Paper Plant Energy Audit Report

ANSH ENERGY SOLUTIONS PVT. LTD.
Task Specific Audit: Steam Generating

admin@anshenergy.com Boilers & Electrical distribution netwrok
Client: Sandeep Paper Mills (P) Ltd.
Auditor: Anshul Singh Yadav
Auditor Registration: EA-3267
TASK SPECIFIC ENERGY AUDIT

OBJECT: EFFICIENCY TESTING OF BOILERS & LOSS IDENTIFICATION
IN ELECTRICAL DISTRIBUTION SYSTEM
CLIENT: M/S SANDEEP PAPER MILLS (P) LTD., NOIDA
AUDITORS: ANSH ENERGY SOLUTIONS PVT. LTD., Gayatri Dham, Lower Bazar,
Modinagar – 201204 (UP)
AUDITOR BEE REGISTRATION: EA – 3267 (Anshul Singh Yadav)
& EA-10465 (Anubhav Gupta)
DURATION: 21 JANUARY, 2010 – 20 FEBRUARY, 2010
REPORT NUMBER: 09-10/R/AG/104
Page | 0
ANSH ENERGY SOLUTIONS PVT. LTD. Task Specific Audit: Steam Generating
Contents
S.No. Description Page No.
1. Executive Summary 2
2. Overview 4
3. Scope of Audit 4
4. Assumptions 5
5. Equipment Verbal Picture 5
6. Energy management Plan 7
7. Maintenance recommendations 8
8. Technical Supplement 8
9. Standard Calculations and Assumptions 17
10. SWOT 19
11. Thermal references 20
12. Appendix – 1 21
13. Appendix – 2 23
14. Electrical bill analysis 2008 24
15. Electrical Bill Analysis 2009 25
16. Electrical Parameters 32
17. Harmonics 41
18. Motor Power Factor 47
19. Scope of Energy Savings in electrical motors 56
20. Comparison of Low efficiency and EED 60
21. Conversion of LV Drives to MV drives 74
pg. 1
EXECUTIVE SUMMARY
The boiler in this report is referred as Boiler No. 1 (IBL). The efficiency was calculated as
below:
Boiler 1 Boiler 2
Average Direct Efficiency 80.20 % NA
The operation has been observed carefully and few areas of carelessness have been
observed. The best achievable efficiencies of 85% + have a path of nearly 5% to be
travelled and continuous monitoring and efforts are required.
The suggested methodology of improvement is diagrammatically represented as below:
pg. 2
The summary of possible savings is tabulated as below:
S.No. Action Tentative Savings Pay Back

Boiler action plan
1. Installation of fixed type oxygen analyzer INR 416114 per month 19 Days
i.e. INR 49,93,368 Per
annum
2. Installation of Automatic Blow Down INR 52014 per month 5 months
Control System i.e. INR 6,24,168 per
annum
3. Replacement of fire doors and better INR 1,83,089 per month 7 days
mud coating i.e. INR 21,97,068 per
annum
Total Boiler savings INR 78,14,604 per
annum
Electrical action plan
1. Installation of only 90 KVAR capacitors on INR 4017 per annum Immediate
transformer LT
2. Conversion of V-Belt to Flat belt drives INR 8,39,446 per annum 6 months
3. Conversion of all old motors to new INR 29,32,356 per 3 months
Energy efficient series motors annum
4. Conversion of LV panels to MV panels INR 9,67,887 NOT suggested
Total Savings in Electrical system INR 37,75,819 per
annum
Total savings by complete INR 1,15,90,423
implementation
pg. 3
OVERVIEW
The client M/s Sandeep Paper Mills (P) Ltd. with registered office at A-20/6, Noida is
operating for production of various grades of paper for which utilities used are Steam,
Water, Compressed air and Electricity (Grid power). The top management of company
includes Mr. Jatinder Singh Jolly and Mr. Sandeep Arora (ED) and they are committed to
cost reduction and energy conservation for betterment of company as well as
environment. The Audit has been done specifically for the steam generating unit and
Electricity Load Distribution. Company possesses 6 TPH capacity of steam generation F &
A 100oC with pressure rating of 10 kg/cm2 and a CD of 1250 KVA at 33,000V distributed
through a 1250 KVA 33KV/433V single Core outlet transformer. The target is to achieve
a reduction of recurring cost to improve business viability.
Scope of Audit
The aim and scope of audit is to quantify and justify the fuel consumption as well as
energy consumption and consumption quality, total and specific steam generation,
boiler efficiency monitoring, load balancing, run-ability optimization and achieving best
possible fuel to steam ratio. The audit will thus cover parameter detection of:
1. Feed water inlet flow.
2. Blow Down flow estimation (If possible).
3. Inlet air temperature.
4. Temperature of exhaust to stack.
5. Feed water quality.
6. Cycle of concentration
7. Variance in phase loading of motors ACB’s and Transformer
8. Heat loss in cabling
9. Heat loss due to poor operation of motors
10. Losses due to poor capacitor behavior or installation faults.
11. Losses due to uneven load pattern.
12. Losses due to voltage variations.
pg. 4
The completion of audit will achieve identification of all types of boiler losses and
almost all possible ECOs (Energy Conservation Opportunities). It will highlight the
efficiency improvement possibilities in motors, capacitors and voltage variations.
This inspection report reflects the conditions of the equipment at the time of the inspection only.
Please note that equipment conditions change with time and use and the conditions noted in this
report may change in appearance and severity as time progresses or with mishandling. Hidden or
concealed defects cannot be included in this report. An earnest effort was made on our behalf to
discover all fallacies; however in the event of an oversight no liability is acceptable. No warranty is
either expressed or implied. This report is not an insurance policy, nor a warranty service.
Assumptions (if Any)

The following assumptions were made taking in consideration to have minimal effect on
the results:
1. Nil
Equipments’ Verbal Picture

The Plant is operating two separate boilers one of which operates continuously using
petcoke as fuel, the second boiler is standby and is capable of using multiple fuels. The
feed water supply quality is common and the water treatment facilities include RO
plant. The condensate from main machine hall is pumped and mixed into the feed water
tank which stands common for both the boilers. The description of boilers is as below:
1. Boiler no. 1 is an IBL make boiler with 6 TPH Evaporation capacity F & A 100oC
and is equipped with high temperature fluidized bed furnace beneath it. Boiler
number 1 is a smoke tube boiler. The boiler is operating at loading pressure of 10
kg/cm2 with both forced and induced drafts involved. The furnace is divided into
two separate chambers to ensure maximum burning of high CV fuel. The fuel is
fed into the primary chamber and the ash carryover is collected in secondary
chamber where next feed of air makes it to burn further due to high CV content.
Both furnace chambers on a 40 HP FD fan which is common, and have side fire
doors for cleaning. The blow down arrangement is manual and is being operated
once for 50 seconds in every 12 hours.
pg. 5
2. Boiler no.2 is similar to above boiler in make and fire side arrangement however
it carries a Brownian furnace and is capable of burning baggasse as fuel.
The electrical circuit consists of an incoming state electricity board line of 33KV which is
received by a 1250 KVA 33/0.433KV single transformer. The transformer is installed with
OLTC AVR and is capable of handling voltage range of +7.5% to – 12.5% of the rated
incomer. The State owned meter and VCB precedes transformer. Multiple single core
cables carry energy from transformer to the MCC which is installed with ACB through
which 2 Separate PCC are connected.
The plant operates mostly inductive load along with some inverting electronic load to
govern the use of inductive load. The premises has been observed to be maintaining
good power factor and good voltage conditions however ACBs installation seems to be
very negligent.
A wide range of VFDs have been installed to compensate for major electrical energy
losses and more or less the aim has been successfully achieved.
pg. 6
Energy Management Plan
pg. 7
Maintenance Recommendations
The following maintenance activities need constant attention:
1. The furnace fire doors need to be proper and closed during operation to avoid
major heat loss at temperatures nearly 900oC. The ambient temperature at 2
mtrs of distance from furnace fire doors was found to be 74 degree celcius which
is dramatically high. WE RECOMMEND USE OF CI DOORS WITH INTERNAL LINING
OF FIRE PROOF CEMENT.
2. Record should be kept, monitored and counter checked for APH cleaning in Boiler
1 as it was observed to be carrying fly ash in itself despite of rotary dust remover
at bottom.
3. The feed water quality needs to be monitored very closely as this may lead to
corrosion and slow damage.
The Technical Supplement

1. Calculation of Efficiency for boiler by direct method.
The data collected shows:
S. No. Feed Water Feed Water Fuel Weight Fuel Steam
Opening Closing (kg) Moisture Produced
Reading Reading Content (%) (kg)
3 3
1. 224.015 m 336.023 m 9096 6 112008
2. 230.683 240.382 m3 835 6 9699
Calculation of actual fuel available on air dry basis (M) =

1 !"# $"%&'"(

Thus, )*%#+#" ,-".&/ ), 0 123 4!"#
And, ,-".&/ 55%-"( %- 5"6 0 5"6 ,-5'#7/ 5 10 +. 49 :"67.
> ? @
A
B
Finally, <%#". " %=%"-=/ 0
@>
pg. 8
Hence, For Boiler Number 1

S.No. Fuel Calorific Available Energy attained Overall
value (kcal/kg) energy (kcal) in steam at Efficiency
10kg/cm2
1 9340 79859241 65860704 82.47%
2 9340 7330966 5703012 77.79%
2. Various types of losses:

With help of the Ultimate analysis of fuel we can followed the below mentioned
procedure:
pg. 9
pg. 10
pg. 11
pg. 12
Ultimate analysis of fuels:

Content Petcoke as fuel
Carbon % 87.17
Hydrogen % 4.67
Nitrogen % 1.96
Oxygen % Remainder
Ash % 0.64
Volatiles % 1.83
GCV (Kcal/KG) 9340
a) Dry Flue Gas Loss

Boiler 1 Boiler 2
11.24% NA
b) Loss Due to Hydrogen in fuel

Boiler 1 Boiler 2
3.02 % NA
c) Loss due to moisture in fuel

Boiler 1 Boiler 2
0.40 % NA
d) Loss due to moisture in air

Boiler 1 Boiler 2
3.22 % NA
e) Approx. heat loss due to surface radiation and leakages

Boiler 1 Boiler 2
2.76 % NA
pg. 13
f) Heat loss due to unburnt in fly ash

Boiler 1 Boiler 2
0.13 % NA
g) Heat loss due to un burnt in bottom ash

Boiler 1 Boiler 2
0.01 % NA
h) Heat loss due to blow down.

