR SUPPLY IN
RESIN HOUSE THERMOPAC TP-405
FOR IMPROVING COMBUSTION
EFFICIENCY
RESIN HOUSE REVOMAX BOILER
RXA06 FOR IMPROVING COMBUSTION
EFFICIENCY
OPTIMIZE THE TP 405 THERMIC FLUID
PUMP OPERATION BASED ON THE
RESIN HOUSE REACTORS
REQUIREMENTS
REPLACE EXISTING AIR HANDLING
BLOWERS WITH HIGH EFFICIENCY
BLOWERS IN INDUSTRAIL PAINT
BLOCK
OPTIMIZE THE OPERATION OF WBU
COOLING WATER PUMPS
OPTIMIZE THE OPERATION OF LDV
COOLING WATER PUMP IN WBU
SECTION
OPTIMIZE THE OPERATION OF NEW
BAZAAR COOLING WATER PUMPS
OPTIMIZE THE OPERATION OF
INDUSTRIAL COOLING WATER PUMPS
REPLACE INEFFICIENT PUMPS WITH
NEW EFFICIENT PUMPS
REDUCE THE GENERATING PRESSURE
OF THE AIR COMPRESSORS IN THE
PLANT
MINIMISE COMPRESSED AIR LEAKAGE
IN THE PLANT
Total
Annual
Savings
(Rs. Lakhs)
Investment
Required
(Rs. Lakhs)
Payback
Period
(Months)
28
31
13
0.9
1.8
24
2.8
13
56
22.3
0.31
13.45
14.5
13
1.97
19
0.44
0.6
17
12
4.2
1.6
3.5
42
9.9
11.54
98.81
75.0
Chapter IV
ENERGY SAVING PROPOSAL No. 1
REPLACE THE 1X36W and 2X36W T5 LAMPS WITH 1X20

W LEDs
During the course of detailed energy audit at Asian Paints Limited,
Patancheru, a detailed study of plant lighting load was carried out to identify
energy saving opportunities.
Present status
Presently at Asian Paints, Patancheru . Nos. of T8 lamps were are installed in
the plant in the following areas: Production blocks, engineering stores, DC,
RMG, PMG and other office areas.
The total power consumption of these T8 lamps is around 146 kW and
individual power consumption of each T8 fixture is watts.
The table given below indicates the T 8 lamp quantities and total power
consumption of the fixtures
Operating
Watt
Quantity
Power in
kW
Other Offices
36w x 2
746
53.71
2432
Engg Store
36w x 2
40
2.88
2432
Production Blocks
(floor wise)
36w x 2
849
61.13
4984
BSR
36w x 2
90
6.48
4984
DC
36w x 2
10
0.72
4272
RMG
36w x 2
219
15.77
4984
PMG
72 w
80
5.76
4984
S.No
Location
hours
Please discuss the LED technology and their benfits. Make a paragraph
Proposed Technology
Give one or two lines about LED technology amnd how it works It is
recommended to replace these T8 lamps with 1X20 W LEDs. Light Emitting
Diode (LED) is the latest technology and offers the following advantages:
Advantages of LED
Lower energy consumption: The energy consumption of LEDs is low

when compared to the other conventional sources for the same amount of
Lumen output.
Type of Lamp
Lumen/Watt
CRI
Life hours
Fluorescent lamps
50
Good (67-77)
5,000
LED lamps
120
Very Good (> 80)
50,000 1,00,000
High S/P ratio: LEDs have higher scotopic/photopic ratio (S/P ratio). The
eye has two primary light sensing cells called rods and cones cones
function in day light and process visual information whereas rods function in
night light. The cone dominated vision is called photopic and the rod
dominated vision is called scotopic. The S/P ratio indicates the measure of
light that excites rods compared to the light that excites cones. In office
environments, illumination is more effective if the S/P ratio is high as it is
under scotopic region. LEDs hence are ideally suited for these applications
as they have a high S/P ratio.
Longer life time: LEDs have longer life time of around 1,00,000 hours.
This is equivalent to 11years of continuous operation or 22 years of 50%
operation.
Faster switching: LED lights reach its brightness instantly upon switching
and can frequently be switched on/off without reducing the operational life
expectancy.
Greater durability and reliability: As LEDs are solid-state devices and
uses semi-conductor material; they are sturdier than conventional sources
that use filaments or glass. LEDs can also withstand shock, extreme
temperatures and vibration as they dont have fragile materials as
components.
Good Colour Rendering Index (CRI): The color rendering index, i.e.,
measure of a light sources ability to show objects as perceived under
sunlight is high for LEDs. The CRI of natural sunlight is 100 and LEDs offer
CRI of 80 and above.
LED offers more focused light and reduced glare. Moreover, it does not
contain pollutants like mercury
LED technology is highly compatible for solar lighting as low-voltage power
supply is sufficient for LED illumination.
Recommendation
It is recommended to replace the existing 2X36W T8 lamps with 1X20 W LEDs.
The energy saving that can be obtained by shifting to LEDs is around 106 kW.
Give Action Plan

Fixtures needs to be replaced in phased manner
Benefits
The estimated annual savings that can be obtained by replacing T8 lamps with
LEDs is Rs. 28 lakhs. The investment required is Rs. 31 lakhs. The payback
period is 14 months.
ENERGY SAVING PROPOSAL NO. 2
REPLACE 2 X 36 W CFLS WITH 18 W LEDS

Present status
108 Nos of 2 X 36 W CFL lamps were installed in the admin block. The power
consumption of these CFL lamps is around 1.3 KW. Power consumption of each
CFL is around . Watts
Proposed
It is recommended to replace these CFL lamps with 1X18 W LEDs. Light
Emitting Diode (LED) is the latest technology and offers the following
advantages:
Advantages of LED
Lower energy consumption: The energy consumption of LEDs is low
when compared to the other conventional sources for the same amount of
Lumen output.
Type of Lamp
Lumen/Watt
CRI
Life hours
Fluorescent lamps
50
Good (67-77)
5,000
LED lamps
120
Very Good (> 80)
50,000 1,00,000
High S/P ratio: LEDs have higher scotopic/photopic ratio (S/P ratio).
The eye has two primary light sensing cells called rods and cones cones
function in day light and process visual information whereas rods function in
night light. The cone dominated vision is called photopic and the rod
dominated vision is called scotopic. The S/P ratio indicates the measure of
light that excites rods compared to the light that excites cones. In office
environments, illumination is more effective if the S/P ratio is high as it is
under scotopic region. LEDs hence are ideally suited for these applications
as they have a high S/P ratio.
Longer life time: LEDs have longer life time of around 1,00,000 hours.
This is equivalent to 11years of continuous operation or 22 years of 50%
operation.
10
Faster switching: LED lights reach its brightness instantly upon switching
and can frequently be switched on/off without reducing the operational life
expectancy.
Greater durability and reliability: As LEDs are solid-state devices and
uses semi-conductor material; they are sturdier than conventional sources
that use filaments or glass. LEDs can also withstand shock, extreme
temperatures and vibration as they dont have fragile materials as
components.
Good Colour Rendering Index (CRI): The color rendering index, i.e.,
measure of a light sources ability to show objects as perceived under
sunlight is high for LEDs. The CRI of natural sunlight is 100 and LEDs offer
CRI of 80 and above.
LED offers more focused light and reduced glare. Moreover, it does not
contain pollutants like mercury
LED technology is highly compatible for solar lighting as low-voltage power
supply is sufficient for LED illumination.
Recommendation
It is recommended to replace the existing 2X36W CFL lamps with 1X18 W
LEDs. The energy saving that can be obtained by shifting to LEDs is around 5.8
KW.
Benefits
The estimated annual savings that can be obtained by replacing CFL lamps
with LEDs is Rs. 0.9 lakhs. The investment required is Rs. 1.8 lakhs. The
payback period is 24 months.
11
RENEWABLE ENERGY FOR LIGHTING (LONG TERM)

energy saving opportunities. The option of using renewable energy for lighting
was explored.
Present Status
At present, 120 Nos of 70 W HPMV and 30 Nos of HPSV lamps are installed for
street lighting in the plant. The power consumption of these lamps is around
10.5 KW. Give per lamp power consumption details also
Proposed Technology
Give background of LEDs it beenfits in brief and then go for recommendation It
is recommended to replace these HPMV and HPSV lamps with 1X18 W LEDs. A
3 KW capacity solar panel can be installed and the requirements of street
lighting can be met through renewable energy.
The solar powered street lighting reduces dependency on conventional power.
It contributed towards green energy and offers long term benefits. Moreover, it
helps in meeting requirements like RPO (Renewable Purchase Obligation).
Asian Paints, Patancheru team can further depict its commitment towards
energy efficiency and sustainability by opting to renewable energy, setting an
excellent example for other plants to follow.
The following approach can be followed to shift to renewable energy for
lighting:
Step 1: Installation of LED lamps in place of HPMV and HPSV lamps. This
reduces the lighting load significantly, to around 2.2 kW from the present 8.4
kW.
Step 2: Solar powered street lighting: As a futherTo go one step further for
energy conservation opportunity, it is recommended to install a 3 kW capacity
solar mill mill and the requirements of street lighting can be met through
renewable energy.
Solar Mill
A Solar Mill is a hybrid system and taps solar and wind energy. It is suitable for
operation at 2 m/s to 17 m/s of wind speed. As it is a hybrid system, the
capacity utilization is also high.
Recommendation
12
It is recommended to replace the existing 70 W HPSV and HPMV lamps with

1X18 W LEDs. A 3 KW capacity solar panel mill can be installed and the
requirements of street lighting can be met through renewable energy.
Benefits
The estimated annual savings that can be obtained by installing a solar
panel/solar mill is Rs. 2.81 lakhs. The investment required is Rs. 13.00
lakhs.
13

OPTIMIZE THE EXCESS AIR SUPPLY IN RESIN HOUSE
THERMOPAC
TP-405
FOR
IMPROVING
COMBUSTION
EFFICIENCY
During the detailed energy audit at Asian Paints Limited, Patancheru,
detailed measurements of the combustion air supply, exit gas gases analysis
and operational modulation of the burner in thermopac TP 405 (20 Lakh
Kcal/hr) were studied in detailed identifying possible energy savings
opportunities.
Present Status
Presently TP 405 (20 Lakh kcal/hr) thermopac is used for providing heat
required for the process for five of the resin house reactors namely R-1, R-3,
R-6, R-8 & R-9.
The thermopac is equipped with blower modulation control for high and low
flame based on the thermic fluid outlet temperature set point.
The schematic of the TP 405 themopac is as below
Fuel Feed Rate: 120 Kg/hr
of LPG
O2: 9.0 %
Temp:
175oC
Thermop
ac
20 Lakh
kcal/hr
Flue gas:
APH
6556 m3/hr
O2: 7.5 %
Temp: 283oC
Flame Modulation: High Flame

Scenario
Ambient air:
28oC
Combustion air: 4284

m3/hr
The flue gas analysis was carried out jointly by CII
results are tabulated below:
and plant team and the
14
Temperature
Thermopack TP 405
% O2
CO (ppm)
Thermopac immediate
outlet before APH
7.5
5.0
283
Air preheater outlet
9%
3.0
175
(Deg C)
The above figure clearly indicates higher combustion air is been supplied
leading to excess of oxygen in thermopac outlet. The CO levels were found to
be in very low range which indicates good condition of the thermopac and
possibility to further optimize the excess air to improve the performance
further.
Effect of excess oxygen
Controlled supply of combustion air is an important criterion for optimum
energy efficiency of a gas fired thermopack. This is because the heat loss
caused by the flue gas leaving the thermopack would be minimal when
controlled excess quantity of excess air near to stoichiometric quantity of
theoretical air required is supplied for combustion.
LPG requires around 15.6 kg to 16 kg of air per kg of LPG being fired. As
gasesous fuels have better combustion properties, the optimum quantity of
excess air to be supplied should not excess 10%. This corresponds to
oxygen concentration of 2% in the flue gas.
Higher air quantity supplied above this will result in increase carryover of
heat from the furnace without significantly aiding in the combustion
process. On the other hand, supplying lesser quantity of combustion air
than optimum may result in incomplete combustion and thus loose some
amount of heat energy in the form of unburnt fuel or Carbon-mono-oxide.
High air quantity additionally leads to higher combustion air blower power
consumption also.
Also provide the recommended value based on the mixability of fuel
leading to excess of oxygen in thermopac outlet. The CO levels were found to
be in very low range which indicates good condition of the thermopac and
possibility to further optimize the excess air to improve the performance
further.
Recommendation
15
We recommend the following:

Option 1:
Reduce the combustion air supply by altering the combustion air blower
damper in steps and measure the O2 and CO level.
Continue to reduce the combustion air supply in steps of 1 % reduction in
O2 at exit and observe the performance and reduce further to reach a level
of 2 % O2 at exit flue gas.
Purchase a portable combustion analyzer and regularly monitor O 2 and CO
level in flue gas to access the combustion performance.
Ensure that the following at the end of this trail
o O2 level should be maintained at less then 2% in flue gases
o Monitor the fuel consumption on daily basis to observe the saving
achieved
Saving in blower power consumption also would be achieved by reducing
the volume of air handled.
Saving of 6.48 Kg of LPG can be achieved by optimization of the combustion
air supply and around 1 KW of blower power consumption.
Option 2:
Install a combustion analyzer with auto controller with feedback control on
the combustion air blower panel to regular the frequency for capacity
control.
The analyzer can be fed with a auto set point of O2 % which would be
always maintained by feedback signal to the combustion air blower.
Minimum saving of 6.48 Kg of LPG can be achieved by optimization of the
combustion air supply and 2.5 KW of blower power consumption.
This arrangement rules out the requirement of regular monitoring and
always ensures consistent excess air supply irrespective any process
disturbances.
Benefits
Option 1:
Optimizing the combustion air supply to the thermopac by reducing the
combustion air by modulating the inlet damper and maintaining 3 % O2 at exit
flue gases would result in an annual savings of Rs. 21.75 lakhs. The
16
investment required for procuring a gas analyzer would be Rs. 3.50 lakhs
which would have a very attractive pay back of 2 months.
Option 2:
Optimizing the combustion air supply to the thermopac by reducing the
combustion air installing an online gas analyzer with a feedback controller to
the blower frequency control and maintaining 3 % O2 at exit flue gases at all
conditions would result in an annual savings of Rs. 22.30 lakhs. The
investment required for analyzer, controller and blower VFD would be Rs. 5.00
lakhs which would pay back on 3 months.
17

REVOMAX BOILER RXA06 FOR IMPROVING COMBUSTION
EFFICIENCY
and operational modulation of the burner in Revomax boiler RXA 06 (0.6 TPH)
were studied in detailed identifying possible energy savings opportunities.
Present Status
The boiler is already having a burner on and off modulation based on the exit
gas temperature set point.
The schematic of the Remomax boiler RXA 06 is as below
Temp: 96oC
O2: 6.5 %
Removax
LPG/HSD
Fired
RXA 06
Flue gas:
Temp: 196 C
1669 m3/hr
With in
built feed
water
economis
er
Ambient air:
28oC
Combustion air: 520 m3/hr