Boiler 1 Boiler 2
1.02 % NA
3. Calculations of tentative and stepwise investment:

The major losses of boilers are clearly evident to be dry flue gas loss, blow down
losses. The suggested tasks to be taken care of shall be:
a) To counteract dry flue gas loss we shall control the excess air (Presently
98.113%) supplied to the furnace by adjusting fan speed balances and by
continuous monitoring of the excess oxygen going into the flue gases. An
estimated 1% reduction in excess oxygen shall bring about 0.9% reduction in
loss. Stack monitoring can be done by either continuous type oxygen scanner
or by handheld type portable oxygen probes.
b) Hydrogen loss is inherent with fuel and is dependent only on fuel type. The
only variation in our control shall be allowance of residence floor time to fuel
so that hydrogen can be slowly converted into water vapors. The process is
slow and may cause not more than 00.25 percent improvement.
c) Again loss due to moisture in air is beyond manual control as it is purely based
on atmospheric conditions. The only precaution that can be taken is to avoid
any spray or source of water on suction side of FD fan.
pg. 14
d) Loss due to furnace leakage can be brought down by nearly 1 % in this case as
the furnace doors and feed hoppers allow lot of heat to escape. This is due to
carelessness of man power involved and due to absence of any provision of
keeping the furnace pressure negative. The flames have been evidently
coming out due to furnace high pressure. The best solution to this problem
shall be to control fan speeds by variable speed drives for which controls are
either with wise operators or alternately a pressure transmitter controls the
flow of FD air.
e) Lastly the blow down losses has been observed to be very high. The water test
report clearly indicates the malpractice being followed. The blow down
should only be made when TDS of drum water reaches 3500ppm. The present
values show operation at very low cycle of concentrations which lead to heat
loss and more significantly costly water loss. The drum pH is also low. The
ideal pH shall be 11. The solution to above mentioned problem is either
vigilant checking of water parameters or installation of an automatic blow
down control system.
f) The list of improvements suggested is not exhaustive and can be revisited.
Further suggested approach is pinch analysis.
4. Approximate costs of equipments and payback periods.

Equipment Tentative Cost Payback period
Oxygen probe INR 2,70,000/- 19 days
(continuous)
Vigilant Feed water INR ZERO
monitoring
Automatic blow down INR 2,50,000/- 4.8 months
control
5. Pay back calculations

The Average Steam used from Boiler No. 1 = 5.333 T/hour
pg. 15
Average operating hours per month = 24 x 26 = 624 hours

Steam produced = 18302 tonnes per month.
Fuel used per tonne of team produced = weight of petcoke/steam produced =
81.2 kg per tonne of steam
Cost of 1 kg of Petcoke = Rs. 7 per kg approx.
Thus cost of 1 tonne of steam = 81.2 x 7 = Rs. 568 (for boiler number 1)

Thus 1% saving in boiler 1 will lead to 568 18302 0 H. 1,04,028being

saved per month.
Now, Oxygen monitoring can reduce excess oxygen by 6% in flue gases. This will
lead to increase in efficiency by 4% in boiler 1.
Thus saving of boiler 1 shall be 4 x Rs. 104028 per month = Rs. 416114
KL
Hence simple payback for Continuous oxygen probe in boiler 1 = 30 0
MNM
19 (/ and
P
Alternatively payback for one portable probe shall be = 30 0 5.76 (/
MNM
However the most lucrative option shall be a continuous monitoring probe for
boiler 1 as it will also iron out any possibilities of man power negligence.
The saving on blow down can be nearly 0.5%.

Hence cost saving in Boiler 1 = 0.5 x Rs. 104028 = Rs. 52014 per month
Hence simple payback after installing continuous blow down for Boiler 1
K
0 0 4.8 6-5'
KM
The payback is although lucrative but we do not recommend installation of
automatic blow down as this result can be very well achieved by vigilant blow
down water quality monitoring, manually.
There is as strong need to bring down the radiation and surface losses to under 1
% i.e. savings of 1.76 % or saying monetarily = 1.76 R 104028 0 ST. UVWXVY
pg. 16
The tentative investment in fire doors and better mud coating and insulation all
together is estimated to be Rs. 40,000.
M
Hence a payback period of R 30 (/ 0 6.55 is attainable which is
PZP[
remarkable.
We strongly recommend immediate change of fire doors and better coating of
boiler and water wall body.
Standard Calculations and Assumptions

1. The calculations along with formulae are mentioned above.
2. Calculations for payback have been done taking in consideration simple payback
only as the payback is extremely fast and IRR calculations are not significant.
3. It is assumed that the equipment suggested shall be allowed to work properly
with adequate staff training or else the payback calculations may vary.
Audit Recommendations
The point wise recommendations are listed below:
1. Installation of Continuous oxygen monitoring on stack of boiler no. 1
2. Adequate staff training and cross checking so as to control blow down frequency
and water’s operating parameters.
3. For maintaining feed water pH we shall suggest installation of a water softener
with capacity of 2 m3/hr. this softener shall feed the RO plant totally and 0.3
m3/hr shall be bypassed directly from RO plant i.e. 0.3 m3/hr shall flow directly
from softener to feed water tank. Alternatively pH booster chemical should be
used as per demand to maintain the pH.
4. The doors of furnace need to be changed to CI casted fire grade doors with cavity
on back so as to be filled with casteable cement for reduction in heat loss.
Appendix
1. Lab Testing Reports.
2. Data collection tables.
pg. 17
3. SWOT Analysis.
Other possible utilities to undergo audits

The possible utilities to undergo audits can be pumping system.
pg. 18
SWOT Analysis
Situation being analyzed: ____Boiler Efficiency Improvement_________
STRENGTHS WEAKNESSES
1. Sufficient Capacity installed. 1. Unavailability of process
2. Availability of down time for instrumentation.
installation of additional 2. Negligence of staff to monitor actual
equipments as interconnecting parameters.
pipeline is already installed.
3. Willingness of management for
improving existing set-up
OPPORTUNITIES THREATS
1. Vast scope of improvement of 1. Instrumentation if installed might
efficiencies. not work properly due to lack of
2. Reduction of loss can be monitoring or knowledge.
achieved by using 2. Biased mindset regarding possibility
instrumentation and of improvements.
monitoring. 3. Lack of equipment maintenance.
3. Monitoring instruments are
readily available in market so
no long lead times.
pg. 19
References
1. BEE Manual on Energy Efficiency testing (Book 4)
2. www.emerson.com
3. Perry’s Handbook of Chemical Engineers (2003)
4. www.lenntech.com/boiler-feedwater.htm
pg. 20
Appendix 1
Client: M/s Sandeep Paper Mills Pvt. Ltd., A-20/6, Noida

Tests to be done: Blow Down (TDS, pH, T.Alk, P. Alk.), Feed Water (TDS, pH, T.Alk, P. Alk.) RO Water
(TDS, pH, T.Alk, P. Alk.)
Sample collected by: Dr.Shubhangi Gupta (MD, AESPL)
Sample collection date: 20.01.09
Qualitative Analysis
PURPOSE
The purpose of this experiment is to identify the boiler operating parameters by getting to know the
TDS, Alkalinity and ph of blow down and feed water of boiler system. The results will help in better
water management and thus will let us control the proper operation practices to enhance equipment
life and maintain low fuel consumption.
DATA
STEP SUBSTANCE Parameter (Std. RESULT INFERENCE
Value)
pH (11-12) A lot of fresh
1 Blow down water 9.20 treated water is
Boiler 1 being inputted or
excessive blow
down is being
operated.
Excessive Blow
2 Blow down water T. Alk as CaCO3 140 ppm Down Operation.
Boiler 1 (750 ppm)
Blow down water Caustic Alk. 60 Excessive Blow

3 Boiler 1 (300 or 30% of Down Operation.
above)
Blow down water Total Dissolved 1824 ppm Excessive Blow

4 Boiler 1 Solids Down Operation.
(2500 ppm)
pg. 21
5 Boiler feed water pH 7.16 No presence of

softener unit.
6 Boiler feed Water Total Hardness 5.8 ppm No effect of RO

(Strictly <5ppm) plant on hardness
or too hard fresh
water
Conclusions
Boiler water monitoring at site is poor and careless. Excessive blow down is being operated and lot of
valuable heat is being wasted. The water treatment for feed water is done by complete Reverse Osmosis
Plant. However this plant is usually not suitable to maintain pH and hardness of feed water. The
observed pH is neutral which could cause mild damage to the boiler tubes and drum. Also the Hardness
of water is higher than the set limits.
Recommendations
Installation of a Soft water treatment plant and that soft water should be inputted to RO system. Only
60% of total feed water should go through RO plant and balance 40% should be taken from softener
itself so as to maintain pH value. The operation of such a system after installation is to be monitored
strictly so that the ratio of 60:40 shall be balanced as per site requirements.
pg. 22
APPENDIX - 2
Client: M/s Sandeep Paper Mills Pvt. Ltd., A-20/6, Noida
Tests to be done: Proximate Analysis of Fuel, Ultimate Analysis of Fuel, GCV
Sample collected by: Dr. Shubhangi Gupta (MD, AESPL)
Sample collection date: 20.01.09
Sample: Petcoke (Source Jamnagar Refinery of Reliance Industries Ltd.)
Qualitative Analysis
PURPOSE
The purpose of this experiment is to identify the Fuel Chemical Composition so the reaction and
consequences inside the furnace can be calculated. The results will help in better Furnace operation,
loss detection and will let us control the proper operation practices to enhance equipment life and
maintain low fuel consumption.
DATA Proximate Analysis