The flue gas analysis was carried out and the results are tabulated below.
Boiler RXA 06
% O2
CO (ppm)
Thermopac immediate
outlet before APH
6.5
43
Temperature
(Deg C)
196
18
leading to excess of oxygen in boiler outlet. The CO levels were found to be in
lower ranges which indicate good condition of the boiler and possibility to
further optimize the excess air to improve the performance further.
Effect of excess oxygen
Controlled supply of combustion air is an important criterion for optimum
energy efficiency of a boiler. This is because the heat loss caused by the
flue gas leaving the boiler would be minimal when controlled excess
quantity of excess air near to stoichiometric quantity of theoretical air
required is supplied for combustion.
LPG requires around 15.6 to 16 kg of air per kg of LPG being fired and for
HSD 14 to 15 kg of air per kg of HSD. As gasesous/liquid fuels have better
combustion properties, the optimum quantity of excess air to be supplied
should not excess 10%. This corresponds to oxygen concentration of 2% in
the flue gas.
Higher air quantity supplied above this will result in increase carryover of
heat from the furnace without significantly aiding in the combustion
process. On the other hand, supplying lesser quantity of combustion air
than optimum may result in incomplete combustion and thus loose some
amount of heat energy in the form of unburnt fuel or Carbon-mono-oxide.
Recommendation
Reduce the combustion air supply by altering the combustion air blower
damper in steps and measure the O2 and CO level.
Continue to reduce the combustion air supply in steps of 1 % reduction in
O2 at exit and observe the performance and reduce further to reach a level
of 2 % O2 at exit flue gas.
Purchase a portable combustion analyzer and regularly monitor O 2 and CO
level in flue gas to access the combustion performance.
Ensure that the following at the end of this trail
o O2 level should be maintained at less then 2% in flue gases
o Monitor the fuel consumption on daily basis to observe the saving
achieved
Saving in blower power consumption also would be achieved by reducing
the volume of air handled.
Minimum saving of 0.56 Kg of LPG/HSD can be achieved by optimization of
the combustion air supply.
19
Benefits
Optimizing the combustion air supply to the boiler by reducing the combustion
air by modulating the inlet damper and maintaining 3 % O2 at exit flue gases
would result in an annual savings of Rs. 1.00 lakhs. The investment required
for procuring a gas analyzer is already considered in the similar excess air
optimization project for thermopac operation and would have no additional
investment requirement.
20

OPTIMIZE THE TP 405 THERMIC FLUID PUMP OPERATION
BASED ON THE RESIN HOUSE REACTORS REQUIREMENTS
During the detailed energy audit at Asian Paints Limited, Patancheru, the
resin house reactor operation cycle and thermopac TP 405 (20 Lakh kcal/hr)
thermic fluid circulation pump operation was studied in detail to identify
possible optimization for the pump operation based on the heat demand of the
reactors.
Present Status
Presently TP 405 (20 Lakh kcal/hr) thermopac is used for providing heat
required for the process for five of the resin house reactors namely R-1, R-3,
R-6, R-8 & R-9.
It was observed that not all the reactors are in heating cycle at all the times
which result in by passing of thermic fluid from that particular reactor when it
is in cooling stage. However, the thermic fluid pump is continuously pumping
the thermic fluid in the circuit and is been routed though a bypass valve and
being sent to header (located after users) by control valves/manual valve
operation.
In this way, the pump is pumping the thermic fluid regardless of the
requirement at user and there exist a good potential to optimize the pump
capacity based on the user requirements.
The throttling at the end user will result in increase in back pressure to the
thermic fluid pump. This increase in back pressure will lead to reduction in
quantity of thermic fluid pumped by the pump and would lead to marginal
reduction in power consumption.
The pressure sensor provided in the common header will continuously monitor
the header pressure and give signal to the variable frequency drive. The
variable frequency drive will reduce / increase the speed of the pump to
maintain the set minimum header pressure.
Whenever the quantity of thermic fluid requirement reduces due to reduction
in requirement at the end user, the speed of the thermic fluid pump will be
reduced automatically with the help of pressure control via variable frequency
drive and would result in reduction in power consumption.
The schematic of the TP 405 thermic fluid circulation circuit is as below
21
R1
R3
R6
R8
R9
Bypass Valve
Thermopac
20 Lakh kcal
Flow: 110 m3/hr

Power: 31.8 KW
Recommendation
The thermic fluid pump is already installed with VFD
Interlock the thermic fluid pump discharge pressure header pressure to
the pump speed.
As per the optimization plan, thermic fluid pump speed can be varied
between 90 to 100 % of the rated speed.
As the pump seal air fan is build in pump main shaft, we recommend to
conduct trails during the night hours when the ambient air temperature
are lower compared to day time. (Caution should be taken in setting the
pump speed control limits to upto maximum reduction to 47.5 Hz)
Benefits
The annual energy saving potential by optimizing the thermic fluid circulation
pump operation based on the heat requirement in the resin house reactors
would be Rs. 0.31 lakhs which doesnt calls for any investment as VFD is
already installed in the pump.
22

REPLACE EXISTING AIR HANDLING BLOWERS WITH HIGH
EFFICIENCY BLOWERS IN INDUSTRAIL PAINT BLOCK
industrial paint block air handling blowers were studied in detail for possible
energy saving opportunity.
Phase I:
Two discharge blowers (VSP 301 & VSP 302) are used for ventilation purpose
in industrial paint block reactor floor for maintaining the air quality.
Phase II:
One discharge blower (VSP 305) and two exhaust blower (VSP 303 & VSP 304)
are used for ventilation purpose in industrial paint block reactor floor for
maintaining the air quality.
CII and plant team jointly carried out pressure and flow measurements in the
blowers
The detailed flow and pressure measurements are as follows:
Fan
Number
VSP301
(Blower 1)
VSP302
(Blower 2)
VSP303
(Exhaust 1)
VSP304
(Exhaust 2)
VSP305
(Discharge1)
Flow
(m3/hr)
43000*
Flow
(CFM)
25298
Power
(KW)
19
Efficiency SEC
SEC Norm
(%)
(W/CFM) (W/CFM)
0.75
0.18
39347
23149
17.79
28
0.77
0.18
43801
25770
8.55
56
0.33
0.18
45512
26776
8.46
49
0.32
0.18
69386
40822
28.44
48
0.70
0.18
* Actual flow to system for VSP 301 was measured to be 22480 m3/hr. This
reduced flow was mainly due to leakage at immediate blower discharge
ducting. For calculation the specific energy consumption (SEC) the rated flow
was considered for comparing the savings possible.
The specific energy consumption of the blowers were measured and are
compared with the specific energy consumption of high efficiency blower of
comparable capacity.
23
Blower VSP 303 AND VSP 304 SEC is in the range of 0.32 to 0.33 W/CFM
whereas for the other three blower is over 0.70 W/CFM. This clearly indicates
lower operating efficiency of the blowers.
Recommendation
Phase I
Replace the discharge blower VSP 301 & 302 with either a two new high
efficient blower of 40000 m3/hr capacity.
Considering the new operating SEC of 0.25 W/CFM, the saving potential
for phase I blower would be 18.7 KW.
Phase II
Replace the discharge blower VSP 305 with a new high efficient blower of
70000 m3/hr capacity.
Benefits
Replacing the low efficiency blower with new high efficiency lower SEC blower
would result in an annual saving of Rs. 13.45 Lakhs. This calls for an
investment of Rs. 14.50 Lakhs for installation of new blower and would have
an simple payback of 13 Months.
24
OPTIMIZE THE OPERATION OF WBU COOLING WATER

PUMPS
During the detailed energy audit at Asian Paints Limited., Patancheru Unit
the cooling water pumps in WBU section were studied in detail for identifying
Present status
In WBU section, there are two nos of reactors of capacities 3 kL & 5 kL.
Approximate batch cycle time in each reactor is 8hrs. Exothermic reaction
takes place in the reactor for 4 hrs. Jacket cooling is required during this
phase. 5kL reactor has three jackets and 3kL reactor has two jackets.
One pump catering to the water requirement each for one reactor is installed
to circulate cooling water through the reactors. Control valves (ON/OFF) are
installed for all the jackets in two reactors. Control valves gets open and close
based on the material temperature in the reactor.
The layout of schematic operation when only 5kL reactor was in cooling phase
is as follows:
As indicated in the figure, when only 5kL reactor pump was running,
recirculation of 27 m3/hr (22%) was observed through 3 kL pump. When only
3kL pump was running, recirculation of 15 m 3/hr (12%) was observed through
5kL pump.
25
Minimum recirculation in the circuit is 15m3/hr when any one reactor runs.
Recirculation is happening due to the failure of non return valves (NRV). This
results in higher power consumption of the pump.
Plant team have already replaced existing NRVs with new ones. CII
congratulates the plant teams efforts in replacing passing NRV to
avoid recirculation.
Temperature difference across each reactor is only 1.5 0C. Minimum
temperature difference that can be maintained across any heat exchanger is 340C. This indicates there is an excess flow through reactor, can be optimized.
A trail can be taken by throttling the pumps in steps of 10% till temperature
difference of 40C is achieved across the reactor. Simultaneously, please
monitor the reactor bulk temperature, as it is critical.
The cooling requirement for each equipment was analyzed in WBU section.
After assessment the combined cooling requirement in WBU section for
(Reactors, LDV, 70TR chiller) is 200TR.
The details are given as below:
S.No
User
Cooling load
(TR)
3 kL Reactor
50
5 kL Reactor
46
LDV
15
70TR Chiller
condenser
90
Total
200
Each equipment runs at a different batch cycle time. When all the equipment
run simultaneously, the cooling requirement is maximum, i.e., 200TR.
But the installed capacity of the cooling tower is only 120TR. Because of this
insufficient cooling tower capacity, chilled water is being used to cool return
cooling water from the users during summer. Installing one more cooling tower
of 120 TR capacity will increases the heat rejection capacity & cooling
efficiency. And the need to use chilled water to cool the return cooling water
during summer can also be avoided, which is an energy intensive method.
Recommendation
We recommend to
26
Avoid recirculation by installing new NRV

o Plant team have already replaced existing NRVs with new ones
Install auto control valve at the outlet of the reactor
Control the flow through reactor based on the temperature difference

across the reactor
Increase the T set value slowly in steps of 10C up to 40C
Install VFD for one pump and operate only that pump even for 2 reactors
Operate VFD based on the header pressure 2.5 kg/cm2
Before installing VFD, plant can take a trail by reducing the flow by
throttling the pump in steps of 10% till temperature difference of 40C is
achieved across the reactor
Install a separate cooling tower of 120TR for chiller condenser and avoid
using chilled water to cool return water during summer
Benefits
Implementing the above recommendation will save Rs 1.90 Lakhs annually.
This requires an investment of Rs 3.0 Lakhs for VFD, control valves & new
cooling tower, which will be paid back with a simple pay back period of 19
months.
27
OPTIMIZE THE OPERATION OF LDV COOLING WATER

PUMP IN WBU SECTION
the LDV cooling water pumps in WBU section were studied in detail for
identifying energy saving opportunity.
Present status
There are two LDVs installed in WBU section. Only one LDV will be in service
at a time.
After cooling the entire mass in the reactor to 65-70 0C, material will be sent to
LDV. Total batch cycle time in LDV is 4hrs. In LDV, addition of digestion
material takes place for 2 hours, is an exothermic process. Cooling is required
during this period.
The whole material is maintained at 70 0C for 1 hour. After this, material should
be cooled to below 500C.
One cooling water pump is installed to circulate the water through LDV. Control
valves (ON/OFF) are installed for LDV, opens and closes based on the material
temperature.
The schematic layout of the operation is shown as below:
28
The temperature difference across LDV is only 20C. For a heat exchanger, the
minimum temperature difference that can be maintained is 4 0C. This indicates
excess flow through LDV which , can be optimized.
This can be done by throttling the pump or installing VFD and operating it with
pump discharge pressure as feedback.
Trail can be taken by throttling the pump in steps till the temperature
difference of 40C is achieved & simultaneously monitoring the material
temperature.
Optimizing the flow by reducing the speed with VFD will save more power.
Recommendation
We recommend to
Before installing VFD, trail can be taken by throttling the pump in steps
till temperature difference across LDV reaches 40C.
Install VFD for the pump
Operate VFD in closed loop with the header pressure
Benefits
Installing VFD and operating VFD in closed loop with header pressure will save
Rs 0.44 Lakhs annually. This requires an investment of Rs 0.60 Lakhs,
which will be paid back with a simple pay back period of 17 months
29
OPTIMIZE THE OPERATION OF NEW BAZAAR COOLING

WATER PUMPS
the New bazaar cooling water pumps in WBU section were studied in detail for
Present status
Seven pumps are installed for the cooling water requirement of resin house
section.
The flow and head measurements were taken by operating each pump
individually to study the performance of all the pumps and the details are
shown as below:
S.No Pump Flow (m3/hr) Head (kg/cm2) Eff (%) Running hours
1
490
49
0.4
8.3
3500
491
25
0.2
2400
492
71
1.2
58.5
5500
470
74
2.6
27
160
481
28
39
100
482
64
3.7
58
1300
483
3500
The following observations can be made from the measurements

Pumps 490, 491 & 492 are pumps of same specifications. But, it can be
observed that pumps 490, 491 were delivering very less flow compared to
pump 492. This must be due to worn out impeller.
The operating efficiency of the 481 pump is less compared to that of the pump
482.
Recommendation
We recommend the following
Replace the existing impeller with a new one for the pump 491
Avoid running the pump 490, 491 till the impeller gets replaced
30
Run only pump 492 as it can deliver required flow

Run higher efficient pump for maximum number of hours
Benefits
Implementing the above proposal will save Rs 1.0 Lakh annually. This
requires an investment of Rs 1.0 Lakh for new impeller, which will be paid
back with a simple payback period of 12 months.
31
OPTIMIZE THE OPERATION OF INDUSTRIAL COOLING

WATER PUMPS
the industrial cooling water pumps in WBU section were studied in detail for
Present Status
Three pumps are installed to circulate the cooling water through the heat
exchangers of industrial reactors & solvent recovery plant. Out of the three
pumps, one is kept stand by.
The schematic layout of the pumping circuit is shown as below:
Cooling tower fans were operating based on the cold well temperature. Fans
switch on when cold well temperature reaches 270C and switches off when it
reaches 250C.
When measurements were taken, CT fans were in OFF condition. Even when
the fans were in OFF condition, 20C cooling was being achieved.
Generally, cooling tower are designed to give a range of 6-80C. By switching on
the fans and running them continuously, cooling tower can give minimum
range of 40C i.e., range will get doubled. Cooling water flow can be halved.
Currently, 2 pumps are running continuously and delivering 93m3/hr (P458)
and 62m3/hr(P457) continuously. Total cooling water flow is around 150m 3/hr.
32
One pump P457 can be switched off. Then the second pump (P458) will deliver
more flow than before as the system resistance reduces as the cooling water
flow reduces.
The power consumption of the second pump can be optimized by installing
VFD and operating it with pump discharge pressure of 2 kg/cm 2 as feedback.
Cooling tower fans can be installed with VFD and operated in closed loop with
cold well temperature interlock of 320C.
Recommendation
Run the cooling tower fans continuously
Install VFD for CT fans and operate the VFDs in closed loop with the cold
well temperature of 320C
Switch off the pump P458
Install VFD for the pump P457
Operate the VFD in closed loop with the discharge header pressure of 2
kg/cm2
Benefits
Optimizing the operation of industrial cooling water pumps will save Rs 1.60
Lakhs annually. This requires an investment of Rs 4.20 Lakhs, which will be
paid back with 5 months
33
REPLACE INEFFICIENT PUMPS WITH NEW EFFICIENT