S.NO. SUBSTANCE Parameter RESULT INFERENCE
1 Petcoke Moisture 6.25
2 Petcoke Ash 0.64
Petcoke Volatile Matter 1.83

3
Petcoke Fixed Carbon (By 91.28

4 Difference)
DATA Ultimate Analysis

S.NO. SUBSTANCE Parameter RESULT INFERENCE
1 Petcoke Ash 0.64
pg. 23
2 Petcoke Carbon 87.17
Petcoke Hydrogen 4.67

3
Petcoke Nitrogen 1.96

4
5 Petcoke Other Remainder
FUEL GROSS CALORIFIC VALUE: 9340kcal/kg
pg. 24
NAME OF THE CONSULTANT:- M/s Ansh Energy Solutions Pvt Ltd.

ANALYSIS OF ELECTRICITY BILLS FOR THE YEAR:- 2008 (FROM JAN-2008 TO DEC- 2008)
( ENERGY AUDIT ANALYSIS SHEET)
(1) NAME OF THE INDUSTRIES :- M/S Sandeep paper Mills Pvt. Ltd. (6 ) SUPPLY VOLTAGE :- 33000 VOLTS
(2 ) TYPE OF INDUSTRIES :- PAPER MILL (7) TARIFF APPLICABLE :- HV - 2
(3) CONTRACT DEMAND :1000KVA (8) CONTINIOUS PROCESS INDUSTRY:-
(4) CONNECTION NO. :- LP-304 (9) PASCHIMANCHAL VIDHYUT VITRAN NIGAM LTD
(5) PLACE:- A-20/6 Noida
SR MONTH CONTRACT MINIMUM ACTUAL DEMAND P. F. ENERGY ENERGY ENERGY TOTAL TOTAL TOTAL NET
NO DEMAND BILLING MAX. CHARGES BILLED CONSUMED CONSUMED CONSUMED ENERGY ENERGY BILL UNIT
DEMAND DEMAND RS. FROM FROM FROM CONSUMED CHARGE AMOUNT IN
BILLED 22.00 - 6.00 06.00 - 17.00 17.00 - KVAh RS. RS. RS.
22.00
1 JAN 1000 750 925 166500 0.98 150500 191280 90480 432260 1483483.00 1648028.00 3.81
2 FEB 1000 750 987 177660 0.99 116380 144940 66260 327580 1122293.00 1306745.00 3.99
3 MAR 1000 750 980 176400 0.97 0 0 0 0 0.00 0.00 0.00
4 APR 1000 750 1023 184140 0.99 223740 307460 138360 669560 2298250.00 2504593.00 3.74
5 MAY 1000 750 1099 219800 0.99 143720 203840 103520 451080 1527067.00 1803058.00 4.00
6 JUN 1000 750 1099 219800 0.99 193080 243020 107500 543600 1826607.00 2110901.00 3.88
7 JUL 1250 937.5 1126 225200 0.99 199120 268700 122300 590120 1988408.00 2202844.00 3.73
8 AUG 1250 937.5 1080 216000 0.99 171180 223620 98460 493260 1658888.00 1837558.00 3.73
9 SEP 1250 937.5 1074 214800 0.99 183340 332100 157400 672840 2287123.00 2533176.00 3.76
10 OCT 1250 937.5 1072 214400 0.99 121660 173300 80500 375460 1267835.00 1505793.00 4.01
11 NOV 1250 937.5 1106 221200 1.00 153600 199920 87720 441240 1483721.00 1699130.00 3.85
12 DEC 1250 937.5 1064 212800 0.99 211540 278300 132400 622240 2730525.00 2366463.00 3.80
13 TOTAL 2448700 11.87 1867860 2566480 1184900 5619240 19674200.00 21518289 42.31
14 AVG 1060 206573 0.99 169805 233316 107718 510840 1788564 1956208 3.85
SD 35671.92 58208.91 27366.23 117480.125
Mean +1 SD 205477.38 291525.27 135084.41 628320.12
Mean-1sd 134133.53 175107.46 80351.95 393359.88

MINIMUM 925 166500 0.98 116380 144940 66260 327580 1122293 1306745 3.72533
MAXIMUM 1126 225200 1.00 223740 332100 157400 672840 2730525 2533176 4.01
LOAD FACTOR = TOTAL ENERGY CONSUMED DURING YEAR X 100 73.7 74%
Page | 24
Name of Consultant : M/s Ansh Energy Solutions Pvt. Ltd.

ANALYSIS OF ELECTRICIY BILLS FOR YEAR 2009 (Jan 2009 – Dec 2009)
1 Name of industry: Sandeep Paper Mills Pvt. Ltd. 6 Supply Voltage: 33 KV
2 Type of Industry: Paper Mill 7 Connection Tarrif: HV-2
3 Contract Demand: 1250 KVA 8 Process type: Continuous
4 Connection No. LP 304 9 Supplier: Paschimanchal Vidhyut Vitran Nigam Ltd.
5 Address: A-20/6, Noida
SR MONTH CONTRACT MINIMUM ACTUAL DEMAND P. F. ENERGY ENERGY ENERGY TOTAL TOTAL TOTAL NET
NO DEMAND BILLING MAX. CHARGES BILLED CONSUMED CONSUMED CONSUMED ENERGY ENERGY BILL UNIT
DEMAND DEMAND RS. FROM FROM FROM CONSUMED CHARGES AMOUNT IN
BILLED 22.00 - 6.00 06.00 - 17.00 17.00 - 22.00 KVAh RS. RS. RS.
1 JAN 1250 937.5 1059 211840 0.993 180280 245780 114060 540120 1821421.00 2042097 3.78
2 FEB 1250 937.5 1059 211840 0.990 167240 215280 102500 485020 1634304.00 1870344 3.86
3 MAR 1250 937.5 1129 203220 0.987 175140 209800 107520 492460 1682465.00 1881232 3.82
4 APR 1250 937.5 1034 186120 0.986 202700 222160 121240 546100 1860189.00 2024631 3.71
5 MAY 1250 937.5 1072 214400 0.987 185280 233300 110940 529520 1783247.00 1990820 3.76
6 JUN 1250 937.5 1085 217000 0.989 198320 256900 118260 573480 1930875.00 2148093 3.75
7 JUL 1250 937.5 1039 207800 0.990 192140 268960 122040 583140 1966608.00 2166587 3.72
8 AUG 1250 937.5 1018 203600 0.996 151520 283750 124370 559640 1899141.00 2031389 3.63
9 SEP 1250 937.5 1092 218400 0.996 80760 268920 121980 471660 1621123.00 1866308 3.96
10 OCT 1250 937.5 1070 214000 0.994 77860 217380 119220 414460 1531041.00 1767243 4.26
11 NOV 1250 937.5 1044 208800 0.995 182340 243900 114280 540520 1822354.00 2079598 3.85
12 DEC 1250 937.5 1056 211200 0.996 198920 274880 122000 595800 2007256.00 2167039 3.64
13 TOTAL 2508220 11.90 1992500 2941010 1398410 6331920 21560024 24035381 45.7
14 AVG 1063 209018.33 0.99 166041.67 245084.17 116534.17 527660.00 1796668.67 2002948 3.81
SD 42990.88 25633.26 6770.89 52669.52
MEAN+1SD 209032.55 270717.43 123305.06 580329.52
MEAN-1SD 123050.79 219450.90 109763.28 474990.48
MINIMUM 1018 186120 0.99 77860 209800 102500 414460 1531041 1767243 3.63
MAXIMUM 1129 218400 1.00 202700 283750 124370 595800 2007256 2167039 4.26
pg. 25
MONTH vs MAX. DEMAND - GRAPH- YEAR 2008
1200
1126 1106
1099 1099 1080 1074 1072 1064
1000 1023
987 980
925
800
600
400
200
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
pg. 26
MONTH vs POWER FACTOR - GRAPH - 2008
1
1.00
0.995 0.99 0.99 0.99 0.99 0.99 0.99
0.99 0.99 0.99
0.99
0.985
0.98
0.98
P. F.…
0.975
0.97
0.97
0.965
0.96
0.955
pg. 27
MONTH vs UNIT RATE 2008
4.50
4.00 3.99 4.00 4.01

3.88 3.85
3.81 3.80
3.74 3.73 3.73 3.76
3.50
3.00
2.50
2.00
pg. 28
MONTH vs MAX. DEMAND - GRAPH- YEAR 2009
1140
1129
1120
1100
1092
1085
1080
1072 1070
1060 1059 1059 1056
1044
1040 1039
1034
1020 1018
1000
980
960
pg. 29
MONTH vs POWER FACTOR - GRAPH - 2009
0.996 0.996 0.996