PUMPS
the performance of the water pumps in the plant were studied in detail for
The water flow and head measurement was carried out for all pumps in the
plant. The design parameters and measured values are as follows.
Pumps
Tag #
70 TR chiller
monomer pump
70 TR chiller hot well
pump
Pump house P504
Design
Parameters
Operating Parameters
Motor
Flow Head Loading Efficiency
m3/hr (m)
kW
%
Flow
m3/hr
Head
(m)
60
43
21.00
24
6.15
24
18
33.00
10*
2.4
41
11-39
21.00
32
5.79
34
23.5-9.5
The operating efficiency of above pumps is low due to mismatch between the
design and operating head / ageing of the pumps / low efficiency by design. In
* marked pumps head is estimated value as provision for measuring pressure
was not available.
Give curve to explain how head mismatch happens
Recommendation
It is recommended to replace the pumps (70 TR chiller monomer pump, 70TR
chiller hot well pump, pump house P504) with new pumps of efficiency >70%.
Specifications of 70TR chiller monomer pump:
Flow
25 m3/hr
Head
25 m
Efficiency
> 70%
Benefits
Installing new high efficiency pumps in identified areas will save Rs 1.0 Lakh
annually. This requires an investment of Rs 3.50 Lakhs for three new pumps,
which will be paid back with a simple pay back period of 42 months.
34

COMPRESSORS IN THE PLANT
OF
THE
AIR
Present status
During the detailed energy audit of Asian Paints Limited Patancheru, a detailed
study of all the compressed air units was carried out for possible energy saving
opportunities.
The plant has installed a centralised compressed air system consisting of two
screw compressors.
The following observations were taken from these compressors:
Compressor
P405
P406
Location
Compressor
House
Compressor
House
Loading
Pressure
bar
Unloading
Pressure
bar
Average
Pressure
bar
Power
kW
5.7
6.2
5.95
88.30
5.5
6.0
5.75
86.03
The compressed air applications and pressure requirements are:

Open/Close valves
4.0bar
Storage tanks & digesters (pipeline)

Conveying (Diverter valves)
Packing Machines (LFM, VFM & FPM)
35
Cooling Water circulation

Steam circulation
Hopper Aeration
3.0bar
Bag Filters
4.0bar
Sheen Machine (Paint spray)
3.0bar
AOD (Diaphragm Pumps)
4.0bar
Lid Pressing (LFM, VFM & FPM)
5.0bar
Cleaning Purpose
3.0bar
It was also observed that the packing machines were installed with additional
booster compressors, which cater to the higher pressure compressed air
requirements of these machines. CII congratulates the plant team for this
excellent initiative towards energy conservation activity.
Presently the compressors are generating compressed air at the pressure
above 5.7 bar and there is a very negligible pressure drop in the compressed
air lines.
Higher operating pressure results in increased power consumption of the
compressor. Hence, there exists a good potential to reduce the power
consumption of the compressors by reducing the pressure generated by the
compressor.
Recommendation
We recommend to reduce the pressure setting of the compressor in the steps
of 0.2 bar and keep on reducing it until the generating set points are:
Load point
- 4.2 bar
Unload point
- 4.7 bar
Detailed energy saving calculations are shown in the back up sheet.

Benefits
The annual energy savings achieved by implementing this project is Rs. 9.9
Lakhs. This does not require any major investment.
36
MINIMISE COMPRESSED AIR LEAKAGE IN THE PLANT

Present status
During the course of the detailed energy audit at Asian Paints Limited,
Patancheru Unit, detailed study was carried out all compressors and the
compressed air lines for possible energy saving opportunities.
The compressed air distribution system is a major potential area in any
chemical plant. Proper utilization and proper distribution system lead to
substantial energy savings.
Leakage of compressed air was also observed in the plant during the audit.
Generally, valves and flanges are more prone for leakage.
Sl. No.
Area
Leakage (%)
Total Leakage
47
Water Based Paint Unit
24
Solvent Based Paint Unit
12
Industrial Paint Unit & Resin Block
11
Following are the identified leakage points:

Solvent Based Paint Block Ground Floor
1. Mixer no.244 pigging line, Pneumatic valve leakage (Major)
2. VFM - P215 tub cut-off pneumatic valve leakage
3. Lid pressing machine LP P217 cylinder leakage
4. VFM P209 cut-off pneumatic valve leakage
5. Near mixer 219 pigging line, pneumatic valve leakage
7. LP 203 FRL leakage
8. H-6 QRL leakage
10. FPM lid placing unit control panel (Heavy Leakage)
11. FPM orientation unit control panel (Heavy Leakage)
12. Leakage in Tin Pusher units Both control panels
13. At AML area near mixer 253, lid pressing unit FRL leakage
37
Solvent Based Paint Unit - First Floor (Processing)

14. Work centre 1, pneumatic valve leakage near FMT P201
15. Sand mill P201 diaphragm pump air inlet line leakage
16. Behind sand mill 202 diaphragm pump air inlet leakage
18. Pneumatic valve leakage above drier tub 1
19. Behind sand mill 209 copper tube leakage
20. Near OHM 209, diaphragm pump inlet line valve leakage
21. Minor leakage in TR P202, additive tub inlet valve leakage
22. Dust collector TSD 211 air inlet line leakage QRC fitting
Industrial Paint Unit
23. LP P304, pipeline leakage
24. SMP 311, diaphragm pump pipeline leakage
26. VSP 351, diaphragm pump pipeline leakage
Resin House
28. Auto control valve near pre coating tub TRP 408
29. Cut-off valve TRP 407
30. Header FM 10, FM 6 near platform Opp: TRP - 404
31. BL 408 bottom valve copper tube fittings
32. CA inlet to BL P413
Resin House (1st Floor)
33. Solenoid valve BLP418
34. Compressed air pipeline
35. CV BLP 402
36. Steam condensate R7 tub middle Control Valve
37. Steam condensate drain valve 3rd coil
38. FRL bottom near R7 tub
39. Control valve in R7 tub middle cooling inlet line
38
40. FRV bottom

41. DLP 406 condensate cooling line Control Valve
42. Control valve vent line is open O/L
Resin House (2nd Floor)
43. Sorbital control valve I/L line R9
44. FRL near R9 (Exhaut R9) push button station
45. FRL bottom air header (near D1-1 function box)
46. Condenser cooling I/L R1 reactor
47. Bypass line thermo pack opposite to vacuum cooler area
Resin House (3rd Floor)
48. FRV I/L header TP2 expansion tank
49. Auto control valve not in use R7 condenser
50. Auto control valve to inlet line to condenser H 10 (M-seal Kept)
51. Copper tube opened
52. LFM P121 solenoid spool valve
53. LFM P121 valve at the bottom of the funnel
54. From QRC near LFM P116, poor silencer valve
55. LPP 131 silencer 2 Pts
56. LFM 124 FRL top damaged
57. Mixer P147 bottom cut-off valve leakage from upper tube
58. Air header near mixer P153 QRC leakage
59. Mixer P161 leakage from copper tube
60. Air header near LDV P165
61. STP 175 near auto control valve silencer
Water Based Paint Unit (1st Floor)
62. FRL unit pug mill inlet to purging line 789
63. PM 181 gate valve FRL inlet fitting
64. PM 184 bottom of FRL
65. PMP 186 bottom gate valve seal leakage
39
66. FRL header near TDS P105

Water Based Paint Unit (2nd Floor)
67. SVA & SVE two different headers liquid trolley area
68. Diverter valve : control cylinder inlet force pipe fitting
69. Pug mill hopper 183 I/L to purge line 3rd from top
70. Pug mill hopper PH 181 I/L to purge line
71. Diverter valves
Terrace
72. Vent line in hopper no 2
73. Hopper no - 5
It is difficult to find out the leakages in a continuous process plant. The ideal
time to find out the leakages is during shut down time by conducting a leakage
test.
A simple procedure for conducting leakage test is:
Close all the user end points
Start the compressor and allow it to run
If there are no leakages, the compressor once unloaded should not load
again as there is no consumption at the user point
If there are leakages, it will operate in load and unload mode
Note down the loading and unloading time of the compressor. The
percentage loading indicates the percentage leakage.
Walk along the compressed air lines to identify the leakage points
Arrest the leakage at all the identified points
However, leakage test and arresting leakages is not one time activity. It is a
continuous activity. Leakage may not be avoided but can be brought down to a
very minimum level by continuous efforts.
Recommendations
It is recommended to
Avoid unwanted purging of compressed air
Arrest the leakages at identified locations
Avoid the use of High Pressure compressed air for cleaning
40
Increase the awareness among the operators and the workers on the value
of compressed air
Conduct leakage test during shut down time
Identify & arrest the leakages
Considering reduction in the leakage to 30% from the current values,
Benefits
The annual energy saving potential by arresting the compressed air leakage
points is Rs. 11.54 Lakhs. This does not require any major investment.
41
Observation
42
OBSERVATION No. 1
ADEQUACY OF LUX LEVELS AT VARIOUS LOCATIONS

During the course of detailed energy audit at Asian Paints, Patancheru
Unit, detailed lux measurements were carried out in the plant. The lux levels
were measured and compared with the recommended standards.
The purpose of Industrial lighting is to aid as a production tool, aids safety and
maintains the comfort and well-being of the users. Good industrial lighting
should take care of adequate quantity and good quality of illumination.
BEE recommends the following lux levels to be maintained for different tasks
of Industrial lighting.
The recommended lux levels are mentioned as a range: L R H
The R represents the middle value that generally applies
H is used in cases where visual work is critical and errors are costly to rectify
L is used when speed and accuracy is not important and task is executed
occasionally.
Source: BEE Energy Efficiency in Electric Utilities, Lighting System
43
The lux measurements were carried out at various locations in the plant,
during the detailed energy audit. The lux levels were low at the following
areas:
Location
Time
Avg lux
Recommend
ed Lux
Pug Mill platform
23
100
Corridor- 1
28
100
Filling area
58
100
Pug Mill platform
23
100
Corridor- 1
20
100
Filling area
27
100
Filling vessels
18
100
Reactors area
101-105
33
100
Reactors area
159-167
22
100
Process area
34
100
Pugmill area- 1
49
100
Pugmill area- 2
26
100
Liquid storage
25
100
Filling vessels
20
100
Reactors area
101-105
22
100
Area
Day time
WBU - Ground
floor
Night time
WBU- First
floor
Day time
Night time
44
Day time
WBU Second floor

Night time
Day time
Reactors area
159-167
18
100
Process area
34
100
Pugmill area- 1
40
100
Pugmill area- 2
30
100
Liquid storage
25
100
Reactors
28
100
Walk away
corridor
27
50
Hoppers
65
100
TSD
24
100
Storage area
34
75
Reactors
20
100
Walk away
corridor
18
50
Hoppers
30
100
TSD
38
100
Storage area
20
75
Below tanks &

filling stations-
53
100
61
100
70
100
circle 1
Below tanks &
filling stationscircle 2
Below tanks &
filling stationscircle 3
45
Below tanks &

filling stations-
77
100
56
100
56
100
80
100
89
100
Corridor
37
50
BOPT changing
area
27
100
Process stations
-1
62
100
Process stations
-2
43
100
Process stations
-1
47
100
Process stations
-2
22
100
Corridor
19
50
Day time
Below tanks
36
100
Night time
Below tanks
18
100
Process stations
-1
68
100
circle 4
Below tanks &
filling
stations -circle 1
Below tanks &
filling
stations -circle 2
SBU Ground
floor
Night time
Below tanks &

filling
stations -circle 3
Below tanks &
filling
stations -circle 4
Day time
SBU
First floor
Night time
SBU MF
SBU - second
floor
Day time
46
Night time
Day time
IPU GF
Night time
IPU FF
Day time
Night time
Process stations
-2
34
100
Corridor
32
50
Process stations
-1
50
100
Process stations
-2
20
100
Corridor
16
50
Mixer/packing
floor ph- 1
63
100
Batching area
18
100
Mixer/ packing
floor ph -2
30
100
Mixer/packing
floor
34
100
Batching area
15
100
Mixer/ packing
floor ph -2
19
100
Mixer floor area

Ph -1
48
100
Premixing area
Ph-1
56
100
Mixer floor area

Ph-2
51
100
Passage area Ph
-2
29
50
Mixer floor area

ph -1
14
100
Lab area ph -1
86
100
Premixing area
ph-1
19
100
22
100
Mixer floor area

Ph-2
47
Day time
IPU SF
Night time
Day time
Passage area Ph
-2
22
50
Spray booth
room Ph - 2
43
100
SM/TR area
77
100
TSD/ATT area
53
100
FG storage area
25
100
Solvent storage
tank area
42
100
Reactor area
(355-389)
25
100
SM/TR area
34
100
TSD/ATT area
17
100
FG storage area
15
100
Solvent storage
tank area
41
100
below and
behind tanksleft side
47
100
below and
behind tanksright side
21
100
Corridor
37
50
MCC room
20
200
below and
behind tanksleft side
12
100
below and
behind tanksright side
10
100
50
17
200
RH GF
Night time
Corridor
MCC room
48
Day time
RH- MF
Night time
Tank area
20
100
entrance corridor
33
50
filter areas
63
100
Tank area
20
100
entrance corridor
33
50
filter areas
63
100
50
Reactor area- left
32
100
Reactor arearight
36
100
Charging area
36
100
MCC room ph-1
31
200
MCC room ph-2
15
200
Reactor area- left
28
100
Reactor arearight
30
100
50
Charging area
15
100
MCC room ph-1
22
200
MCC room ph-2
20
200
stair case
Day time
RH- SF
Night time
Walk way
corridor
It is recommended to improve the lux levels in these areas. Instead of

replacing the lamps with the same no. of LEDs, as suggested in the previous
proposals, the plant team may go for slightly higher watt lamp/ more no of
lamps to improve the lux levels. Task lighting can be provided at required
locations, to meet the standards. IS 6665 suggests that distribution of light
with a maximum and minimum illumination at any point should not be more
than one-sixth above or below the average level in the area. Strip lighting can
be used to maintain uniformity.
49
OBSERVATION No. 2
HARMONIC MEASUREMENTS
During the course of detailed energy audit at Asian Paints,
Patancheru Unit, harmonic measurements were carried out in detail.
Harmonics are measured at the transformer and main incomers at the
following locations:
Location
THD-V%
THD-I%
Main incomer
0.9
4.3
Transformer
2.6
6.3
WBU 1
2.2
22.3
WBU 2
2.7
16.8
Resin House 1
2.7
8.5
Resin House 2
2.6
4.2
SBU 1
2.9
10.5
SBU 2
2.9
5.9
IPU 1
16
IPU 2
8.6
Recommendation
In most of the places, harmonic levels are with in the permissible limit of 5%
for voltage harmonics and 15% for current harmonics (as per IEEE standard).
It was observed that % Current THD is higher than the permitted range at
WBU and IPU.
The 5th order current harmonics were observed to be high at WBU and IPU.
50
Order of harmonics
WBU 1
I1= 187.2 A
WBU 2
I1= 193.5 A
IPU 1
I1= 95.6 A
THD
22.3 %
16.8 %
16 %
3rd
0.4 %
3%
0.6 %
5th
22.4 %
18 %
10.2 %
7th
4%
7.7 %
8%
9th
0%
1.8 %
1.1 %
11th
0.4 %
3.1 %
4.2 %
The harmonics above the recommended values may result in failure of

capacitor banks, mal functioning of relays and false tripping of breakers,
overheating of motors and transformers. It is recommended to install
harmonic filters at WBU and IPU after carrying out detailed study.
A trail was carried out to assess the impact of reactors installed in IPQP panel
in the following scenarios:
Scenario 1: IPQP switched off (All capacitors and reactors switched off)
Scenario 2: Capacitor panel MCCB on
Scenario 3: Manual operation of Capacitor and reactor
Scenario 4: Auto mode
The measured values are as follows:
It was observed that there isnt much difference in the harmonic levels with
the reactors switched on or off. These reactors can be shifted to the areas of
concern, to eliminate the 5th and 7th order harmonics.
51
52
OBSERVATION No. 3
REDUCTION OF DISTRIBUTION AND CABLE LOSSES

During the course of detailed energy audit at Asian Paints, Patancheru
Unit, the distribution system of the plant was studied for possible identification
of voltage drops and cable losses.
Simultaneous measurements were carried out at the PCC and MCC. The values
measured are as indicated below:
Location
Voltage at
PCC (V)
Voltage at
MCC (V)
Drop (V)
SBU 1
247.50
244.83
2.57
SBU 2
246.30
243.30
3.00
WBU 1
244.13
243.67
0.47
WBU 2
243.30
239.00
4.30
RH 1
244.83
241.00
3.83
RH 2
248.84
244.30
4.54
IPU 1
242.73
241.00
1.73
IPU 2
243.20
242.00
1.20
The voltage drop is recommended to be less than 4 - 5 V from main

distribution board to each sub-distribution per phase as per NEC. The voltage
drop is below the permissible limits
The voltage drop between the origin of the installation and the fixed current
using equipment should not exceed 4 percent of the normal voltage of supply
At one of the areas of concern, the compressor end:
Voltage drop per phase is 5.9 V from PCC to compressor
4% of 242 V= 9.68 V
The voltage drop is within the permissible limits.
The current carrying capacity of the cable is calculated to check if it the cable
size at present is as recommended. The specifications of the cable from RH to
compressor are as follows:
4C 300 sq mm cable
53
120 m length
20 m underground (open trench)
100 m in air cable tray
The current carrying capacity of the compressor cable is:
Current carrying capacity
381 A
De-rating factor of 0.71 for 500C

above ground
270.51 A
De-rating factor of 0.89 for 300C 300C

soil temp
339.09 A
The motor full load current is 159 A. It is in the permissible limits.
54
OBSERVATION No. 4
RECOVER HEAT FROM RESIN HOUSE CONDENSATE FOR
PREHEATING THE BOILER FEED WATER
resin house boiler and condensate recovery system was studied in details to
identify any possible energy savings.
The revomax boiler are used to provide steam to the industrial resin reactors
and the condensate from the reactor discharge is been collected in condensate
tank. The Condensate was observed to be at a temperature of above 60 Deg C
at all the time.
As the TDS levels of the condensate is very higher cause of intermixing of
cooling water and steam being passed though the same reactor coils it is not
possible to recycle the same condensate though the boiler feed water pump
due to increased chances of scaling in boiler coils.
This condensate at over 60 Deg C can be used for pre heater the boiler feed
water to reduce the boiler fuel consumption. The heat available in condensate
at 60 Deg C can be used for heating up the boiler feed water which is at 30
Deg C.
Preheating the boiler feed water would increase the feed water vapour
pressure which again can effect the NPSH of the boiler feed water pump. After
installation of heat exchanger for preheating boiler feed water from process
condensate would increase the water temperature to around 45 Deg C. The
vapour pressure of the water at 45 Deg C is 0.15 bar, so at all the time a
positive head of over 0.15 bar has to be maintained for smooth operation of
boiler feed water pump.
The water vapour pressure curve is as below:
55
Additionally after installation of a heat exchanger would lead to pressure drop

across the feed water side and the pump inlet pressure would get reduced and
the NPSH would get compromised.
Hence, to maintain the required pump NPSH and required pressure drop
across heat exchanger, the boiler feed water tank height have to be increased
from present location of around 3-4 m above the pump level to the top of the
building to increase the available head and the heat exchanger have to be
installed above the pump level. The condensate before being taken to storage
tank can be passed directly via heat exchanger.
At present the water to the tank is being taken via gravity and same line can
be used with the newer arrangement also.
Saving potential:
Boiler feed water temperature
30 Deg C
Condensate temperature
60 Deg C
Boiler feed water flow
0.65 m3/hr
Considering condensate flow
0.65 m3/hr
At least 10 Deg C increase in boiler feed water can be achieved at all the time
Heat savings
1 kcal/kg/Deg C x 650 kg x 10 Deg C
6500 kcal/hr
LPG GCV
10700 kcal/kg
Saving in LPG
6500 Kcal/hr
10700 kcal/kg
0.60 kg of LPG
Running hours
3000 Hours/Annum
Annual savings
=
0.60 kg x 3000 hrs/annum x Rs.
60/kg of LPG
=
Rs. 1, 08, 000
Say Rs. 1.08 Lakhs
Investment considered includes

1. For shifting the tank to the top of the building
2. For installation of heat exchanger (PHE) of flow 0.6 m3/hr of both fluids
3. For laying of new pipeline for both condensate and boiler feed water
56
Investment required
Rs. 4.0 Lakhs
Payback
Rs. 4.00 Lakhs x 12 months

Rs. 1.08 Lakhs
44 months
57
Chapter V
Management Aspects and Conclusions
58
CHAPTER V
MANAGEMENT ASPECTS & CONCLUSIONS

5.0
THE OBJECTIVES OF ASIAN PAINTS LIMITED, PATANCHERU

SHOULD BE
To make energy conservation a permanent activity at the plant
To achieve power consumption possible in the unit
To reduce the electrical energy consumption to the minimum
To have a firm top management commitment, so that, the company
achieves energy conservation on a time bound basis.
To implement the recommended proposals and reap the maximum
benefits
5.1
Approach to an Energy Conservation Idea

Each energy conservation idea should be seen as an opportunity for
improvement. The approach must be on how to implement each
proposal and overcome the problems, if any.
It is easier to say that a proposal is not possible or not implementable,
but the benefit comes from the actual implementation, which needs a lot
of courage, conviction, will power and perseverance to implement.
5.2
Specific Recommendations
Asian Paints Limited, Patancheru should form an energy conservation
committee. The committee should consist of senior operating, electrical
and maintenance personnel.
The committee should meet once in a month with a specific agenda to
review the progress of implementation of proposals and to guide the
implementation team.
Asian Paints Limited, Patancheru should also select a senior person as
energy manager and he should coordinate all the implementation
activities. The main responsibility of implementing the proposals and
achievement of savings should be with the concerned operating and
maintenance personnel and not with the energy manager.
The immediate task of Asian Paints Limited, Patancheru should be to
implement the identified proposals and get the savings.
We would recommend Asian Paints Limited, Patancheru to introduce a
suggestion scheme for energy conservation. The energy conservation
committee should review all suggestions and good proposals should be
implemented. The originator for the good suggestion, which has been
successfully implemented, has to be rewarded.
59
5.3
Assign Specific Responsibility

While the overall responsibility for energy conservation rests with the top
management, the concerned plant operating, electrical & maintenance
personnel should implement and report progress on energy saving
proposals.
Therefore, each energy saving proposal should be assigned to a specific
operating / maintenance personnel for implementation and monitoring.
The suggested format is enclosed as Annexure B.
Specific time bound action plan is required for implementation and
monitoring of energy saving proposals.
5.4
Monitoring of Proposals
All the implemented proposals are to be monitored on a proposal-byproposal basis for actual achievement of savings on a monthly basis.
5.5
Motivational Aspects
The successful management of energy depends on motivation of
technical personnel and their commitment. For this reason, Asian Paints
Limited, Patancheru should carry out the following motivational aspects
to sustain energy conservation activities.
Send operating, electrical and maintenance personnel for training
programs in specific areas like:
Pumps
Fans & Blowers
Air Compressors
Refrigeration and Air conditioning
Motors
Organise visits for executives to similar units to know the energy
conservation / process development, etc.
5.6
Conclusions
The Asian Paints Limited, Patancheru and CII Godrej GBC
teams have jointly identified 14 energy saving proposals worth an
annual savings potential of Rs. 98.81 Lakhs. The investment
required for implementation of energy saving proposals is
Rs. 75.0 Lakhs. The total investment will have a simple payback
period of 9 months.
Implementation of identified proposals should be given top priority
and should be done step-by-step.
60
5.7
Asian Paints Limited, Patancheru should

Assign specific responsibility for implementation of proposals
Monitor savings achieved on proposal by proposal basis
Monitor overall auxiliary power consumption and reduction in energy
consumption equipment-wise
Have the goal of becoming the best energy efficient unit in the
country
61
Annexure
62
AnnexureA
SUPPLIER ADDRESS
VFD and other drives
1. Rockwell Automation India Pvt.
Ltd. (Allen-Bradley India Ltd.)
C - 11, Industrial Area
Site - 4, Sahibabad
Ghaziabad - 201 010
Tel: +91 120 2895245, 2895252
Fax: +91 120 2895226
4. Danfoss Industries Pvt. Ltd.

296, Old Mahabalipuram Road
Sholinganallur
Chennai - 600 119
Tel : 044- 24503511-16
Fax: 044-24503521,18
E-mail: danfoss.india@danfoss.com
2. Asea Brown Boveri (ABB) Ltd.

Plot No. 5 & 6, II Phase
Peenya Industrial Area
P B No. 5806, Peenya
Bangalore - 560 058
Tel: +91 80 2294 9585
Fax: +91 80 2294 9389
5. Larsen & Toubro Ltd

Headquarters
Mount Poonamallee Road
Manapakkam
P.B.No.979, Chennai 600 089
Tel: 044-22526000, 22528000
Fax: 044-2249 3317
3. Control Techniques India Ltd.

117/B, Developed Plot
Industrial Estate, Perungudi
Chennai - 600 096
Tel : 044 - 2496 1123/1130/1083
044 - 42152091
Fax: 044 2496 1602
Email:
ct.india@controltechniques.com
6. Eurotherm DEL India Limited

152, Developed plots Estate
Perungudi
Chennai 600096
Ph: 044 24961129, 24961186,
24961230
Fax: 044 24961831
E-Mail: info.in@eurotherm.com
7. Siemens Ltd., Bangalore -A&D

3rd Floor, Jyoti Mahal.No.49
St. Marks Road
Bangalore - 560 001
Ph: 080 - 22042000, 22219450,
22219460, 22042000
Fax: 080 22224131, 22489320
8. Schneider Electric India Ltd.

(Corporate Office)
A-29, Mohan Co-operative
Industrial Estate, Mathura Road
New Delhi, Delhi
India - 110 044
Tel: 011- 41590000, 42590000;
Fax: 011-41678010/11/12
Email: in-care@in.schneiderelectric.com
63
ENERGY EFFICIENT MOTORS

1.
2.
Kirloskar Electric Co. Limited

Post Box No. 5555
Malleshwaram West
Bangalore 560 055
Tel : +91-80-23572111, 23371771
Fax : +91-80-23372488
Siemens Limited
Kalwe Works
Belapur Road
Thane 400 601
Tel: +91 22 27600001-04
Fax: +91 22 2762 3730
3.
ABB Global Services Ltd.

#49, 2nd Floor,
E-Wing Khanija Bhavan Race
Course Road
Bangalore - 560 001
6.
Baldor Electric India Pvt Ltd

19, Commerce Avenue
Mahaganesh Colony
Paud Road
Pune 411 038
Ph: 020 2545 2717 / 18
Tel: +91 80 22949150-53

Fax: +91 80 2353245
4.
Crompton Greaves Limited.

CG House, 6th Floor,
Dr. Annie Besant Road.
Worli, Mumbai - 400 030
INDIA.
Tel : +91 022 2423 7777
Fax : +91 022 24382288
5.
Bharat Bijilee Limited

37, Lady Curzon Road
II floor, Ramanashree Chambers
Bangalore 560 001
Tel: 080-25595547/ 25592646
Fax: 080-5592823
Email:
bblbangalore@blr.bharatbijlee.com
bblbangalore@gnblr.global.net.in
AUTOMATIC STAR-DELTA-STAR CONVERTOR

1. Vijay Energy Products Pvt. Ltd.
Sagar Apartmenst G F
No 23 Gopalakrishna Road
T Nagar
Chennai 600017
Tel: 044 28156540, 28152906
Fax: 044 - 28152906
Email: vijayenergy@eth.net
2. Excellent Industrial Instruments

1/63, E Type, SIDCO Nagar
Villivakkam, Chennai 600 049
Tel : 044 26172977
Fax : 044 26172531
Email: xlenergy@vsnl.net
Web: www.xlntenergy.com
64
LIGHTING ENERGY SAVER / LIGHTING TRANSFORMER

1. BEBLEC (INDIA) PVT. LTD.,
P.O. # 3411, 711, 6th " B" CROSS
3RD BLOCK, KORAMANGALA
BANGALORE - 560 034.
(KARNATAKA) INDIA
Phone: 91 - 080
25520831/25530831/25531752/255
35734
Fax: 91 - 080 25530807
e mail: info@beblec.com
2. Beblec (India) Pvt. Ltd.,
126, Sipcot Indl. Complex
Hosur - 635 126 (TN)
Tel : 91-4344276358/278658/276958/276959
Fax: 91-4344-276358/59
3. Beblec India Pvt. Ltd.
III, Anand Estates
J M C Compound
189/A, S G Marg
Mumbai - 400 011
Tel: 022 - 23080078/23073321
Fax: 022 - 23071494

Email: mumbai@beblec.com
4. ES Electronics (India) Pvt. Ltd.
No. 438, 4th Main Road, Nagendra
Block,
B.S.K. Ist Stage, Bangalore 560050
Karnataka, India
Ph: 91-8026420623/624/26728761/26727836
Fax: 91-8026420623/624/26728761/26727836
Key Personnel
Mr. R. Sekar (Managing Director)
Mobile: +91 - 9448491548,
9844136209, 919448354504
5. Jindal Electricals
390 A, Industrial Area-A,
Ludhiana-141003
Phone : 0091-161-2607271,
2220035, 2600051
Fax : 0091-161- 2600385
E-Mail :je@jindalelectricals.com
6. Servomax India Limited
No 38 E.C.Extn, ECIL (post)

Hyderabad-500062. INDIA
Ph: 91 40 27123927, 27123279
www.servomax.net
7. Consul Consolidated Private Limited
9/6, Ist Street, Venkateshwara Nagar, Adyar
Chennai -600 020, Tamil Nadu, India.
Phone : +(91)-(44) 24403473/24403476
Fax : +(91)-(44)-24403470
E-mail : consul@vsnl.com, npkrishnan@consulindia.com
65
AUTOMATIC VOLTAGE CONTROLLER/STABILIZER

1. Consul Consolidated Private
Limited
9/6, Ist Street, Venkateshwara
Nagar, Adyar
Chennai -600 020, Tamil Nadu,
India.
Phone : +(91)-(44)
24403473/24403476
Fax : +(91)-(44)-24403470
E-mail : consul@vsnl.com,
npkrishnan@consulindia.com
2. Neel Controls
# 112, Minerva Industrial Estate
P K Road, Near Hercules Hoist
Mulund (W)
Mumbai 400 080
Ph: 022 2560 3371 / 2569 5047
Fax: 022 2568 3211
Email: harit@neel.in
3. Jindal Electric & Machinery Corp.
C-57, Focal point, Ludhiana
141010
Ph: +91-161-2670250, 2676890,
2676968
Fax: 0161-2670252
E-mail: jemc@jindalelectric.com
4. Globe Rectifiers
Plot no. 211, sector-24
Faridabad-05, Haryana
Ph: +91-129-2237896/97, 4060708
Fax: 0129-2442072
E-mail:
globerectifiers@rediffmail.com,
gr@globerectifiers.com
5. Muskaan Engineers
423, Industrial area A
Ludhiana 03
Ph: +91-161-5088381
Fax: 5022381
Mob: 99157-03056, 94170-33948
E-mail:
info@muskaanengineers.com
6. Power Engineers & Consultants