0.995
0.995 0.994
0.993
0.990 0.990
0.99 0.989
0.987 0.987
0.986 P. F.…
0.985
0.98
0.975
pg. 30
MONTH vs UNIT RATE
4.50
4.26
4.00
3.96
3.86 3.82 3.85
3.78 3.76 3.75
3.71 3.72
3.63 3.64
3.50
3.00
2.50
2.00
pg. 31
Measurement of Electrical Parameters of Transformer no. 1 (1250

KVA)
L. T. side measurement:
Voltage - R - Y = 411 V Current - R phase = 917 Amp
Y - B = 417 V Y phase = 945 Amp
B - R = 412 V B phase = 909 Amp
Average phase to phase Voltage = 413 V Average phase Current = 924 A
Average Measured Power Factor:- 0.996
Power output on secondary side

1.73 R 413 R 924 R 0.996
\0 0 658.31 ]3) 0 660.95 ]9
1000
Calculation of % loading with respect to full load capacity of transformer:
Rated full load of transformer in KVA. – 1250 KVA
∴ % Loading on Transformer
NP.Z ^
0 0 52.66%
K
Page | 32
Performance Evaluation of Transformer No. 1 - 1250 KVA:

For a Transformer,

dA K
Losses at present loading 0 ` a( a" b c f R a( a"
e
A dA
Where,
No load losses = Power consumed to sustain the magnetic effect in the
transformer’s steel core. Core loss occurs whenever the transformer is energized;
core losses do not vary with the load. Core losses are caused by two factors:
hysteresis and eddy current losses.
Load losses = these losses are associated with full load current in the transformer
windings. Copper loss is power lost in the primary and secondary windings of a
transformer due to the ohmic resistance of the windings and this loss varies with
square of the current.
For the transformer of 1250 KVA

No load losses are - 2000 W
Load losses are - 11880 W
NP.Z K
Losses at loading of 658.31 KVA 0 2000 b c f R 11880 0 5295 9
K
nopqop r UXX
% ghhijikljm 0
nopqop b stTTkT
ukvTowkT nopqop r UXXX r UXX
0
ukvTowkx nopqop r UXXX b ys b ss r z{
Where,
NL = No load Losses in Watts
LL = Load losses in watts at full load at 75 C
TF = Temperature correction factor
PF = Load power factor
The basic D.C. resistance copper losses are assumed to be 90% of the load losses.
Eddy current losses (in conductors) are assumed to be 10% of the load losses.
Basic I2R losses increase with temperature, while eddy losses decreases with
increase in temperature. Thus, 90% of the load losses vary directly with rise in
temperature and 10% of the load losses vary inversely with temperature.
pg. 33
Calculations are done for an assumed temperature rise, and the rise in
temperature is dependent on the total losses to be dissipated.
Operating temperature = Ambient temperature + Temperature rise.
To estimate the variation in resistance with temperature, which in turn depends

on the loading of the transformer, the following relationship is used.
Rt – op = F + T amb + T rise
Rt – ref F + T ref
Where F = 234.5 for Copper

= 225 for Aluminium
= 227 for Alloyed Aluminium
Rt. op = Resistance at operating temperature
T ref = Standard reference temperature, 75 C
Temperature correction factor, T

= Load losses at operating temperature
Load losses at reference temperature
= 0.9 X (Rt – op) + 0.1 X (Rt – ref)

(Rt – ref) (Rt – op)
Here, Rt – op = 234.5 + 31.5 + 53 = 1.024
Rt – ref 234.5 + 75
So, T = 0.9 x 24 + 0.1 x1.024 = 1.024
% Efficiency * = 658 x 1000 x 100

(658 X 1000) + 2000 + [(658/1250) 2 x 11880 x 1.024]
= 658000 x 100
663370.91
= 99.19% say 99 %
pg. 34
The efficiency of transformer no – 1 at the 52 % load is 99%, which is observed to

be very good.
-: Efficiency Curve of A Transformer :-
pg. 35
System unbalance checking with respect to voltage and current
Transformer no – 1 - L. T. side measurement:-
L. T. side measurement:-
Voltage:- R to Y = 422 V Current:- R phase = 1024 Amp
Y to B = 436 V Y phase = 1098 Amp
B to R = 434 V B phase = 1001 amp
Average phase to phase Voltage = 430.66 V, Average phase Current = 1041 A
Measured Average Power Factor = 0.991
Calculation of Voltage unbalance:-
% Voltage unbalance = Maximum voltage on any phase – Average voltage x 100

Average voltage
= 436 – 430.66 x 100 = 1.24 %

430.66
% Voltage unbalance is observed to be 1.24% which is more than 1 % and hence

it is not good.
One percentage System unbalance voltage wills increases System losses by five
percent so you are advised to keep voltage balance in each Phase for Energy
conservation.
We have observed that you already have OLTC voltage control panel but it is
running on Last step of its setting. So we are giving you some other suggestion for
voltage balance in your system.
1. Check all major Electrical Equipment connections and tighten if necessary.

2. Check H.T. Side and Transformer side connection and tighten if necessary.
3. Check all capacitor terminal connection and tighten it if necessary.
4. Try to keep all loads in balance on each phase.
pg. 36
5. Transformer body to earth insulation and Neutral connection checking.
Calculation of Current unbalance:-
% Current unbalance = Maximum Current on any phase – Average Current x 100

Average Current
= 1098 – 1041 x 100 = 5.47 %

1041
Comments:- Since current unbalance is more than 1.5 %, Following suggestions

are given to bring
% Current unbalance will come under 1 %.
Suggestions are made for balancing unbalance currents in the plant:-
a. Lighting loads of the plants are to equally balance on all the three phases.
b. Single-phase motor loads of the plants are to equally balance on all the three
phases
c. All the loose connections in the plants are to be tightened.
d. Request power supply board. to tightened their H.T. line connections for
balancing incoming loads.
pg. 37
Table for Transformer Losses as per Standards: -
KVA Rating No Load Losses in Full Load Copper Efficiency %

W losses at 75oC in
W
100 500 2000 97.50
125 570 2350 97.66
160 670 2840 97.81
200 800 3400 97.90
250 950 4000 98.02
315 1150 4770 98.15
400 1380 5700 98.23
500 1660 6920 98.28
630 1780 8260 98.37
750 1800 9200 98.40
800 1900 9980 98.45
1000 2000 11880 98.54
1500 2100 15500 99.00
2000 2500 22000 99.00
2500 2800 26000 99.00
3200 3240 31050 99.00
Energy saving Opportunities in Transformer:-

Power and distribution transformer which works on the principle of
electromagnetic induction and
∴ These transformers consume reactive power (KVAr) for their own needs for
formation of magnetic flux even when its secondary is not connected to any load
or at very low load.
The power factor will be very low under such a situation which is COSØ = COS 75o
= 0.2588 and this can be confirmed from the below mention vector diagram of no
load transformer.
The low power factor condition of transformer will increase no load losses and
hence for reduction of no load losses and to improve no load power factor a fixed
pg. 38
capacitor or banks of a fixed capacitors are required to be install at the L. T.

(secondary side) side of the transformer.
The table gives the approximate KVAr of capacitor required for improving no load
poor P. F. of the transformer:-
Sr. No KVA rating of Transformer KVAr required for compensation
1 Up to and including 315 KVA 5 % of KVA rating
2 315 KVA – 1000 KVA 6 % of KVA rating
3 1000 KVA – 2000 KVA and 7 % of KVA rating
above
In our case Sr. no 3 will apply.
The KVAr required for compensation is 1250 KVA x 0.07 = 87.5 KVAr say 90 KVAR
The calculation of no load losses and reduction due to improvement of no load

P.F. by installing fixed capacitors of 90 KVAr at the L.T. side of the each
transformer. (COSØ = COS75° = 0.2588 to new COSØ = COS74.5° = 0.2672)
}A ~ K
% No load losses reduction in Transformer 0 |1 c f R 100
~
.KPP K
0 |1 c f R 100
.KNLK
0 1 0.9382 R 100
= 6%
No load vector diagram of transformer:
Primary Voltage
Iw
↓ = 75° E1
Iw = Active current component or working or iron loss component

Im = Magnetizing current component
Io = No load Primary input current
= 1.0 % of rated primary current
In our case primary full load current = 21.86 Amp
∴ 1.0 % of primary input current =21.86 x 0.01 = 0.2186 Amp
Im Io
pg. 39
Assuming, transformer works 365 days in a year. The no load losses generated
during the year as under.
6 % of No load losses of the year = 17520 KW H x 0.06 = 1051.20 KWH say 1052
KWH
(Detailed calculation In Final Report)
Cost of 6 % no load losses of the year = 1052 KWh x Rs. 3.81/-
(Average unit rate for year – 2009)
= Rs. 4008.12/- say Rs. 4010/- per year.
The saving per year by installing 90 KVAr capacitor to one Transformer

= Rs. 4010/-
Please note that we will have to reduce the capacitors installed directly on the
transformers as similar calculations are reversed if power factor is leading instead
of lagging.
As the transformers already have a higher installation of capacitors we have to
make no investment. Simple reshuffling of capacitors involving some man hours
will solve the problem and lead us towards better efficiency.
pg. 40
What is Harmonics:-
At the time of the designing any A.C. machine, it is assumed that voltage and
current wave from at the output terminals of A. C. machines is assumed to be
sinusoidal and consists of only one frequency which is called fundamental
frequency or 1st harmonics and such sinusoidal wave from dose not contain
harmonics of other frequency.
Due to non linear system load such as thyristorised control, variable frequency
drive and D. C. motor, a harmonics are generated at the output side of the A.C.
machines and hence original sinusoidal wave form are disturbed and wave form
becomes complex and non sinusoidal in nature generating 2nd, 3rd, 4th and so on
frequencies of the fundamental frequency.
The above phenomenon is shown in the below given diagram.
These 2nd, 3rd, 4th frequencies are called harmonics of the fundamental frequency.
In short waveform with frequencies other than fundamental frequency is called
harmonics.
2nd, 4th etc frequencies are called even harmonics and 3rd, 5th, 7th, etc frequencies
are called harmonics.
Harmonics in transformer:-
The non-sinusoidal nature of the magnetizing current necessary to produce a sine
wave of flux produces harmonics in current and voltage wave –forms of the three
phase transformers.
The effects of current harmonics:-

1. Increased heating of winding.
2. Inductive interference with communication circuits.
3. Increased iron losses.
The effects of voltage harmonics:-

a) Increased heating of winding.
b). Capacitive interference with communication circuits.
c). Production of large resonant voltages.
pg. 41
Major Causes of Harmonics

Devices that draw non-sinusoidal currents when a sinusoidal voltage
is applied create harmonics. Some of these devices are listed below:
Electronic Switching Power Converters

1. Computers, UPS, Solid-state rectifiers.
2. Electronic process control equipments
3. Electronic Lightning Ballasts.
4. Reduced voltage motor controllers.
Arcing Devices
1. Discharge lighting.
2. Arc furnaces, welding equipments.
Ferromagnetic devices.
1. Transformers operating near saturation level.
2. Magnetic ballasts.
3. Induction heating equipment chokes.
Appliances
1. TV sets air conditioners, washing machines, and microwave
ovens.
2. Fax machines, photocopiers, and printers.
Higher RMS current and voltage in the system are caused by
harmonic currents, which can result in any of the problems listed
below:
1. Blinking of Incandescent Lights- Transformer Saturation.
2. Capacitor Failure- Harmonic Resonance.
3. Circuit Breakers Tripping- Inductive Heating and Overload.
4. Electronic Equipment Shutting down- Voltage Distortion.
5. Flickering of Fluorescent lights- Transformer Saturation.
6. Fuses Blowing for no apparent reason- Inductive heating and
Overload.
pg. 42
7. Motor Failures (overheating) – Voltage Drop.

8. Conductor Failure- Inductive heating.
9. Neutral conductor and terminal failures – Additive Triplen
currents.
10. Electromagnetic Load Failures – Inductive heating.
11. Overheating of Metal Enclosures- Inductive heating.
12. Power Interference on voice communication- harmonic noise.
13. Transformer failures- Inductive Heating.
Overcoming Harmonics
Tuned Harmonics filters consisting of a capacitor bank and reactor in
series are designed and adopted for suppressing harmonics by
providing low impedance path for harmonic component. The
harmonic filters connected suitably near the equipment generating
harmonics help to reduce THD to acceptable limits. For overcoming
and troubleshooting of some problems in the electrical power system
HARMONICS WAVE FORM
pg. 43
Measurement of Harmonic Level in the Plant:-

We have measured Harmonic Level in the plant and results are mentioned as
under.
Location THD % Harmonics in Harmonics in

Voltage % Current %
rd
V A 3 5th 7th 3 rd
5th 7th
Main ACB incomer 11.2 24.7 0.8 10.3 3.1 4.7 19.6 5.2
Table – Harmoni cs measurem ents
Observations-
1. THD Levels in both Voltage and Current are above the permissible limits.
This is because of many VFD Drives in your system.
2. These higher THD Level create problems in system for example ACB tripping
without any fault flag, Burning of capacitors, Motor winding Bursting,
Frequent tripping of machinery on voltage fluctuation, and we advise to
install harmonic Filters in your Electrical network.
Power factor improvement with the use of static capacitors:-
In case of alternating current power supply system current is always lag behind
the voltage. This is due to the fact that the A.C. machines works on the principle
of electromagnetic induction and these A.C. machines consume reactive power
for their own needs for formation of magnetic flux and this phenomenon will
cause current vector to lag behind the voltage vector and this will generates the
P.F. in the system. The above fact is shown in below sine wave diagram.
pg. 44
What is Power Factor:-
The P. F. = CosØ is the ratio of KW = Active Power

KVA Apparent Power
Methods of improving power factor:-

1. With the use of static capacitors.
2. With the help of synchronous condenser.
3. With use of phase advancers.
Here we can discuss the use of static capacitor and there advantages for
improving
How Power factor improves with the use of static capacitors:-
pg. 45
The static capacitor generates reactive current of opposite nature at leading

power factor when connected to the supply mains parallel to inductive load and
compensates reactive current of the inductive load, which is running at lagging
power factor.
∴ When static capacitor is connected parallel to the inductive load, the inductive
load starts receiving reactive power of opposite nature at leading power factor
from the capacitors and thus this reactive power neutralizes the inductive power
requirement of the load and thereby improves the P. F. of the load.
The above Explanations are made simple with the below mentioned Vector
Diagram.
pg. 46
The P. F. = CosØ is the ratio of KW = Active Power

KVA Apparent Power
Vector diagram and physical diagram of inductive load with use of capacitor
pg. 47
Effect of Different Power Factor on 100 KW Industrial Motor Working

Load:-
Assume 3 phase, 100 KW rating inductive motor., V = 415, P.F. = Cos ↓ =

Cos 0°° = 1,
∴↓ = 0°°,
F = 50 HZ, Efficiency = 90 % Sin ↓ = Sin 0°° = 0
η Of Motor = Output Input = 1.73 x V x I x Cos ↓ = output x

100
Input η
I = 100 x1000
1,73 x 415 x1 x 0.90
I (line) = 155 Amp.
Active Current = I active = I(line) x Cos ↓ = 155 x 1 = 155 Amp.
Reactive Current = I reactive = I(line) x Sin ↓ = 155 x 0 = 0 Amp.
The KVA = KW = 100 =100 KVA
Cos ↓ 1
pg. 48
KW = KVA x Cos ↓ = 100x1 = 100

KVAr = KVA x Sin ↓ = 100x0 = 0
Vector Diagram
Active Power – (KW) = 100
Reactive power-(KVAr) = 0
Apparent or resultant power – (KVA) = 100
(B) 100 KW load working at Cos ↓ = P. F. =0.90, ∴↓ = 25°°

The KVA = KW = 100 = 111 KVA
Cos ↓ 0.90
Line Current = I (line) at P.F of 0.90 = 155 Amp./ 0.90 = 172 Amp
Active Current = I active = I(line) x Cos ↓ = 172 x 0.90 = 155 Amp
Reactive Current = I reactive = I(line) x Sin ↓ = 155 x 0.422 = 64.4 Amp.
KW = KVA x Cos ↓ = 111x0.90 = 100

KVA = 111
KVAr = KVA x Sin ↓ = 111x0.422 = 47
-: Vector Diagram :-
Active power – (KW) = 100 KW
↓ = 25° Voltage vector - V
Current vector – A . Reactive power–(KVAr) = 47
Apparent or resultant power – (KVA) = 111
pg. 49
(C) 100 KW load working at Cos ↓ = P. F. = 0.80, ∴↓ = 36.8°°
Line Current = I (line) at P.F of 0.90 = 155 Amp./ 0.80 = 194 Amp
Active Current = I active = I(line) x Cos ↓ = 194 x 0.80 = 155 Amp
Reactive Current = I reactive = I(line) x Sin ↓ = 194 x 0.599 = 116 Amp
The KVA = KW = 100 = 125 KVA

Cos ↓ 0.80
KW = KVA x Cos ↓ = 125x0.80 = 100
KVA = 125
KVAr = KVA x Sin ↓ = 125x0.599 = 75
-: Vector Diagram :-
Active power – (KW) = 100 KW
↓ = 36.8°
Voltage Vector - V
Reactive power–(KVAr) = 75
Current vector - A
Apparent resultant power – (KVA) = 125
From the above vector diagrams and below mentioned calculation it can be
seen that at
(A) 100 KW load and P. F. = 1 ∴KVA = 100 KVA
∴ Demand charges = 100 x Rs.200 = Rs.20000/-
(Assuming Demand Charges = Rs. 200 /KVA)
(B) 100 KW load and P. F. = 0.90 ∴KVA = 111 KVA

∴ demand charges = 111 x Rs. 200 = Rs.22200/-
pg. 50
Effects of Transmission & Distribution Losses Due Power Factor

Improvement:-
Transmission losses of plant + Distribution losses of plant = 3 % + 7 % = 10 %

(On total yearly Consumption)
The above Transmission and Distribution losses of plant are called plant
losses.
Transmission losses of plant are the losses occurring in main

transformers, H.T. Cables, Switch Gear etc. = 3 % (Of total yearly
Consumption)
Distribution losses of plant are the losses occurring in main L.T. Cables, L.T.
Switch Gear, L.T. Bus -Bar etc. = 7 % (Of total yearly Consumption)
Now % loss reduction due to improvement of average P.F. from 0.94 to 0.99
Now Plant Copper losses in any A.C. System = I2 xR α 1

Cos ↓2
∴ Plant Copper losses = K

Cos ↓2

Now Plant copper losses at 0.94 P.F. 0
.[M ^ .[M

0
.PPZN
0 ] R 1.1317

Now Plant copper losses at 0.99 P.F . 0
.[[ ^ .[[
pg. 51
0 ] R 1.0203
Thus Plant heat loss reduction by improving PF at consumption point
277". a 5 0.94 \4 277". # 5 0.99 \4
0
277". # 5 0.94 \4
] R 1.1317 1.0203
0
] R 1.1317
0.1114
0
1.1317
0 0.0984 / 10 %
Thus, by improvement in P.F. from 0.94 to 0.99, there will be a plant loss
reduction of 10 %. However the exact saving percentage can’t be calculated as
all motors are running at various PF varying form 0.7 – 0.9. But it is evident
that heat loss reduction is enormous and substantial, as per the example
calculation above.
* What are Transmission and Distribution losses of plant?
Transmission losses of plant are those electrical losses occurring in the