E-731, Phase-VIII, focal point, Opp.
Hero cycle Ltd,
Ludhiana-10
Ph: +91-161-3294989
Fax: 0161-2303021
Mob: 9317562989, 9872862989
E-mail: business@powerengineer.biz
Energy Efficient Lighting

GE Lighting
Plot No. 42/1 & 45/14,
Electronic City - Phase II
Bangalore - 560100
Ph: +91-80-28528375-80 (Board
Numbers)
Lighting division Extn: 3128
Fax: +91-80-28528552
gelighting@geind.ge.com
Philips India Limited
Ashoka Estate, 9th Floor,
24, Barakhamba Road, Connaught
Place
New Delhi 110001
Ph: +91-1123353280
Ph: +91-1123321167
Fax: +91-1123314332
Email: s.k.dangi@philips.com
Asian Electronics Ltd.
D-11, Road No. 28
Wagle Ind. Estate
Thane - 400 604, India
Ph: 022 - 2583 5504 - 09
Fax: 022 - 2582 7636
OSRAM India Pvt. Ltd.
Signature Towers, 11th Floor
Tower B, South City-I
Gurgaon 122001,
Haryana, India.
Tel: +91-124-4081581,
+91-124-4150100
Fax: +91-124-4081577
Havells India Ltd. (Corporate office)

66
E-1, Sector 59, Noida-201307 (U.P.),

India
Ph: +91-120 - 2477777
Fax: +91-120 - 2583904 / 2588182 /
2477666
Havells India Ltd.
304, 308, 3rd Floor, 19th

Brigade Garden
Church Street, Bangalore-560001
Ph: 080-25594397-98
Fax: 080-25590130
E-mail: bangalore@havells.com
LED LAMPS
1. Binay Opto Electronics Pvt Ltd.
44, Armenian Street
Calcutta 700 001
Ph: 033 22103807, 22429082,
22102039
Fax : 033 22421493
Email: binay@vsnl.com
info@binayLED.com
3. Kwality Electricals Pvt. Ltd.

Mfg. Solar Modules & LED Lighting
3-6-145/9, Himayatnagar
Hyderabad 500 029
Ph: 040 2322 6889
Fax: 040 2344 0571
Email: gupta01@kwalityindia.com
kwality@kwalityindia.com
4. CKON VISIONS PVT. LTD.
Oberoi Chambers I
4th Floor, OPP. SAB TV
New Link Road, Andheri (West)
Mumbai - 400053
Ph : 022 - 26733398, 26733472, 73
Fax : 022 26742965
E-mail: ckonimpex@vsnl.net,
ckonimpex@gmail.com
2. Kanmur Electronics (P) Ltd. (LED

& Motor Control)
44, Puramprakasa road
Balaji Nagar, Royapettah
Chennai-600 014
Tel: 91-44-28130353/91-4428131982
Fax: 91-44-28131982
Email: kanmur@vsnl.com
5. OSRAM India Pvt. Ltd.

Signature Towers, 11th Floor
Tower B, South City-I
Gurgaon 122001
Haryana, India.
Tel: +91-124-4081581,
+91-124-4150100
Fax: +91-124-4081577
6. IC NASA LED Lights
Chandmor Agencies 10/76, Old
Anand Nagar
Next toReliance Energy, Santacruz
(E), Mumbai 400 055
Ph: 022 26101930 / 31 / 32,
Fax: 26102419
Contact Person Name
Mona 0 98201 22652
67
CAPACITORS
1. Momaya Capacitors
401, Madhav Apartments
Jawahar Road, Opp. Rly. Stn.
Ghatkopar (East)
Mumbai - 400 077
Tel: 022 - 25168281/82,
65754001/02
Fax: 022 - 2516 0758
4. EPCOS India Private Ltd.
2. Baron Power
No. 3, Karpagambal Nagar,
Mylapore, Tamil Nadu, India
Ph: +91-44-24356383/84/86,
42131849/50
Fax: +91-44-24356385
3. Meher Capacitors
Mr. Omer Kaiser

(Business Development
Manager)
Meher Capacitors (P) Ltd.
#52/1, Basappa Rd.,
Bangalore
Karnataka, India - 560027
Ph: 080-57704962
Mob: 09845019200
Fax: 080-22225325
14/2, Brunton Road

Bangalore 560 025
Tel : +91 80 40390615,
40390640
Fax : +91 80 40390603
sales.in@epcos.com
Mehta Industrial Estate
Mathuradas Vasanji Road
Chakala, Anheri (East)
Mumbai 400093
Tel: +91 22 26 83 26 50
+91 22 26 83 26 51
Fax: +91 22 26 83 26 45
11th Floor
28 Dr. Gopal Das Towers
Barakhamba Road
New Delhi- 110 001
Tel: + 91 11 23 70 41 43
+ 91 11 23 70 41 44
Fax: + 91 11 23 70 41 46
ENERGY MANAGEMENT SYSTEMS

1. Enercon Systems Pvt Ltd.
23, KHB Light Industries Area
P B No.6418, Yelahanka
Bangalore
Tel : 080 8460666 / 8460555
Fax : 080 8460667
Email : marketing@enercon.co.in
2. Conzerv Systems Pvt. Ltd.

44P Electronic City East Phase Hosur
Road, Bangalore - 560 100 INDIA
Ph: 91 80 4118 9700
Fax: 91 80 4118 9729
91 80 41102659
email: contact@conzerv.com
3. KLG Systel
Plot No. 70A,
Sector - 34, Gurgaon - 122 004
Haryana (India)
Telephone: +91 (0) 124-4129900
Fax: +91 (0) 124-4129999
e-mail : klg.ho@klgsystel.com
68
Product Infra red sensor for lighting energy saving

Blue Technologies
61, shreepal chambers, 481/c shaniwar peth,
opp shaniwarwada, Pune - 411030, India.
Tel : +91 20 65209611 T/ F : 24468058,
Cell : +91 9371042444, 9326042444
bluesachin@gmail.com
Fixed Speed Drive (Power Boss)
ASR Associates
Street No.71/2, 21st A Main
Marenahalli,
JP Nagar 2nd Phase
Bangalore 560 078
Ph: 91 80 26493204
Fax: 91 80 2665 1157
Email: info@asrgroup.net
Flat belts
2. Habasit-Iakoka Pvt. Ltd.
Goldwins
Civil Aerodrome Post
IND-Coimbatore, 641 014
Tel.: +91-(0)422-262 78 79, 262
84 20/21
Fax: +91-(0)422-262 72 14
Email:habasit.iakoka@habasit.com
1. Elgi Ultra Industries Ltd.

India House, Trichy Road
Coimbatore - 641 018. India.
Phone: 91 (422) 2304141
Fax: 91 (422) 2301377
Email: info@elgiultra.com
Cogged flat Belts

K. K. Rubber Company (India) Pvt. Ltd.
51, Rani Jhansi Road
New Delhi 110055, India
Telephone: +91 11 23619942, 23531215
23612072, 23679045
Fax: +91 11 23621862
Email: sales@kkrubber.com
Fenner India Ltd
Khivraj Complex II
V Floor, 480, Anna Salai
Nandanam, Chennai - 600 035
India
Tel: +91-44-24312450 to 57
Fax: +91-44-24349016, 24320193
ptd_mhq@fennermail.com
69
Agitators
1. Fluidyme Technologies
E-2/4, Popular Prestige,
Near Highway Bridge, Warje,
Pune-411058
Maharashtra, INDIA
TeleFax : +91-20-25293397
Mobile : 09422009479
E-mail :fluidyme@sanchaernet.in
fluidyme@yahoo.co.in
2. Pinnacle Equipments
Gat No - 103, Jyotiba Nagar
Talawade Road, Pune
Maharashtra - 412 114
Ph: 020-27690413/27690890 /
32661602
Fax: 020-27690413/32661602
3. Indofab Industries
Street Address: C/3, Hatkesh Udyog
Nagar
City: Thane
Maharashtra 400 606
Ph: + (91)-9820077092
4. Elof Hansson (India) Pvt. Ltd.
Old No 11, New No. 23
2nd Main Road
Raja Annamalai Puram
Chennai - 600 028
India
Ph: +91-44 461 7901/ 7905
Fax: +91-44 461 7907 / 790
Automatic Power Factor Controllers / Harmonic Filters

Baron Power Ltd
1, Second Cross Street
Seethamma Colony Extension
Teynampet, Chennai - 600018
TamilNadu, India.
Office: 044-24356383/84&86 /
42131849/50, Fax: 044-24356385
Office Mobile: 93810 47234
(Marketing), 93828 21143 (Technical)
Email: baronpower@vsnl.net
baronpower@satyam.net.in
corporate@baronpower.com
Crompton Greaves Limited.
CG House, 6th Floor
Dr. Annie Besant Road
Worli, Mumbai - 400 030
India
Tel: +91 022 2423 7777
Fax: +91 022 2423 7788
Cummins India Limited
Power Generation Business Unit
35 A/1/2 Erandawana
Pune 411 038
Ph: 020 6602 7525

Fax: 020 6602 8090
Contact Person
Mr. S Ravichandran
General Manager
Mob: 098220 93785
Email:
subramaniam.ravichandran@cummins.c
om
Neel Controls
#112, Minerva Industrial Estate
P K Road, Near Hercules Hoist
Mulund (W), Mumbai 400 080
Ph: 022 2560 3371 / 2569 5047
Fax: 022 2568 3211
ABB Limited
Khanija Bhavan, 2nd Floor
East Wing, No. 49, Race Course Road
Bangalore - 560 001
Ph: 080 - 22949150 to 54
Fax: 080 - 22949148
70
UPS
APC
# 16, Row House, Goyal Inter City
Behind Drive in cinema, Thaltej Road,
Thaltej
Ahmedabad, Gujarat 380 054
India
Ph: (079) 2684 0124/ 324
APC
# 5, Lake Avenue,
Near Mudiali Bus Stop
Kolkata, West Bengal 700 026
India
Ph: (033)2465 5519, 2463 0064
Numeric Power Systems Ltd

"Numeric House"
No 5, Sir P.S Sivasami Salai
Mylapore, Chennai - 600 004, India.
Phone: 91-44-2499 3266 (10 Lines)
Fax: 91-44-2499 5760, 24998210
Email: npsl.corporate@numericups.com
Emerson Network Power

Plot No. C - 20, Road No.19
Wagle Industrial Estate
Thane (West), PIN - 400604
Maharashtra
Tel: 022 67208000/8002/7800
Fax: 022 - 25828358, 25800829,
25824286
Consul Consolidated Private Limited

9/6, Ist Street, Venkateshwara Nagar, Adyar
Chennai -600 020, Tamil Nadu, India.
Phone: + (91)-(44) 24403473/24403476
Fax: + (91)-(44)-24403470
E-mail: consul@vsnl.com, npkrishnan@consulindia.com
Waste Heat Recovery

Thermax Ltd.
Dhanraj Mahal, 2nd Floor
Chatrapati Shivaji Maharaj Marg
Nr. Gateway of India
Mumbai - 400 039
Ph: 022 - 22045391, 22045324
Fax: 022 22040859
Thermax Limited
Process Heat Division
Fathima Akhtar Court
3rd Floor, 453, Anna Salai
Thermal Systems (Hyd) Pvt. Ltd.
Plot No.1, Apuroopa Township
IDA, Jeedimetla
Hyderabad - 500 055
Tel: 91-040-23091801-06
Fax(s): 91-040-23097433
info@thermalindia.com
Chennai - 600 018

Tel: 04424303400, 24353831-4
Fax: 04424353841
Thermax Limited
6-3-649, Nalanda Complex
2nd Floor, Somajiguda, Behind
Medinova
Hyderabad - 500 482
Ph: 040-23310254, 23312013
Fax: 040-23312335
Megatherm D'tech Pvt Ltd

Plot 150, Perungudi Industrial Estate
Perungudi, Chennai - 600096. INDIA
Phone: 91-44-65479255 / 42629008
Email ID : govinmega@sify.com /
govinmega@gmail.com
71
Furnace
Thermal Systems
Plot No.150, SIDCO Industrial Estate (NP)
Ambattur, Chennai - 600 098
Tamil Nadu, India
Ph: 044 - 42140877, 26257625, 26255790
Fax: 044 - 42140977
Email: thermalsystems@yahoo.com
thermalsystems@airtelbroadband.in
Radiant Recuperative Heaters

Thermax Babcock & Wilcox Limited
Energy Building, D1 Block, Plot No. 7/2
RD Aga Road, MIDC, Chinchwad
Pune 411019
Tel: 020 6612 6464, 6612 6411
Fax: 020 6612 6612
FRP BLADES FOR MANCOOLERS & AIR WASHERS
ENCON (INDIA)
2B/06, Shivkripa,
N. C. Kelkar Road, Dadar (West)
Mumbai - 400 028, India.
Ph: +91 22 2437 2949 / 2430 6578
Fax: +91 22 2431 0992 / 2432 1929
Email: enconindia@vsnl.com
Email: akrai@encongroups.com
Amalgamated Indl. Composites P. Ltd.
Unit No.111 /112, Ashok Service Industrial Estate
L.B.S. Marg, Bhandup (West)
Mumbai - 400 078. India
Tel: 022-25964566, Tele Fax: 022-25346920 / 25963611
Email: info@aicomposites.com
Compressors & compressed air systems

Elgi Industrial Complex
Trichy Road, Singanallur
Coimbatore - 641 005
India. Tel: 0422 - 2589555
Fax: 0422 2573697
Atlas Copco Compressor Sales
6-3-1191, 2nd Floor, Brij Tarang
Greenlands, Begumpet
Hyderabad - 500016
Tel: +91 40 32949090
Fax: +91 40 23417923
(Mr. Dhananjay Desai
Regional Manager)
Atlas Copco Compressor Sales
2nd Floor, Tellus Technologies Pvt Ltd, 209/1B/1A, Range Hill, Pune 411020, Ph: +91
20 32949090
Fax: +91 20 27145778
Mob: +91 9823014158
Email: d.desai@in.atlascopco
Ingersoll-Rand (India) Ltd Air Center
Solitaire Corporate Park IV
Unit 411-412, 1st Floor
Andheri-Ghatkopar Link Road
Mumbai 400093
Chakala, Andheri (East)
Ph: 022-6697-5555
Fax: 022-6697 5566
Godrej Group EE services
Mr H N Daruwala
Godrej & Boyce Mfg. Co. Ltd.
Pirojshanagar, Vikhroli,
Mumbai - 400079,
Maharashtra,
India.
Ph: +91-22-6796 5656 / 67965959
Fax No. : 91-22-6796 151
Denvik Technology Private Limited
H 11/5, Arundale Beach Road
Kalakshetra Colony
Besant Nagar, Chennai 600090
http://www.denvik.in
Contact Person
Vijay Krishna, Director, Business Development
Ph: 09840851800 Email: vijay@denvik.in
HOC Dryers
Gaso Energy Systems (I) Pvt. Limited

T-122 , M.I.D.C., Bhosari, Pune - 411 026
Tel. : + 91 20 2712 8823 / 3068 5256
Fax: 020 - 27119573
Email:kgiram@gasoenergysystems.com
Drytech Engineers
Sh. No. 12-15, Sapana Co.op. Hsg. Soc.,
Opp. Konark Vihar, Off. Pune-Satara Road
Dhankawadi, Pune - 411043. Maharashtra, INDIA
Tel : +91-20-24371445, 24376601
Fax : +91-20-24376789
Email: drytechengineers@eth.net, vbk_drytech@yahoo.co.in,
jmd_drytech@yahoo.co.in, response@drytechengineers.com
Energy Efficient Pumps

Sulzer Pumps India Ltd.
9 MIDC, Thane Belapur Road
Digha, Navi Mumbai 400 708
Ph: + 91-22-65134321-28, 39130500
Fax: + 91-22-2760 6814
E-mail: spisales@sulzer.com
Grundfos Pumps India Private Ltd.
118 Old Mahabalipuram Road
Thoraipakkam, Chennai 600 097
Tel: +91 44 2496 6800
Fax: +91 44 2496 6969
Kirloskar Brothers Ltd. Fax: +91 20 2444-0824,
Udyog Bhavan, Tilak Road, 2444-4198,2444-0156
Pune 411 002 (India)
Ph: +91 20 24440770
Email: kblin@kbl.co.in
Energy efficient fans

Dustech Engineers Pvt Ltd
Contact Person : Mr R K Gupta [Dir]
Address : P-27 2nd Flr malviya Ngr Mkt
New Delhi - 110017,
Delhi, India.
Telephone No. : 91-011-6686085
Aerotech Equipments & Projects (p) Ltd.
101-a, Ansal Sumedha, Raj Nagar Distt. Centre
Ghaziabad - 201001, Uttar Pradesh, India.
91-120-2710513 / 2711513
TCF-NADI Industrial Fans Pvt. Ltd.
Ponniammanmedu
No. 34, G.N.T. Road
Madhavaram, Chennai, 600 110 Phone: 91-44-2553-2206
Fax: 91-44-2553-2205
Email: nadiair@vsnl.net
Website: www.nadiindia.com
Low pressure drop flow meters

Emerson Process Management (India) Private Ltd.
D-Wing, 2nd Floor, Modern Mills Compound
Sane Guruji Marg, Jacob Circle, Mahalaxmi
Mumbai 400011, India
Tel +91 22 5662-0566
Fax +91 22 5662-0500
Email : Marcom@EmersonProcess.co.in
Switzer Instrument Limited
9, South Boag Rd. T.Nagar,
CHENNAI (Madras) - 600 017 India
Phone : +91-44-2434 0999/3956/4321
Fax: +91-44-24347887
email: sales@switzerinstrument.com
Chandak Instruments Pvt. Ltd.
G-004, Smruti, Opp. Dhanwatey
National College, Congress Nagar,
Nagpur-440012 (India)
Phone : +91-712-2420025
Fax
: +91-712-2420026
info@chandakinstruments.com
www.chandakinstruments.com
Air conditioning system

United Engineering Corporation
147, R P Road, Secunderabad-500 003
Telefax: 2754-5501, 1113, 3559, 2753-8956
Email: uecajay@gmail.com & hyd2_uecajay@sancharnet.in
Visit: www.smartcool.co.in
Transvector Nozzle
General Imsubs Pvt. Ltd.
3711/A, GIDC, Phase-IV, Vatva
Ahmedabad 382445, India
www.giplindia.com,info@giplindia.com
Ph: +91-79-2584 0845;
25842503; (M) 0 99984 20601
Computational Fluid Dynamics Study

Mr. V.T. Jadhav
Sr. Manager (Marketing)
Mech-Well Industries Ltd
7-A, Old Anjirwadi
Mazgaon, Mumbai 400 010
Contact No.:022-66200314 (Direct Line)
Fax No. 022-66200380
Mobile No. - 9223393614
E-mail: mechwell@vsnl.com; vtjadhav@gmail.com
Mr. Sanaka Prasad
CFD team leader
Satyam Intergrated Engineering Solutions - IES
Satyam Technology Center
Bahadurpally, Hyderabad
Mob: 9849273302
IES_Marketing@satyam.com
Insultions
Megha Insulations Pvt Ltd.
A-11/6th Floor, Dada Saheb Flats
Kalanala, Bhavnagar 364001
Ph: 0278-3004523/26
Fax: 0278-3004728
Email: mipl@meghainsulation.com
Contact Person
Mr H V Shah -98252-07723 & 94262-12823
Mrs. Madhu: 98795-46523
Energy Management Software

Manoj Telrandhe
Manager Knowledge Based Businesses & ITes
SEE-Tech Solutions Pvt. Ltd.
11/5, Lets Conserve, MIDC InfoTech Park
Near VRCE Telephone Exchange
South Ambazari Road, Nagpur-440 022
Mobile: +91-9975325831
Ph: 0712-2222177, Fax: 0712-2225293
Web: www.letsconserve.org
Email: utisave@gmail.com
seemil_ngp@sancharnet.in
Compressed Air Audit and Control Systems

1.
Godrej & Boyce Manufacturing Company Limited.

Godrej Electricals & Electronics, Plant - 1
Pirojshanagar, Vikhroli
Mumbai - 400 079, India.
Tel.: +91 22 6796 1700 / 1800
Fax: +91 22 6796 1525
Contact Details
Mr. Homi. N. Daruwalla
(Vice-President)
Godrej Electricals & Electronics
Tel.: +91 22 6796 2201
Email: hnd@godrej.com
Mr. Umesh V. Shah
(Chief General Manager)
Industrial Electronics & Automation
Tel.: +91 22 6796 2211
Email: uvs@godrej.com;
2.
Ingersoll-Rand (India) Limited.

Plot No. 35, KIADB Industrial Area
Bidadi, Bangalore - 562 109
Tel: +91 80 2216 6000
Fax: +91 80 2216 6022
Orchid Industrial Equiments & Energy Utility Services

New no 86, Velmurugan Complex
Arya Gowda Road, West Mamabalam
Chennai 600 033
Tele fax: 044 23712834
Email: orchidie@eth.net; orchidies@eth.net;
Mr S Baskaran
Mobile: 94440 10371
Suppliers for Computational Fluid Dynamics (CFD) Study
and Analysis
Mahindra Satyam Technology Centre
Bahadurpally Village
R R Dist, Hyderabad 500 043
Telephone: +91 40 3063 5082
Mr Rahul S. Tamboli
Telephone: 040-3063-5271
Mobile: +91-998-550-6261
Mech-Well Industries Limited

Head Office: Contact person
Mr V T Jadhav
Marketing Executive
Mobile: 09223393614
7 - A, Old Anijrwadi, Mazgaon
Mumbai - 400 010
Tel: +91 - 22 - 2373 74 54
+91 - 22 - 2374 23 54
Fax: +91 - 22 - 2371 94 46
PL Engineering Limited
(A Punj Lloyd Group Company)
76 Institutional Area, Sector 32
Gurgaon - 122001, India
Contact Person
Mr Priyaranjan Kumar
DGM - Business Development
Mobile: +91-9953950005
Direct: +91-124-339-3110
Disclaimer
While every care has been taken in compiling this list, Confederation of
Indian Industry does not accept any claim for compensation, if any entry is
found to be wrong, abbreviated, omitted or inserted incorrectly either as to
the wording space or position in the list. While attempts are being made
continuously to make the list as elaborate as possible, CII wishes to inform
that neither the list of technologies nor list of suppliers for a given product /
technology is comprehensive. The list is only an attempt to create awareness
on energy conservation and sharing of best practices being adopted in Indian
Industry.
FORMAT FOR MONITORING THE IMPLEMENTATION OF ENERGY SAVING PROPOSALS

Annual
Savings
(Rs. Lakhs)
Investment
Required
(Rs. Lakhs)
Payback
Period
(Months)
REPLACE THE 1X36W and 2X36W T5

LAMPS WITH 1X20 W LEDs
28
31
13
REPLACE 2 X 36 W CFLS WITH 18 W

LEDS
0.9
1.8
24
2.8
13
56
22.3
Sl.
No
0.31
RENEWABLE ENERGY FOR LIGHTING

(LONG TERM)
RESIN HOUSE THERMOPAC TP-405 FOR
IMPROVING COMBUSTION EFFICIENCY
RESIN
HOUSE
REVOMAX
BOILER
RXA06 FOR IMPROVING COMBUSTION
EFFICIENCY
OPTIMIZE THE TP 405 THERMIC FLUID
PUMP OPERATION BASED ON THE
RESIN
HOUSE
REACTORS
REQUIREMENTS
REPLACE EXISTING AIR HANDLING
BLOWERS WITH HIGH EFFICIENCY
BLOWERS
IN
INDUSTRAIL
PAINT
BLOCK
13.45
14.5
13
OPTIMIZE THE OPERATION OF WBU

COOLING WATER PUMPS
1.97
19
3
4
Person/Depa
rtment
Responsible
Target
Date
Remarks
OPTIMIZE THE OPERATION OF LDV

COOLING WATER PUMP IN WBU
SECTION
0.44
0.6
17
10
OPTIMIZE THE OPERATION OF NEW

BAZAAR COOLING WATER PUMPS
12
11
OPTIMIZE THE OPERATION OF

INDUSTRIAL COOLING WATER PUMPS
4.2
1.6
3.5
42
13
REPLACE INEFFICIENT PUMPS WITH

NEW EFFICIENT PUMPS
OF THE AIR COMPRESSORS IN THE
PLANT
9.9
14
MINIMISE COMPRESSED AIR LEAKAGE

IN THE PLANT
11.54
Total
98.81
75.0
12
Backup Calculations
81
REPLACE THE 1X36W and 2X36W T5 LAMPS WITH 1X20

W LEDs
Present status
T8 lamps were installed in the plant in the following areas: Production blocks,
engineering stores, DC, RMG, PMG and other office areas.
The power consumption of these T8 lamps is around 146 kW.
Operating
Watt
Quantity
Power in
kW
Other Offices
36w x 2
746
53.71
2432
Engg Store
36w x 2
40
2.88
2432
Production Blocks
(floor wise)
36w x 2
849
61.13
4984
BSR
36w x 2
90
6.48
4984
DC
36w x 2
10
0.72
4272
RMG
36w x 2
219
15.77
4984
PMG
72 w
80
5.76
4984
S.No
Location
Total
Power consumption of T8 lamps
hours
146.45
Say around 146 KW
Proposed
It is recommended to replace these T8 lamps with 1X20 W LEDs.
Power consumption of LEDs
Savings
2034 Nos X 20 W each
40.68 kW
Say 40 kW
146 - 40 kW
82
Say 106 kW
Annual Savings is calculated based on operating hours at individual locations.
S.No
Location
Watt
W1
Quantity
Nos (Q)
Power
in kW
Annual
Operating
hours (h)
Savings kW
= Q*(W120)
Savings=
kWhXRs
6.7/kWh
Other Offices
36w x 2
746
53.71
2432
38.79
6,32,059.78
Engg Store
36w x 2
40
2.88
2432
2.08
33,892.35
Production
Blocks (floor
wise)
36w x 2
849
61.13
4984
44.15
14,74,292.10
BSR
36w x 2
90
6.48
4984
4.68
1,56,278.30
DC
36w x 2
10
0.72
4272
0.52
14,883.65
RMG
36w x 2
219
15.77
4984
11.39
3,80,343.99
PMG
72 w
80
5.76
4984
4.16
1,38,914.05
2034
146.45
105.77
28,30,664.24
Total
Annual Savings
Rs. 28.30 Lakhs
Investment (Rs. 2000 for LED)
2034 X 1500
Rs. 30.51 Lakhs
(Investment) X 12 months
(Savings)
Rs. 30.51 Lakhs X 12 Months

Rs. 28.30 Lakhs
12.9 Months
Say 13 months
Payback period
83
REPLACE 2 X 36 W CFLS WITH 18 W LEDS

Patancheru, a detailed study of plant lighting load was carried out to
identify energy saving opportunities.
Present status
108 Nos of 2 X 36 W CFL lamps were installed in the admin block.
Power consumption of the CFL lamps
108 X 2 X 36 W
7.776 kW
Say 7.78 kW
Proposed
It is recommended to replace these CFL lamps with 1X18 W LEDs.
Power consumption of LED lamps
Savings in KW
Annual Savings in Rs.
Investment (Rs. 2000 for LED)
Payback period
108 X 18 W
1.94 kW
7.78 1.94 kW
5.84 kW
Say 5.8 kW
5.8 kW X 2432 hrs X

Rs. 6.7/kWh
Rs. 94,507/-
Rs. 0.94 Lakhs
108 Nos X Rs 2000/LED
2,16,000/-
Rs. 2.16 Lakhs
Investment X 12 Months
Savings
Rs.2.16 Lakhs X 12 Months

Rs.0.94 Lakhs
28 months
84
RENEWABLE ENERGY FOR LIGHTING (LONG TERM)

Patancheru, a detailed study of plant lighting load was carried out to
identify energy saving opportunities. The option of using renewable energy
for lighting was explored.
Present status
At present, 120 Nos of 70 W HPMV and 30 Nos of HPSV lamps are

installed for street lighting in the plant.
The power consumption of these lamps is around 10.5 kW.
Present power consumption
Energy consumption of LEDs
150 X 70 W
10.5 kW
150 X 18 W
2.7 kW
A 3 KW solar mill can be installed at the plant. A Solar Mill is a hybrid system
and taps solar and wind energy. It is suitable for operation at 2 m/s to 17 m/s
of wind speed. As it is a hybrid system, the capacity utilization is also high.
The street lighting requirement can be met through this.
Investment for LEDs
150 Nos X Rs. 2000/LED
Rs. 3.00 Lakhs
Investment for Solar Mill
Rs. 9 Lakhs
Total Investment
Say 13 Lakhs
Savings
10.5 kW X 4000 hrs

X Rs. 6.7/kWh
Rs. 2.81 Lakhs
Rs 13.0 Lakhs x 12
Rs 2.80 Lakhs
55 months
Simple pay back period
85

THERMOPAC
TP-405
FOR
IMPROVING
COMBUSTION
EFFICIENCY
and operational modulation of the burner in thermopac TP 405 (20 Lakh
Kcal/hr) were studied in detailed identifying possible energy savings
opportunities.
The savings is calculated considering 3 % of oxygen being maintained
at thermopac exit flue gases.
Present O2 at Thermopac outlet
7.5 %
Excess air supplied
7.5 x 100 %
(20.9 7.5)
55.9 %
Maintaining O2 at 3 % at themopac outlet the excess air would be

=
Present blower air quantity
3 x 100 %
(20.9 3)
16.7 %
4284 m3/hr
3885.5 Nm3/hr
Reduction in inlet air quantity i.e. reduction in Flue gases quantity

=
3885.5 Nm3/hrx(55.9%-16.7%)
1523.5 Nm3/hr
Flue gas temperature at APH outlet =
175 Deg C
Ambient temperature
28 Deg C
Heat savings
=
0.31 kcal/kg/DegC x 1523.5 Nm3/hr
x (175- 28) Deg C
=
69426 Kcal/hr
LPG GCV
10700 kcal/kg
Saving in LPG
69426 Kcal/hr
10700 kcal/kg
6.48 kg of LPG
5500 Hours/Annum
Running hours
86
Annual savings
=
60/kg of LPG
=
Rs. 21, 38, 400
Say Rs. 21.38 Lakhs
Present blower air delivery
Present blower power consumption =
4284 m3/hr
7.68 KW
Option 1:
Combustion
modulation:
air
supply
blower
capacity
controlled
by
damper
Reduction in air volume handled by combustion air blower at all time
Possible power saving in blower
55.9 % - 16.7 %
39.2 %
39.2 % x 7.68 KW
3 KW
Savings of only 1 KW is considered as most of the power would be lost across

the damper.
Annual savings
=
1 KW x 5500 hrs/annum x Rs.
6.7/KWh
=
Rs. 36,850
Thermal savings
Rs. 21, 38, 400
Total savings
Rs. 21, 75, 250