Transformers, H.T. Cables, and Switch Gears etc and which is standardized at
the rate of 3 % of the yearly energy consumptions of the Plant.
Distribution losses of plant are those electrical losses occurring in the L.T.
Cables, Fuse links, bus bars and Meters etc and which is standardized at the
rate of 7 % of the yearly energy consumptions of the plant.
∴Transmission losses of plant + Distribution losses of plant = 3 % + 7 % = 10

% (On yearly Consumption)
Power factor improvement with the use of static capacitors:-
pg. 52
In case of alternating current power supply system current is always lag

behind the voltage. This is due to the fact that the A.C. machines works on the
principle of electromagnetic induction and these A.C. machines consume
reactive power for their own needs for formation of magnetic flux and this
phenomenon will cause current vector to lag behind the voltage vector and
this will generates the P.F. in the system. The above fact is shown in below
sine wave diagram.
Methods of testing & checking of running capacitors:-

1. With the help of AVO meter - A good capacitor will show dead short
between any two terminals first & then charge up to battery voltage.
2. Megger test- A good capacitor will show infinity resistance between any
terminals & earth.
3. With the help of Ampere meter - A good capacitor will draw rated current at
rated voltage.
We have observed that Most major motors in your plant are working with VFDs
with proper capacitor installation and they are maintaining motor and panel PF
over 0.95 which is excellent in terms of controlling the transmission and
distribution losses. We suggest to check the APFC capacitor current ratings,
every week and replace any faulty capacitors as soon as possible.
Importance of good Power Factor and various benefits thereof: -

1. The KW capacity of the prime movers is better utilized.
2. The KVA capacity of the transformers and cables are increased.
3. The efficiency of every plant is increased.
4. The overall production cost per unit decreased.
pg. 53
5. Heat losses in any electrical machine = k x 1/P.F. and hence high P. F. will
generate less heat.
6. Reduction of plant electrical losses due to improvement of P. F. =
}A ~
1
~

7. KVA reduction =a6 R
~ ~ K
Disadvantages of poor power factor: -

1. Losses in any electrical equipment are proportional to i² which means
proportional to 1/P.F.² thus losses at P.F. = Unity = 1 and losses at P.F. =
0.8 are 1/ [0.8] ² = 1.57 times higher than those at unity P. F.
2. Rating of motors and transformers etc. are proportional to current hence to
1/P. F. therefore large motors and transformers are required.
3. Poor P. F. causes a large voltage drop, hence extra regulation equipment is
required to keep voltage drop within prescribed limits.
Indirect benefits of improved P. F. to the industries:- (Example for

understanding)
1. Losses reduction of the plant due to improvement in P. F. from P. F. 1 (0.92)
to P. F. 2 (0.98)
Now we are raising the existing P. F. of 0.92 to new P. F. of 0.98.
Therefore, monthly energy loss reduction in the plant, due to improvement of PF
~
=1
~ K
pg. 54
.[K
=1
.[P
= 1 – 0.8812
= 0.1188
= 11.88 %
When current I amperes flow through any electrical machines having resistances
R ohms for t seconds the electrical energy expended is I² x R x t joules.
∴Heat produced = I² x R x t / 4187 kilocalories.
∴Heat produced at PF 1 (0.92) = k [1/ (PF 1)2] & Heat produced at PF 2 (0.98) = k
[1/(PF 2)2]
∴Reduction in heat generation due to improvement of P. F.

=R
~ ~ K
= k x [ 1.1814 – 1.0412 ]
= k x 0.1402 Calories
Sample Calculation for input to the motor, % shaft loading on motor and load
factor Table – (A) for Sr. No.1. (Assuming average η of motor = 82 %)
Input Power in KW
1.73 R 3 R R 2
0
1000
1.73 R 425 R 155 R 0.87
0
1000
0 99.14 ]9 / 99 ]9
η Of Motor = Output x 100

Input
∴Output of motor (Shaft Loading) = ηx Input = 82 x 99 = 81.18 KW.
pg. 55
100 100 say 81 KW
∴% Shaft Loading = Measured output in KW x100 = 81 x100 = 36 %

Rated output power in KW 225
% Load factor of motor = Input Power in KW x 100

Rated Output Power in KW
= 99 x100 = 44 %
225
Similarly the others motor’s shaft loading and Load factor had been summer
breaks but completion.
Scope of Energy Saving In Electrical Motors

(A)
Energy Saving By Replacing Existing V- Belt Drive Into Energy Saving Flat Belt
Drive:-
Engineering for Energy Saving in Energy Saving Flat Belt Drive:-
Energy Saving Flat Belt Drive is made from Nylon (Super Polyamide) and Chrome
leather materials while that of V – belt drive is made from Rubber and hence
Energy Saving in Flat Belt Drive is possible.
Disadvantages of V – belt drive:-
1. Thick rigid sections of V- belt drive absorb a great deal of useful power and
add to running costs. Theses power losses are typically dissipated in the
form of heat. Which in-turn has a deleterious effect on the belt life.
pg. 56
2. The wedging action of V- belt drive involves an irreversible energy loss, as

each V- belt is continuously wedged into the pulley groove and pulled out
again. This loss is aggravated by misalignment and unmatched V- belts in a
set. Further loss of energy occurs in the flexing of solid rubber and in the
shuffling of power between V – belts in a set.
3. Over all Weight of the V – belt drive is higher.(Including Pulleys)
The above three negative points of the V – belt drive can be converted in to
positive points by converting existing V – belt drive in to Energy Saving Flat Belt
Drive.
Advantages of Energy Saving Flat Belt Drive over V – belt drive:-
1. Efficiency of Energy Saving Flat Belt Drive is 98 % while that of V – belt drive
is 86 % and hence 12 % Energy Saving is possible with Flat Belt Drive.
2. Energy Saving Flat Belt Drive is generate very less vibrations while that of V
– belt drive generate more vibrations and hence long life of bearings and
machines with less noise are possible with Flat Belt Drives.
3. Energy Saving Flat Belt Drive is made from Nylon (Super Polyamide) and
Chrome leather while that of V – belt drive is made from Rubber and hence
less weight are possible with Flat Belt Drive which results high load transfer
with
4. High transmission efficiency.
5. Energy Saving Flat Belt Drive is vibrations free, slip free and maintenance
free while in that of V – belt drive above actions are not possible.
6. 5 % Energy Saving in Flat Belt Drive is possible while in that of V – belt drive
is not possible
Calculations for Energy Saving in Flat Belt Drive:-
There is total 14 big and major Motors which are running on V – Belt drive , so
total KW of those motors is 916 KW.
pg. 57
Cost benefits analysis are mentioned as under. Considering 83 % Load Factor

(From Billing Analysis sheet – 2009)
1. The Total Effective Load V – belt drive Motor = 916 KW x 0.83 = 760 KW
1 Energy Saving with flat belt drive = 4 %

Daily load reduction due to replacement of existing V belt drive in to Flat Belt
Drive
= 760 x 0.04 = 30 KW
= 30/0.99 KVA = 31 KVA
Monthly monitory saving due to 31 KVA reduction

= 31 x Rs. 200 /-
= Rs. 6200/--
Annual monitory saving due to 31 KVA reduction
= Rs. 6200 x12 Month
= Rs. 74400/-
So total saving by Replacing V – belt Drive in to Flat belt drive by reduction of KVA
demand is Rs. 74400/-
2. Annual consumptions on 83 % load factor of 12 months working

= 30 KW x 24 x 365 Days x 0.83
= 218124 KWH
= 220327 KVAh
Annual Monitory saving in Rs by above conversion = 220327 KVAh x Rs.
3.81/-
= Rs. 8,39,446/-
pg. 58
4. Cost of converting one no. Of V – belt drive in to Flat Belt Drive with other
Exp.
= Rs32000/- (assumed average)
5. Salvage value of existing Of V – belt drive = Rs.2000/-
6. Net Cost of converting one no. Of V – belt drive in to Flat Belt Drive
= Rs32000/-- - Rs.2000/- = Rs.30000/-
7. Net Cost of converting 14 no. Of V – belt drive in to Flat Belt Drive
= Rs.30000/- x 14
= Rs. 4,20,000/-
8. The payback period for all conversion = Net cost of V - belt drive
conversion
Total yearly saving by conversion
= Rs. 420000/-
Rs. 839446/-
= 0.50 year = 0.50 x12 months =6 months
9. Rate of yearly return = 200 %
Remarks:-
(1) The annual saving in energy bill is 4 % = Rs. 839446/- for all 14 Nos. Motors.
(2) KVA demand saving of Rs. 74400/-
(3) Total saving in Rs. Due to conversion of V belts to flat belt drive. = (1) + (2)
= Rs.
913846/-
(4) The payback period on investment is only Six months
(5) Rate of annual interest on capital invested is 200 % and hence installations of
Flat Belts drive are strongly recommended.
pg. 59
S.No. Motor Details KW

1. Main Motor PM1 110
2. Vacuum Pump PM1 165
3. Turbo Main 75
4. Boiler 4 Ton ID Fan 18
5. Vacuum Pump PM2 200
6. Machine Chest Pump x 2 Nos. 15 KW Each
7. Couch Pit Pump PM1 15
8. TDR Pump x 2 Nos. 37
9. Chest Agitator x 3 Nos. 15 KW Wach
10. Rewinder 22
11. Blower PM2 x 2 Nos. 15 KW Each
12. Pulper 132
(B) Energy saving by replacing Old Low Efficiency Motors by New Energy
Efficient Motors.
We have observed that in your plant there are so many old Low Efficiency motors
are working. Old Low Efficiency motor and rewinded motors consumed more
energy as compared to New Energy efficient Motor.
Motor Efficiency Test (No Load Method)