Say Rs. 21.75
Investment for gas analyser
Rs. 3.50 Lakhs
Payback

Rs. 21.75 Lakhs
2 months
=
Option 2:
Combustion air supply blower capacity controlled by VFD:

Reduction in air volume handled by combustion air blower at all time
Power saving in blower
55.9 % - 16.7 %
39.2 %
39.2 % x 7.68 KW
3 KW
87
As VFD reduces the capacity of the blower by altering the operating speed this
arrangement doesnt calls for any need of damper control operation. Saving of
at least 2.5 KW can be achieved.
Annual savings
=
2.5 KW x 5500 hrs/annum x Rs.
6.7/KWh
=
Rs. 92, 125
Thermal savings
Rs. 21, 38, 400
Total savings
Rs. 22, 30, 525

Say Rs. 22.30
Investment for online gas analyser with controller for blower frequency
(includes the VFD cost)
Payback
Rs. 5.0 Lakhs

Rs. 22.3 Lakhs
3 months
88

REVOMAX BOILER RXA06 FOR IMPROVING COMBUSTION
EFFICIENCY
and operational modulation of the burner in Revomax boiler RXA 06 (0.6 TPH)
were studied in detailed identifying possible energy savings opportunities.
The savings is calculated considering 3 % of oxygen being maintained
at boiler exit flue gases.
Present O2 at Boiler outlet
6.5 %
Excess air supplied
6.5 x 100 %
(20.9 6.5)
45.1 %
Maintaining O2 at 3 % at themopac outlet the excess air would be

=
Present blower air quantity
3 x 100 %
(20.9 3)
16.7 %
520 m3/hr
471 Nm3/hr
Reduction in inlet air quantity i.e. reduction in Flue gases quantity

=
471 Nm3/hr x (45.1%-16.7%)
133 Nm3/hr
Flue gas temperature at APH outlet =
175 Deg C
Ambient temperature
28 Deg C
Heat savings
=
0.31 kcal/kg/DegC x 133 Nm3/hr x
(175- 28) Deg C
=
6060 Kcal/hr
LPG GCV
10700 kcal/kg
Saving in case of LPG
6060 Kcal/hr
10700 kcal/kg
0.56 kg of LPG
10200 kcal/kg
HSD GCV
89
Saving in case of HSD
6060.0 Kcal/hr
10200 kcal/kg
0.59 kg of LPG
Running hours
3000 Hours/Annum
Annual savings
=
60/kg of LPG
=
Rs. 1, 00, 800
Say Rs. 1.0 Lakhs
Investment required
NIL
90

OPTIMIZE THE TP 405 THERMIC FLUID PUMP OPERATION
BASED ON THE RESIN HOUSE REACTORS REQUIREMENTS
Operating parameters of the TP 405 thermic fluid circulation pump are as
follow:
Head
: 55 m
Discharge
: 110 - 115 m3/hr
Power
: 31.8 KW
Considering for an average of 4000 hrs/annum for calculation purpose at least

one of the reactor out of 5 would be out of heating cycle.
Present pump power consumption
31.8 KW
Reducing the pump speed by 10 % would result in 10 % reduction in pump

power consumption
Savings in pump power
10 % x 31.8 KW
3.1 KW
Considering the operation can be only carried out during the night hours when
the ambient temperatures are lower, the above only 1500 hours of the above
4000 hours are taken for savings calculations.
Annual savings
=
3.1 KW x 1500 hrs/annum x
Rs. 6.7/KWh
=
Rs. 31, 155

Say 0.31 Lakhs
Investment required
NIL
NOTE:
As the pump seal air fan is build in pump main shaft, we recommend to
conduct trails during the night hours when the ambient air temperature are
lower compared to day time. (Caution should be taken in setting the pump
speed control limits to upto maximum reduction to 47.5 Hz)
91

REPLACE EXISTING AIR HANDLING BLOWERS WITH HIGH
EFFICIENCY BLOWERS IN INDUSTRAIL PAINT BLOCK
industrial paint block air handling blowers were studied in detail for possible
Phase I:
Two discharge blowers (VSP 301 & VSP 302) are used for ventilation purpose
in industrial paint block reactor floor for maintaining the air quality.
Phase II:
One discharge blower (VSP 305) and two exhaust blower (VSP 303 & VSP 304)
are used for ventilation purpose in industrial paint block reactor floor for
maintaining the air quality.
The detailed flow and pressure measurements are as follows:
Fan
Number
VSP301
(Blower 1)
VSP302
(Blower 2)
VSP303
(Exhaust 1)
VSP304
(Exhaust 2)
VSP305
(Discharge1)
Flow
(m3/hr)
43000*
Flow
(CFM)
25298
Power
(KW)
19
Efficiency SEC
SEC Norm
(%)
(W/CFM) (W/CFM)
0.75
0.18
39347
23149
17.79
28
0.77
0.18
43801
25770
8.55
56
0.33
0.18
45512
26776
8.46
49
0.32
0.18
69386
40822
28.44
48
0.70
* Actual flow to system for VSP 301 was measured to be 22480 m3/hr. The
reduction in the flow was mainly due to leakage at immediate blower discharge
The specific energy consumption of the blowers were measured and are
compared with the specific energy consumption of high efficiency blower.
Blower VSP 303 AND VSP 304 SEC is in the range of 0.32 to 0.33 W/CFM
whereas for the other three blower is over 0.70 W/CFM. This clearly indicates
lower operating efficiency of the blowers.
Recommendation:
92

Phase I
Replace the discharge blower VSP 301 & 302 with either a new high
efficient blower of 80000 m3/hr capacity of two smaller blowers of 40000
m3/hr.
Phase II
Replace the discharge blower VSP 305 with a new high efficient blower of
70000 m3/hr capacity.
Savings Calculation:
Phase I:
Present Flow of VSP 301
43000 m3/hr
Power consumption of VSP 301
17.79 KW
Present SEC of VSP 301
0.75 W/CFM
SEC of new high efficiency blower
0.25 W/CFM
Saving potential
(0.75 0.25) x 19 KW
9.5 KW
* Actual flow to system for VSP 301 was measured to be 22480 m3/hr. This
reduced flow was mainly due to leakage at immediate blower discharge
39347 m3/hr
17.79 KW
0.77 W/CFM
SEC of new high efficiency blower
0.25 W/CFM
Saving potential
(0.77 0.25) x 17.79 KW
9.25 KW
93
Annual savings in Phase I
Annual savings
(9.5 + 9.25) KW
18.75 KW
=
6.7/KWh
=
Rs. 8, 79, 375

Say Rs. 8.79 Lakhs
Phase II:
69386 m3/hr
28.44 KW
0.70 W/CFM
SEC of new high efficiency blower considering blower head of 65 mm WC

=
0.35 W/CFM
(0.70 0.35) x 28.44 KW
9.95 KW
Annual savings in Phase II
9.95 KW
Annual savings
=
6.7/KWh
Saving potential
Rs. 4, 66, 655

Say Rs. 4.66 Lakhs
Total savings in Phase I & II
Rs. 13.45 Lakhs
Investment requirements
Phase I
Two blower of 40000 m3/hr capacity would be Rs. 7.5 Lakhs
Phase II
Single blower of 70000 m3/hr capacity would be 7.0 Lakhs
Total investment
Payback
=
=
=
Rs. 14.5 Lakhs

Rs. 13.45 Lakhs
13 months
94
OPTIMIZE THE OPERATION OF WBU COOLING WATER

PUMPS
the cooling water pumps in WBU section were studied in detail for identifying
Present status
In WBU section, there are two nos of reactors of capacities 3 kL & 5 kL.
Approximate batch cycle time in each reactor is 8hrs. Exothermic reaction
takes place in the reactor for 4 hrs. Jacket cooling is required during this
phase. 5kL reactor has three jackets and 3kL reactor has two jackets.
One pump each for one reactor is installed to circulate cooling water through
the reactors. Control valves (ON/OFF) are installed for all the jackets in two
reactors. Control valves open and close based on the material temperature in
the reactor.
The layout of schematic operation when only 5kL reactor was in cooling phase
is as follows:
As indicated in the figure, when only 5kL reactor pump was running,
recirculation of 27 m3/hr (22%) was observed through 3 kL pump. When only
3kL pump was running, recirculation of 15 m 3/hr (12%) was observed through
5kL pump.
95
Minimum recirculation in the circuit is 15m3/hr when any one reactor runs.
Recirculation is happening due to the failure of non return valves (NRV). This
results in higher power consumption of the pump.
Plant team have already replaced existing NRVs with new ones. CII
congratulates the plant teams efforts in replacing passing NRV to
avoid recirculation.
Temperature difference across each reactor is only 1.5 0C. Minimum
temperature difference that can be maintained across any heat exchanger is 340C. This indicates there is an excess flow through reactor, can be optimized.
A trail can be taken by throttling the pumps in steps of 10% till temperature
difference of 40C is achieved across the reactor. Simultaneously, please
monitor the reactor bulk temperature, as it is critical.
The cooling requirement for each equipment was analyzed in WBU section.
After assessment the combined cooling requirement in WBU section for
(Reactors, LDV, 70TR chiller) is 200TR.
The details are given as below:
S.No
User
Cooling load
(TR)
3 kL Reactor
50
5 kL Reactor
46
LDV
15
70TR Chiller
condenser
90
Total
200
Each equipment runs at a different batch cycle time. When all the equipment
run simultaneously, the cooling requirement is maximum, i.e., 200TR.
But the installed capacity of the cooling tower is only 120TR. Because of this
insufficient cooling tower capacity, chilled water is being used to cool return
cooling water from the users during summer. Installing one more cooling tower
of 120 TR capacity increases the heat rejection capacity & cooling efficiency.
And the need to use chilled water to cool the return cooling water during
summer can also be avoided, which is an energy intensive method.
Recommendation
We recommend to
96
Avoid recirculation by installing new NRV

o Plant team have already replaced existing NRVs with new ones
Install auto control valve at the outlet of the reactor
Control the flow through reactor based on the temperature difference

across the reactor
Increase the T set value slowly in steps of 10C up to 40C
Install VFD for one pump and operate only that pump even for 2 reactors
Operate VFD based on the header pressure 2.5 kg/cm2
Before installing VFD, plant can take a trail by reducing the flow by
throttling the pump in steps of 10% till temperature difference of 40C is
achieved across the reactor
Install a separate cooling tower of 120TR for chiller condenser and avoid
using chilled water to cool return water during summer
Savings calculation
Avoiding Recirculation in the circuit
Minimum recirculation in the circuit
15m3/hr
Actual flow in the circuit
120 m3/hr
Minimum % of recirculation
=
=
15 m3/hr x 100
120 m3/hr
12.5%
Operating power of 5kL pump
7.7 kW
Annual Saving
12.5% x 7.7kW x 10hrs x

330days x Rs 6.7/kWh
Rs 21, 280/Rs 0.21 Lakhs
=
=
Optimizing the excess flow in the circuit by installing VFD

Operating speed of the VFD
As Power (speed)3,
Power saving in 5kL pump
Power saving in 3kL pump
75% of rated speed
=
=
(1-0.753)x7.7kW
4.4 kW
=
=
(1-0.753)x6.3kW
3.6kW
97
Total power saving
=
=
Annual saving
=
8kW x 10hrs x 330days x Rs
6.7/kWh
=
Rs 1, 76, 880/=
Rs 1.76 Lakhs
Total annual savings
=
=
=
Rs 0.21 Lakhs + Rs 1.76 Lakhs

Rs 1.97 Lakhs
Rs 1.97 Lakhs
Investment for VFD & control valves

Investment for new cooling tower
=
=
Rs 1.50 Lakhs
Rs 1.50 Lakhs
Total investment
Rs 3.0 Lakhs
Simple payback period
Rs 3.0 Lakhs x 12
Rs 1.97 Lakhs
19 months
4.4kW + 3.6kW
8 kW
98
OPTIMIZE THE OPERATION OF LDV COOLING WATER

PUMP IN WBU SECTION
the LDV cooling water pumps in WBU section were studied in detail for
Present status
There are two LDVs installed in WBU section. Only one LDV will be in service
at a time.
After cooling the entire mass in the reactor to 65-70 0C, material will be sent to
LDV. Total batch cycle time in LDV is 4hrs. In LDV, addition of digestion
material takes place for 2 hours, is an exothermic process. Cooling is required
during this period.
The whole material is maintained at 70 0C for 1 hour. After this, material should
be cooled to below 500C.
One cooling water pump is installed to circulate the water through LDV. Control
valves (ON/OFF) are installed for LDV, opens and closes based on the material
temperature.
The schematic layout of the operation is shown as below:
99
The temperature difference across LDV is only 20C. For a heat exchanger, the
minimum temperature difference that can be maintained is 4 0C. This indicates
excess flow through LDV, can be optimized.
This can be done by throttling the pump or installing VFD and operating it with
pump discharge pressure as feedback.
Trail can be taken by throttling the pump in steps till the temperature
difference of 40C is achieved & simultaneously monitoring the material
temperature.
Optimizing the flow by reducing the speed with VFD will save more power.
Recommendation
We recommend to
Before installing VFD, trail can be taken by throttling the pump in steps
till temperature difference across LDV reaches 40C.
Install VFD for the pump
Operate VFD in closed loop with the header pressure
Saving calculation
Operating power of LDV pump
5kW
50% of the flow can be reduced, i.e, VFD will operate at 50% speed
As Power (speed)3, considering at least 25% reduction in speed
New operating speed
=
75%
Annual saving
=
(1-0.753) x 5kW
330days x Rs 6.7/kWh
=
Rs 44, 738/=
Rs 0.44 Lakhs
Investment for VFD
Rs 0.60 Lakhs
Rs 0.60 Lakhs x 12
Rs 0.44 Lakhs
17 months
7hrs
100
OPTIMIZE THE OPERATION OF NEW BAZAAR COOLING

WATER PUMPS
the New bazaar cooling water pumps in WBU section were studied in detail for
Present status
Seven pumps are installed for the cooling water requirement of resin house
section.
The flow and head measurements were taken by operating each pump
individually to study the performance of all the pumps and the details are
shown as below:
S.No Pump Flow (m3/hr) Head (kg/cm2) Eff (%) Running hours
1
490
49
0.4
8.3
3500
491
25
0.2
2400
492
71
1.2
58.5
5500
470
74
2.6
27
160
481
28
39
100
482
64
3.7
58
1300
483
3500
The following observations can be made from the measurements

Pumps 490, 491 & 492 are pumps of same specifications. But, it can be
observed that pumps 490, 491 were delivering very less flow compared to
pump 492. This must be due to worn out impeller.
The operating efficiency of the 481 pump is less compared to that of the pump
482.
Recommendation
Replace the existing impeller with a new one for the pump 491
Avoid running the pump 490, 491 till the impeller gets replaced
101
Run only pump 492 as it can deliver required flow