We have taken measurement on your old rewind 10 HP motor for calculation of
efficiency for this motor.
Motor Specifications
Rated power = 7.5 kW/10 HP
Voltage = 415 Volt
Current = 17 Amps
Speed = 935 RPM
Connection = Delta
pg. 60
No load test Data

Voltage, V = 424 Volts
Current, I = 5.9 Amps
Frequency, F = 50 Hz
Stator phase resistance at 20 °C = 2.5 Ohms
No load power, Pnl = 156 Watts
( a) Let Iron Plus Friction and windage Loss , Pi + fw

No load Power Pnl – 156 Watt
o
Stator copper Loss, Pst @ 20 C (Pst.Cu)
= 3 x (5.9/1.73) 2 x 2.5
= 87.23 Watt
Now Pi + fw = Pnl – Pst.cu = 156 – 87.23 = 68.77 Watt
(b) Stator Resistance at 120◦ C
KKZ
HK 0 2.5 R
K KZ
0 3.48 '6
0
(c) Stator Copper Losses at Full Load Pst.cu 120 C
= 3 x (17/1.73) 2 x 3.48
= 1008.32 Watt
[Z

(d) Full Load Slip = 0

= 0.065

Thus, Input to Rotor =
L
0
.N
L
0
.[Z
pg. 61
= 8021.40
(e) Total Full Load Input Power

= 8021.40 + 1008.32 + 68.77 + 37.5 ( stray Losses 5 % of rated Output)
= 9135.99 Watt Say 9136 watt
nopqop
(E) Motor efficiency at Full Load = r UXX
lqop
= 82.09 % say 82 %
Above test clearly shows that Old and many times rewind Motors have very low
efficiency as compared to new Energy efficient Motor. New Energy Efficient
Motors have efficiency up to 95%.
So you are advised to change all possible old motors in one go and install New
Energy efficient Motors.
Cost benefits analysis of New Energy Efficient Motor in place of Old Motor
Sample calculations for 100 KW Motor – (Old) with compare to new 100 KW
Energy efficient Motor.
1. Power Consumption for 100 KW – Old Motor Considering 82 % efficiency On

Full load.
= 100 KW/0.82 = 121.95 Kw Input Power
2. Power Consumption for 100 KW – New Motor Considering 0.95 % On Full load.
= 100 KW/0.95 = 105.26 KW Input Power
Energy Saving by Installing New Energy Efficient Motor = 121.95 - 105.26

= 16.68 KW
pg. 62
From above calculations we can save 16.68 Unit per Hour By replacing Old motor
with new motor
(Considering running motor on Full Load)
Area S.No. Motor HP VFD Make RPM Rated Voltage Measured Efficiency Present Required
Details (kw) current(A) Measured current(A) % current at
loading 90%
of efficiency
Motors and 75%
loading
PM-1
1 Vacuum 7.5 5.5 Kirloskar 2800 7.8 410 5 68.41 75.0 4.5
separator
2 Holly Roll 3.5 2.5 ABB 960 3.5 410 4.4 100.0 3.5
3 Nozzle 1 0.75 CG 2800 1.5 410 2.7 100.0 1.5

Pump
PM-2
4 Pope reel 20 15 ABB 1440 28 14.3 55.15 51.1 13.5
5 MG 75 55 ABB 1440 98.5 58.8 58.42 59.7 50
6 Second 75 55 ABB 1440 98.5 53 51.40 53.8 46.5

Press
7 Wire 120 90 ABB 1440 157 72 38.00 45.9 66
8 Vacuum 270 200 NGEF 1440 340 260 96.64 76.5 142.8
Pump
9 Blower 1 20 15 ABB 1440 21 13.5 48.39 63.4 11.5
10 Blower 2 20 15 ABB 1440 21 12.5 47.06 58.7 11
11 Nozzle 1 0.75 CG 2800 2 410 2.6 100.0 2.00

Pump
Pulp
mill
12 Turbo Main 100 75 106.5 136 100.0 106.5
13 Turbo 50 35 49.7 40 69.40 80.5 36

Pump
14 Refiner 40 30 42.6 30 56.01 70.4 24
Pump
15 Back water 15 10 14.2 10 64.88 70.4 8
Boiler
16 Compressor 15 10 14.20 15.5 100.00 14.2

Boiler
pg. 63
KVA required by above machines @ 321.332 KVA

present loading conditions
KVA required after replacing above 238.5296 KVA
machines @ present loading conditions
Reduction in KVA demand by replacing 82.80242 KVA
above machines by new energy efficient
machines
Monthly Reduction in KVAh required by 59617.75 KVAh
using new energy efficient motors
Monitory saving @Rs3.81/KVAh/ 244363 Rs

annum
Annual Savings 2932356 Rs
The approx. Net cost of conversion of all old Motor Rs. 6,50,000/- (we have
considered a thumb rule of Rs. 2300 per KW) (Salvage value of Old Motor has
been Considered)
The payback Period = Cost Of Conversion = Rs.650000/- = 0.22 Years x 12 Month = 3 Months
Yearly Saving Rs. 2932356/-
Looking to the above benefits and yearly saving of Rs. 2932356/- every year, you
are recommended to change motors in one go with new energy efficient motor.
New motors have energy saving benefits, long life and trouble free operation, less
maintenance cost and with manufacturer guarantee. So we suggest you to
implement this change as early as possible.
-: Power Stages In An Induction Motor:-
pg. 64
Variation of Motor Efficiency /P. F / Stator Current / Torque & Speed

with receipt to Load Demand
Power Loss Due to Under Load Operation of Induction Motor
(% of Power Loss in Motor):
Motor):-
Whenever induction motors rrunsuns in under load conditions, heavy power

losses are observed and hence under loading and no load running of the
inductions motor are to be avoided.
pg. 65
For our customers knowledge a following chart of power losses is attached.
Power Loss Due to Under Load Operation of Induction Motor

(% of Power Loss in Motor) :-
Motor Capacity in No Load 25 % Load 50 % Load Full Load

H.P.
5 50 40 25 18
7.5 45 30 20 17
10 44 26 18 17
15 43 23 17 14
20 42 20 15 14
25 41.5 19 15 13
30 41 18 14 13
40 40 17 15.5 10.5
50 40 16 12.5 10
60 39 15.5 12.5 10
75 38.5 13 12 9
100 38 13 12 9
Motor Rating Capacitor rating (kVAr) for Motor Speed

(HP) 3000 1500 1000 750 600 500
5 2 2 2 3 3 3
7.5 2 2 3 3 4 4
10 3 3 4 5 5 6
15 3 4 5 7 7 7
20 5 6 7 8 9 10
25 6 7 8 9 9 12
30 7 8 9 10 10 15
40 9 10 12 15 16 20
50 10 12 15 18 20 22
60 12 14 15 20 22 25
75 15 16 20 22 25 30
100 20 22 25 26 32 35
125 25 26 30 32 35 40
150 30 32 35 40 45 50
200 40 45 45 50 55 60
pg. 66
250 45 50 50 60 65 70
Table – Rating of Capacitor required for different rating and

speed.
pg. 67
Performance Evaluation of Motors
Electrical motors accounts for a major part of the total electrical consumption. So
a careful attention should be given to the performance of this utility.
Measurements of the different electrical parameters of the major motors of the
plant are given in Table
The efficiency of the induction motor and loading condition of the motors are
directly proportional to each other. Higher the loading and higher is the efficiency
of the motors. The best efficiency of the motors is achieved at a load very much
near to the rated load.
pg. 68
Moreover at lower loads the power factor is on the lower side increasing the load
current and thereby increasing the copper losses, resulting in lower efficiency, the
rating of the motors should be decided after carefully understanding the process
requirement in the absence of which the motor might come out to be oversized.
Also one should run a motor, which has been rewound more than once as every
time a motor is rewinded it losses 2 – 5% of its actual efficiency.
Motor performance is affected considerably by the quality of input power that is

the actual volts and frequency available at motor terminals, vis-à-vis rated values
as well as voltage and frequency variations and voltage unbalance across the
three phases.
Mostly all the motors are old or rewound at least once. A good saving can be
achieved if higher efficient ones replace them. Though it’s a scheme with higher
initial investment but can be implemented phase wise. Induction motors are
characterized by power factors less than unity, leading to lower overall efficiency
(and higher overall operating cost) associated with a plant’s electrical system.
Capacitors connected in parallel (shunted) with the motor are typically used to
improve the power factor. The impacts of PF correction include reduced KVA
demand (and hence reduced utility demand charges), reduced I2R losses in cables
(leading to improved voltage regulation), and an increase in the overall efficiency
of the plant electrical system.
It should be noted that PF capacitor improves power factor from the point of
installation back to the generating side. It means that, if a PF capacitor is installed
at the starter terminals of the motor, it won’t improve the operating PF of the
motor, but the PF from starter terminals to the power generating side will
improve, i.e., the benefits of PF would be only on upstream side.
pg. 69
The size of capacitor required for a particular motor depends upon the no-load
reactive KVA (KVAR) drawn by the motor, which can be determined only from no-
load testing of the motor. Higher capacitors could result in over-voltages and
motor burnouts. Alternatively, typical power factors of standard motors can
provide the basis for conservative estimates of capacitor ratings to use for
different size motors. The capacitor rating for power connection by direct
connection to induction motors is shown in Table
We are suggesting some Measures to Improve Efficiency of Motors and

Distribution system
1: Electrical Distribution Correction

Measures available to improve power quality and reduce electrical losses are
1. Maintain voltage level close to nameplate level as far as possible, with a
maximum deviation of 5% (at 5% under voltage, copper loss is increased to
10%).
2. Minimize phase imbalance within a tolerance of 1%. As deviation of one
phase voltage from average phase voltage increases, it will result in
increased winding temperature.
3. Maintain high power factor to reduce distribution losses.
4. Avoid excessive harmonic content in the power supply system, as increased
harmonic content in power supply system will increase motor temperature.
5. Use oversize distribution cable in the new installation to reduce copper
losses. This will also help in reducing voltage drop during starting and
running and minimizing the motor losses.
2: Motor Efficiency Improvement

The measures available to improve motor efficiency are:
1. If motor is running at partial load then convert motor from delta to star
connection. This will improve motor efficiency.
pg. 70
2. Replace rewound induction motor (with reduced efficiency) with new

energy efficient motor.
3. If process demands oversized motor then possibility of use of VFD may be
explored to save energy. This is also applicable in case of varying load duty
cycle motor application.
4. Control the motor drive temperature. This will reduce copper losses and
increase motor life.
3: Better System Matching

Measures available are:
1. Use an on/off control system using timer, PLCs, etc to provide motor power
only when required.
2. Size the motor to avoid insufficient low load operation. Motor should run at
65% to 100% of its nameplate rating to get maximum efficiency.
4: Driven Load and Process Optimization

Measures available to optimize the process and its operation are:
1. Change or reconfigure the process or application so that less input power is
required.
2. Downsize the over sized pumps, fans, compressors or other driven loads if
possible.
3. Install more efficient mechanical subsystems. Check that coupling, gearbox
fan or pump must be energy efficient.
Miscellaneous Measures to Improve Motor Efficiency

Maintenance Energy savings of 10 to 15 percent of motor energy consumption
can typically be realized, depending on change from existing maintenance
practices.
These are:
pg. 71
1. Proper lubrication: it will minimize wear on moving parts. Lubrication is best

done on a regular schedule to ensure wear is avoided. Once it occurs, no
lubricant can undo it. It is crucial that the correct lubricant is applied in the
right quantities.
2. Correct shaft alignment: It ensures smooth, efficient transmission of power
from the motor to the load. Incorrect alignment puts strain on bearings and
shafts, shortening their lives and reducing system efficiency. Shafts should
be parallel and directly in line with each other. It is necessary to use
precision instruments to achieve this. Shaft alignment is an important part
of installation and should be checked at regular intervals.
3. Proper alignment: Belts and pulleys must be properly aligned and tensioned
when they are installed, and regularly inspected to ensure alignment and
tension stay within tolerances. Abnormal wear patterns on belts indicate
specific problems that may require correction. Loose bests may squeal and
will slip on the pulleys, generating heat. Correctly tensioned pulleys run
cool. Excess tension strains bearings and shafts, shortening their lives.
4. Painting of motor: Avoid painting motor housing because paint acts as
insulation, increasing operating temperatures and shortening the lives of
motors. One coat of paint has little effect, but paint buildup accumulated
over years may have a significant effect.
● Maintenance Schedule for MOTOR for Energy Conservation
i). Daily: -
Clean the motor and starter.
ii). Weekly: -
Clean slip rings with soft brush dipped in white spirit.
iii). Monthly: -
Check earth connections of motor and starter.
Blow through motor and starter with dry compressed air at 2 Kg/Cm .
Check tightness of cable connections.
pg. 72
Check motor for overheating and abnormal noise / sound, sparking and
for proper bedding of brushes.
Tighten belts and pulleys to eliminate excessive losses.
iv). Quarterly: -
Check motor terminal voltage for balanced supply. If more than +1% of
average, then check from transformer onward.
Carry out SPM checks viz. vibrations and sound of bearing. Record reading
and
compare With earlier / other motor readings.
Slip Ring: - Inspect the brushes and make sure that they move freely in the
brush holder clips.
Clean brushes, holder chip and wipe with cloth dipped and in gasoline.
Replace
the brush if they are worn out less than 5 mm in length from brush
holder.
Clean the starter and motor contacts with white spirit.
v). Six Monthly Maintenance: -

Check over load mechanism of starter.
Check alignment of motor with driven equipment.
Check no load current and compare with earlier / original.
Check / change lubrication as per lubrication schedule given on next
pages.
Check the securing foundation nuts for tightness.
Inspect the paint coating and do-touching wherever required.
Check IR(Insulation) Resistance of motor and starter with 500 V megger.
It should be more than 2 MΩ
pg. 73
Projected savings by converting LV drives to MV drives @ 6.6 KV
As it is clearly evident in all cases that the cabling, transmission, core and iron losses etc are
related to current which in turn is inversely proportional to the voltage it is a fact that changing
certain drives from 415 V to 6.6 KV may reduce energy consumption due to reduced losses and
variations.
Below is the list of proposed motors which can be converted to the MV operation.
Saving calculation by replacement of following motors with HT drives

Location S.No. Motor HP VFD Motor RPM Rated Measured Measured Current
Details (kw) Make current current @ KW required
(Amps) 415v level @ 6.6kv
(Amps) level
(Amps)
PM-1 1 Main Motor 120 110 CG 987 162 138 91.5 10
2 Vacuum 180 132 ABB 960 229 162 120 14.5
pump
PM-2 5 Wire 120 90 ABB 1440 157 72 34.4 10

6 Vacuum 270 200 NGEF 1440 340 260 192 21
Pump
Pulp mill 1 Pulper 180 132 229 197 96 14.4
motors
2 Refiner 150 110 150 131 57.8 9.5
Total 1267 79.4
Tentative savings are calculated below.
KVA required by existing(above) motors 557.48 KVA
KVA required by new HT (above) motors 524.04 KVA
Reduction in KVA required by new HT (above) 33.44 KVA

motors
Monthly Reduction in KVAh required by new HT 24076.8 KVAh
(above) motors
Monitory saving @Rs3.35/KVAh/ annum 967887.4 Rs
pg. 74
As the market price of drives for 6.6 KV is not very standard as of date and
availability of the panels in this segment is poor we have not calculated the
payback or investments for this operation. However the idea can be stored for
future reference as we may sometime achieve better pricing or better availability
in the same. Higher rating motors like 300 KW are still viable for this operation.
pg. 75

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ANSH ENERGY SOLUTIONS PVT. LTD.

Task Specific Audit: Steam Generating

TASK SPECIFIC ENERGY AUDIT

AUDITOR BEE REGISTRATION: EA – 3267 (Anshul Singh Yadav)

& EA-10465 (Anubhav Gupta)

DURATION: 21 JANUARY, 2010 – 20 FEBRUARY, 2010

REPORT NUMBER: 09-10/R/AG/104

The summary of possible savings is tabulated as below:

S.No. Action Tentative Savings Pay Back

Assumptions (if Any)

Equipments’ Verbal Picture

Energy Management Plan

The Technical Supplement

Calculation of actual fuel available on air dry basis (M) =

And, ,-".&/ 55%-"( %- 5"6 0   5"6  ,-5'#7/ 5 10 +. 49 :"67. 

Hence, For Boiler Number 1

2 9340 7330966 5703012 77.79%

2. Various types of losses:

Ultimate analysis of fuels:

a) Dry Flue Gas Loss

b) Loss Due to Hydrogen in fuel

c) Loss due to moisture in fuel

d) Loss due to moisture in air

e) Approx. heat loss due to surface radiation and leakages

f) Heat loss due to unburnt in fly ash

g) Heat loss due to un burnt in bottom ash

h) Heat loss due to blow down.

3. Calculations of tentative and stepwise investment:

4. Approximate costs of equipments and payback periods.

5. Pay back calculations

Average operating hours per month = 24 x 26 = 624 hours

The saving on blow down can be nearly 0.5%.

Standard Calculations and Assumptions

Other possible utilities to undergo audits

Situation being analyzed: ____Boiler Efficiency Improvement_________

Client: M/s Sandeep Paper Mills Pvt. Ltd., A-20/6, Noida

Blow down water Caustic Alk. 60 Excessive Blow

Blow down water Total Dissolved 1824 ppm Excessive Blow

5 Boiler feed water pH 7.16 No presence of

6 Boiler feed Water Total Hardness 5.8 ppm No effect of RO

DATA Proximate Analysis

1 Petcoke Moisture 6.25

2 Petcoke Ash 0.64

Petcoke Volatile Matter 1.83

Petcoke Fixed Carbon (By 91.28

DATA Ultimate Analysis

1 Petcoke Ash 0.64

2 Petcoke Carbon 87.17

Petcoke Hydrogen 4.67

Petcoke Nitrogen 1.96

5 Petcoke Other Remainder

FUEL GROSS CALORIFIC VALUE: 9340kcal/kg

NAME OF THE CONSULTANT:- M/s Ansh Energy Solutions Pvt Ltd.

Mean +1 SD 205477.38 291525.27 135084.41 628320.12

Mean-1sd 134133.53 175107.46 80351.95 393359.88

Name of Consultant : M/s Ansh Energy Solutions Pvt. Ltd.

MONTH vs MAX. DEMAND - GRAPH- YEAR 2008

MONTH vs POWER FACTOR - GRAPH - 2008

MONTH vs UNIT RATE 2008

4.00 3.99 4.00 4.01

MONTH vs MAX. DEMAND - GRAPH- YEAR 2009

MONTH vs POWER FACTOR - GRAPH - 2009

0.996 0.996 0.996

MONTH vs UNIT RATE

And, ,-".&/ 55%-"( %- 5"6 0 5"6 ,-5'#7/ 5 10 +. 49 :"67.

Situation being analyzed: Boiler Efficiency Improvement_____