Run higher efficient pump for maximum number of hours
Saving calculation
Operating power of pump 491
5kW
Operating hours of pump 491
3200 hrs
=
=
=
5kW x3200hrs/yr x Rs 6.7/kWh

Rs 1, 07, 200/Rs 1.0 Lakhs
Investment
Rs 1.0 Lakh
Rs 1.0 Lakh x 12
Rs 1.0 Lakh
12 months
By avoiding operating pump 491

Annual saving
102
OPTIMIZE THE OPERATION OF INDUSTRIAL COOLING

WATER PUMPS
the industrial cooling water pumps in WBU section were studied in detail for
Present Status
Three pumps are installed to circulate the cooling water through the heat
exchangers of industrial reactors & solvent recovery plant. Out of the three
pumps, one is kept stand by.
The schematic layout of the pumping circuit is shown as below:
Cooling tower fans were operating based on the cold well temperature. Fans
switch on when cold well temperature reaches 270C and switches off when it
reaches 250C.
When measurements were taken, CT fans were in OFF condition. Even when
the fans were in OFF condition, 20C cooling was being achieved.
Generally, cooling tower are designed to give a range of 6-8 0C. By switching on
the fans and running them continuously, cooling tower can give minimum
range of 40C i.e., range will get doubled. Cooling water flow can be halved.
Currently, 2 pumps are running continuously and delivering 93m 3/hr (P458)
and 62m3/hr(P457) continuously. Total cooling water flow is around 150m 3/hr.
103
One pump P457 can be switched off. Then the second pump (P458) will deliver
more flow than before as the system resistance reduces as the cooling water
flow reduces.
The power consumption of the second pump can be optimized by installing
VFD and operating it with pump discharge pressure of 2 kg/cm 2 as feedback.
Cooling tower fans can be installed with VFD and operated in closed loop with
cold well temperature interlock of 320C.
Recommendation
Run the cooling tower fans continuously
Install VFD for CT fans and operate the VFDs in closed loop with the cold
well temperature of 320C
Switch off the pump P458
Install VFD for the pump P457
Operate the VFD in closed loop with the discharge header pressure of 2
kg/cm2
Saving calculation
Power consumption of CT fans
6kW
By installing VFD for CT fans, at least 25% of the flow can be reduced
i.e., VFDs will operate at 75% of the speed
As Power (Speed)2,
Annual saving in the fans
=
=
(1-0.752) x 6kW x17hrs x 330days x

Rs 6.7/kWh
Rs 98, 665/Rs 0.90 Lakhs
Investment
Rs 0.8 Lakhs
Power consumption of pump 458
9kW
=
=
=
9kW x 17hrsx 330daysxRs 6.7/kWh

Rs 3, 38, 223/Rs 3.38 Lakhs
Rs 0.80 Lakhs
By switching off the pump 458,

Annual saving of the pump
By installing VFD to the pump 457

Investment for VFD
104
Total annual savings

Total investment
=
=
Rs 4.20 Lakhs
Rs 1.60 Lakhs
Simple pay back period
Rs 1.60 Lakhs x 12
Rs 4.20 Lakhs
5 months
105
REPLACE INEFFICIENT PUMPS WITH NEW EFFICIENT

PUMPS
the performance of the water pumps in the plant were studied in detail for
The water flow and head measurement was carried out for all pumps in the
plant. The design parameters and measured values are as follows.
Pumps
Tag #
Design
Parameters
Flow
m3/hr
Head
(m)
60
43
21.00
24
6.15
24
18
33.00
10*
2.4
41
11-39
21.00
32
5.79
34
70 TR chiller
monomer pump
70 TR chiller hot well
pump
Pump house P504
Operating Parameters
Motor
Flow Head Loading Efficiency
m3/hr (m)
kW
%
23.5-9.5
The operating efficiency of above pumps is low due to mismatch between the
design and operating head / ageing of the pumps / low efficiency by design. In
* marked pumps head is estimated value as provision for measuring pressure
was not available.
The efficiency calculation of 70TR chiller monomer pump is as below.
Measured flow
21 m3/hr
Head
24 m
Power consumption
2.4 kW
Operating efficiency
= 21 m3/h x 24 m x 1 x 100%
3.6x102x 6.15 kWx0.90(motor )
=
24 %
Similarly the operating efficiencies of other pumps can be calculated.

Recommendation
It is recommended to replace the pumps (70 TR chiller monomer pump, 70TR
chiller hot well pump, pump house P504) with new pumps of efficiency >70%.
Savings calculation for 70TR chiller hot well pump:
kW savings with pump of
efficiency 70%
6.15 6.15 x 24 %
106
70 %
=
4 kW
* 70% new pump efficiency is considered only for savings calculatio n.
Specifications of 70TR chiller monomer pump:
Flow
25 m3/hr
Head
25 m
Efficiency
> 70%
Present power consumption
6.15 kW
Annual savings
=
4 kW x 3300 hrs/year
/kWh
=
Rs. 0.8 Lakhs
x Rs. 6.7
Savings can be calculated similarly for remaining pumps

Total Annual savings
Rs. 1.0 Lakhs
Investment for 4 new pumps
Rs. 3.5 Lakhs
Simple Payback period

Rs. 1.0 Lakhs
42 months
107

COMPRESSORS IN THE PLANT
OF
THE
AIR
Present status
During the detailed energy audit of Asian Paints Limited Patancheru, a detailed
study of all the compressed air units was carried out for possible energy saving
opportunities.
The plant has installed a centralised compressed air system consisting of two
screw compressors.
The following observations were taken from these compressors:
Compressor
P405
P406
Location
Compressor
House
Compressor
House
Loading
Pressure
bar
Unloading
Pressure
bar
Average
Pressure
bar
Power
kW
5.7
6.2
5.95
88.30
5.5
6.0
5.75
86.03
The compressed air applications and pressure requirements are:

Open/Close valves
4.0bar
Storage tanks & digesters (pipeline)

Conveying (Diverter valves)
Packing Machines (LFM, VFM & FPM)
108
Cooling Water circulation

Steam circulation
Hopper Aeration
3.0bar
Bag Filters
4.0bar
Sheen Machine (Paint spray)
3.0bar
AOD (Diaphragm Pumps)
4.0bar
Lid Pressing (LFM, VFM & FPM)
5.0bar
Cleaning Purpose
3.0bar
It was also observed that the packing machines were installed with additional
booster compressors, which cater to the higher pressure compressed air
requirements of these machines. CII congratulates the plant team for this
excellent initiative towards energy conservation activity.
Presently the compressors are generating compressed air at the pressure
above 5.7bar and there is a very negligible pressure drop in the compressed
air lines.
Higher operating pressure results in increased power consumption. Hence,
there exists a good potential to reduce the power consumption of the
compressors by reducing the pressure generated by the compressor.
Recommendation
We recommend to reduce the pressure setting of the compressor in the steps
of 0.2 bar and keep on reducing it until the generating set points are:
Load point
- 4.2 bar
Unload point
- 4.7 bar
Detailed energy saving calculations is shown in the back up sheet.

Calculations
For Compressor P405:
Percentage Pressure reduction
= (5.95 4.45) kg/cm2 x 100

(5.95 +1) kg/cm2
= 21 %
Annual Savings
= 0.21 (%reduction in kW) x 5000 hrs x

0.83 x 88.03 kW x Rs. 6.7/kwhr
= Rs. 5, 14,001 /Say 5.1 Lakhs

109
Percentage Pressure reduction
= (5.75 4.45) kg/cm2 x 100

(5.75 +1) kg/cm2
= 19 %
Annual Savings
= 0.19 (%reduction in kW) x 5000 hrs x

0.88 x 86.30 kW x Rs. 6.7/kwhr
= Rs. 4, 83,383 /Say 4.8 Lakhs
Total Annual Savings
= Rs. 5.1 Lakhs + Rs. 4.8 Lakhs

= Rs. 9.9 Lakhs
Investment
= Nil
110
MINIMISE COMPRESSED AIR LEAKAGE IN THE PLANT

Present status
The compressed air distribution system is a major potential area in any
chemical plant. Proper utilization and proper distribution system lead to
substantial energy savings.
A detailed study was carried out for all compressors and the compressed air
lines for possible energy saving opportunities.
Leakage of compressed air was also observed in the plant during the audit.
Generally, valves and flanges are more prone for leakage.
Sl. No.
Area
Leakage (%)
Total Leakage
47
24
Solvent Based Paint Unit
12
Industrial Paint Unit & Resin Block
11
Following are the identified leakage points:

Solvent Based Paint Block Ground Floor
1.
Mixer no.244 pigging line, Pneumatic valve leakage (Major)
2.
VFM - P215 tub cut-off pneumatic valve leakage
3.
Lid pressing machine LP P217 cylinder leakage
4.
VFM P209 cut-off pneumatic valve leakage
5.
Near mixer 219 pigging line, pneumatic valve leakage
6.
7.
LP 203 FRL leakage
8.
H-6 QRL leakage
9.
10. FPM lid placing unit control panel (Heavy Leakage)

11. FPM orientation unit control panel (Heavy Leakage)
12. Leakage in Tin Pusher units Both control panels
13. At AML area near mixer 253, lid pressing unit FRL leakage
111
Solvent Based Paint Unit - First Floor (Processing)

15. Sand mill P201 diaphragm pump air inlet line leakage
16. Behind sand mill 202 diaphragm pump air inlet leakage
18. Pneumatic valve leakage above drier tub 1
19. Behind sand mill 209 copper tube leakage
20. Near OHM 209, diaphragm pump inlet line valve leakage
21. Minor leakage in TR P202, additive tub inlet valve leakage
22. Dust collector TSD 211 air inlet line leakage QRC fitting
Industrial Paint Unit
23. LP P304, pipeline leakage
26. VSP 351, diaphragm pump pipeline leakage
Resin House
28. Auto control valve near pre coating tub TRP 408
29. Cut-off valve TRP 407
30. Header FM 10, FM 6 near platform Opp: TRP - 404
31. BL 408 bottom valve copper tube fittings
32. CA inlet to BL P413
Resin House (1st Floor)
33. Solenoid valve BLP418
34. Compressed air pipeline
35. CV BLP 402
36. Steam condensate R7 tub middle Control Valve
37. Steam condensate drain valve 3rd coil
38. FRL bottom near R7 tub
39. Control valve in R7 tub middle cooling inlet line
112
40. FRV bottom

41. DLP 406 condensate cooling line Control Valve
42. Control valve vent line is open O/L
Resin House (2nd Floor)
43. Sorbital control valve I/L line R9
44. FRL near R9 (Exhaut R9) push button station
45. FRL bottom air header (near D1-1 function box)
46. Condenser cooling I/L R1 reactor
47. Bypass line thermo pack opposite to vacuum cooler area
Resin House (3rd Floor)
48. FRV I/L header TP2 expansion tank
49. Auto control valve not in use R7 condenser
50. Auto control valve to inlet line to condenser H 10 (M-seal Kept)
51. Copper tube opened
52. LFM P121 solenoid spool valve
53. LFM P121 valve at the bottom of the funnel
54. From QRC near LFM P116, poor silencer valve
55. LPP 131 silencer 2 Pts
56. LFM 124 FRL top damaged
57. Mixer P147 bottom cut-off valve leakage from upper tube
58. Air header near mixer P153 QRC leakage
59. Mixer P161 leakage from copper tube
60. Air header near LDV P165
61. STP 175 near auto control valve silencer
Water Based Paint Unit (1st Floor)
62. FRL unit pug mill inlet to purging line 789
63. PM 181 gate valve FRL inlet fitting
64. PM 184 bottom of FRL
65. PMP 186 bottom gate valve seal leakage
113
66. FRL header near TDS P105

Water Based Paint Unit (2nd Floor)
67. SVA & SVE two different headers liquid trolley area
68. Diverter valve : control cylinder inlet force pipe fitting
69. Pug mill hopper 183 I/L to purge line 3rd from top
70. Pug mill hopper PH 181 I/L to purge line
71. Diverter valves
Terrace
72. Vent line in hopper no 2
73. Hopper no - 5
It is difficult to find out the leakages in a continuous process plant. The ideal
time to find out the leakages is during shut down time by conducting a leakage
test.
A simple procedure for conducting leakage test is:
Close all the user end points
Start the compressor and allow it to run
If there are no leakages, the compressor once unloaded should not load
again as there is no consumption at the user point
If there are leakages, it will operate in load and unload mode
Note down the loading and unloading time of the compressor. The
percentage loading indicates the percentage leakage.
Walk along the compressed air lines to identify the leakage points
Arrest the leakage at all the identified points
However, leakage test and arresting leakages is not one time activity. It is a
continuous activity. Leakage may not be avoided but can be brought down to a
very minimum level by continuous efforts.
Recommendations
It is recommended to
Avoid unwanted purging of compressed air
Arrest the leakages at identified locations
Avoid the use of High Pressure compressed air for cleaning
114
Increase the awareness among the operators and the workers on the value
of compressed air
Conduct leakage test during shut down time
Identify & arrest the leakages
Calculations
Leakage Test:
Loading time (LT)
= 83 sec
Unloading time (UT)
= 92 sec
% Leakage
= {LT/ (LT+UT)} x 100

= {19/ (19+23)} x 100
= 47.4%
= 587 CFM x 47.4%
= 276 CFM
Considering reduction in the leakage by 30% from the current values,

Annual savings
= 0.3 (%) x 5000hrs x (88.03-30) kW x

Rs. 6.7 /kwhr
= Rs. 5, 82, 900 /Say Rs. 5.82 Lakhs

Annual savings
= 0.3 (%) x 5000hrs x (86-29) kW x Rs.

6.7 /kwhr
= Rs. 5, 72, 850 /Say Rs. 5.72 Lakhs
Total Savings
=
=
Rs. 5.82 Lakhs + Rs. 5.72 Lakhs

Rs. 11.54 Lakhs
Investment
Nil
115
116

CII-Sohrabji Godrej Green Business Centre
Survey No. 64, Near Kothaguda Cross Road
Kothaguda Post, Ranga Reddy (Dt)
Hyderabad 500 084
Ph: + 91 40 23112971 73;
Fax +91 40 23112837
Email: encon@cii.in
Web: www.greenbusinesscentre.com
117

Draft DEA Report Asian Paints LTD, Patancheru1

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Confederation of Indian Industry

CII-Sohrabji Godrej Green Business Centre

Detailed Energy Audit

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

List of Energy Saving Proposals

Energy Saving Proposals

Management Aspects and conclusion

Total Pages: 114

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

: Rs. 98.81 Lakhs

Investment required (10 proposals)

: Rs. 75.0 Lakhs

Average payback period for capital Proposals

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

SPECIFIC ACTION PLAN

e) As On a second priority and after verification by the plant team, the

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

LIST OF ENERGY SAVING PROPOSALS

Energy Saving Proposals

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL No. 1

REPLACE THE 1X36W and 2X36W T5 LAMPS WITH 1X20

CIISohrabji Godrej Green Business Centre

Lower energy consumption: The energy consumption of LEDs is low

Very Good (> 80)

CIISohrabji Godrej Green Business Centre

Give Action Plan

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 2

REPLACE 2 X 36 W CFLS WITH 18 W LEDS

Very Good (> 80)

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 3

RENEWABLE ENERGY FOR LIGHTING (LONG TERM)

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

It is recommended to replace the existing 70 W HPSV and HPMV lamps with

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL No. 4

Flame Modulation: High Flame

Combustion air: 4284

and plant team and the

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

Air preheater outlet

CIISohrabji Godrej Green Business Centre

We recommend the following: