Ring Plus Aqua Limited

Sinnar
Nashik

The Energy and Resources Institute (TERI)

Bangalore.

ISO 9001 : 2008 Certified Institute

 Introduction
Energy Audit Carried out between 4th December – 10th December 2012

• Establishing energy consumption pattern;

• Identify energy saving potential areas in different sections;
• Prepare a comprehensive list of energy conservation measures and determine the energy
saving potential by implementing various measures;
• Estimate the costs required to implement the energy conservation measures.

Areas covered
• Furnace
• Electrical System
• Electrical Drives
• Heat treatment furnace
• Pumps, Air compressors, Fans & Blowers
• Lighting System
 Electricity Energy Profile

Month KVA Units Over all Cost

Apr-12 1368 602807 7.04
May-12 1362 513755 7.14
Jun-12 1392 621594 7.53
Jul-12 1250 409506 7.70
Aug-12 1410 614070 8.47
Sep-12 1320 552015 8.71
Oct-12 1250 542726 8.62

• Monthly Average Power consumption 5.51 lakh kWh

 FO Fuel

Month MT Rate per Unit Amount

Jan-12 31910 40.751 1300364.41

Feb-12 28090 43.123 1211325.07

Mar-12 28400 42.608 1210067.2

Apr-12 29700 44.33 1316601

May-12 24900 44.428 1106257.2

Jun-12 21833 42.394 925588.202

Jul-12 14150 38.093 539015.95

Aug-12 26120 39.195 1023773.4

Sep-12 17480 41.794 730559.12

Oct-12 16775 41.405 694568.875

Nov-12 25775 39.236 1011307.9

 Energy Consumption : Break-up

Basis : 24 hours profile

S. Area / Equipment Avg. Electrical
No Load, kW
Power Consumption 800 - 1000
1 Production Lines 500 - 700
2 Air Compressor 80
3 Pumps ( Cooling tower pumps) 141
4 Lighting 35
5 Other Loads 10
Plant load almost flat except during shift change over period ( short duration)
Trend of Incomer of the 33kV line

Load trend deep valleys are observed, during the shift-change over periods & Break time,
(Morning session 7AM, 11.30AM and Evening session 7.00PM, 11.30PM).
 Harmonics level at the 33kV level

30 0.30

20 0.20
% %
10 0.10

0 0.0
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
Ah5 Ah7 Ah9 Ah17 Ah19 Ah21
12/4/2012 - 2:30:00.000 PM 12/4/2012 - 2:30:00.000 PM

2.0 0.40
% %
1.0 0.20

0.0 0.0
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
Ah11 Ah13 Ah15 Ah23 Ah25 Ah27
12/4/2012 - 2:30:00.000 PM 12/4/2012 - 2:30:00.000 PM
 Effect's of Harmonics
• False /Nuisance Tripping of Circuit Breaker
• Overheating of Capacitors, series/parallel resonance
• Induction type energy meter reads high/low
• Unpredictable behavior of Protective relays
• Increased losses, Noise & Vibration in Rotating Machines
• Saturation, increased Cu & Iron losses, high temp. rise in
Transformers
• Insulation failure, increased Cu. Losses in Cables
• Ballast failure, flicker in Lighting overheating
• Overheating of fuses & nuisance fuse blow
• Interference in Telecom Lines
 Harmonics
• As per IEEE-519, the % voltage distortion should be below 5.0%.
Total harmonic distortion of current (%THD-I) should be below
15.0%. Regulation by State Government law.
The following are suggested to reduce the harmonics levels

• Install isolation transformer at the sources(near machines).

• Parallel operation production lines, to reflect at the transformer level
as 12pulses operation.
• Install of 5th Harmonic filters.
• Capacitor bank with Tuner circuit.
Trend @ 4503 4504 Unit
 Harmonics Trend @ 4503 4504 feeder

25.00
25.00

20.00
20.00

15.00
15.00
%

10.00
10.00

5.000
5.000

12/5/2012
12/5/2012 2:53.000
2:53.000 (M:S)
(M:S) 12/5/2012
3:18:06.000
3:18:06.000PM
PM 34
34 Sec/Div
Sec/Div 3:20:59.000 PM
Trend @ 4505 4506 Unit
Trend @ 4507 4508 Unit
Trend @ 4509 4510 unit
 kW

100.00
150.00
200.00
250.00

0.00
50.00
3:28:43 PM
3:28:46 PM
3:28:49 PM
3:28:52 PM
3:28:55 PM
3:28:58 PM
3:29:01 PM
3:29:04 PM
3:29:07 PM
3:29:10 PM
3:29:13 PM
3:29:16 PM
3:29:19 PM
3:29:22 PM
3:29:25 PM
3:29:28 PM
3:29:31 PM
3:29:34 PM
3:29:37 PM
3:29:40 PM

Time
3:29:43 PM
3:29:46 PM
3:29:49 PM
3:29:52 PM
3:29:55 PM
Loading Trend of 4313 Unit

3:29:58 PM
Trend @ 4313 unit

3:30:01 PM
3:30:04 PM
3:30:07 PM
3:30:10 PM
3:30:13 PM
3:30:16 PM
3:30:19 PM
3:30:22 PM
3:30:25 PM
3:30:28 PM
3:30:31 PM
3:30:34 PM
3:30:37 PM
3:30:40 PM
Trend @ 1104 unit
Trend @ 1204 Unit
Trend @ 1309 unit
Trend @ 1610 unit
Trend @ 1705 Unit
Trend @ 3107 Unit
Trend @ 3147 unit
Trend @ 1709 unit
Trend @ 3124 unit
 Suggestion

• Install Soft starter for under loading motor/

variable loading.
• Replace the re winded motors.
• Automatic power correction panel @ LT room.
• Install auto star – delta convertor for small
motor.
 Normalizing Furnaces

Flue Gas Analysis Furnace - 1501 Furnace – 1504

Measured O2 % 4.5 5.0

Measured CO2% 12.0 11.5
Flue gas temperature, OC 575 585

Excess Air level, % 27 31

Furnace oil temperature, OC 85 80
Combustion air temperature, OC 92 90

Optimum Excess air levels for oil fired furnace – 20 to 25%

Furnace surface temperatures are High
Furnace doors are not closed properly
It was suggested to send furnace oil sample to reputed lab for Ultimate
analysis report.
 Normalizing Furnaces

Thermal Images for Furnace - 1501

 Normalizing Furnaces

Thermal Images for Furnace - 1501

Present Surface Heat loss - 9% of input Heat

Optimum surface Heat loss should be 5 to 6 % of Input Heat
 It was recommended to provide ceramic fiber lining on inner surface of furnace
Estimated Energy savings by providing Ceramic lining – 3 to 4% of input heat.
 Tempering Furnace

Major Observations

• Installed Furnace – 6 nos of different capacity.

• One furnace is installed with thyrister based controller & other five with contactor
type controller.
• Furnace power consumption and production was monitored for one cycle.
• Furnace surface temperatures are with in acceptable limits.
• Leakages found in Furnace – 4602 Feeding Door
• Loading and unloading time in furnace – 4602 & 4603 was more.
• Time delay of about 25 minutes for unloading and loading, monitored power
consumption during this delay was 8 units / batch.
• Furnace Door wood, fume suction fan is operating continuously, measured power
consumption of each fan is 3.5 kW.

Recommended to install thyrister based temperature controller for all the electric
furnace for better temperature control.
Recommended to switch ON fume suction fans, only during loading & unloading
of stock (Energy saving – 10 kW).
Educate furnace operator for better operation of electric furnace.
 Tempering Furnace

Tempering furnace fume suction fan

Suction duct was not connected to furnace fume duct

 Loading Trend of 4601 HT Furnance
60.00

50.00

40.00
kW

30.00

20.00

10.00

0.00
3:20:00 3:30:00 3:40:00 3:50:00 4:00:00 4:10:00 4:20:00 4:30:00 4:40:00 4:50:00 5:00:00 5:10:00
PM PM PM PM PM PM PM PM PM PM PM PM
Time
 Lighting

• Replace MH with Induction lamps.

• Replace 40 FTL lamp fittings with T5 lamp
fitting.
• Separate lighting feeder connected with
step down transformer.
• Install of Photo sensor and motion control
at the selected areas
• Install of Timer circuit for the security
lighting.
 Air compressor

Parameters Design Values

Free Air Delivery, cfm 488
Discharge pressure, kg/cm2 7.5
Drive rating, kW 75
Operating Parameter
Free Air Delivery, cfm 495
Load pressure, kg/cm2 5.5
Un load pressure, kg/cm2 6.5
Load power, kW 83
Un load power, kW 28
Load Percentage 80
Unload percentage 20
Specific Energy Consumption, kW/cfm 0.16

Average Best SEC for Air cooled screw compressor – 0.16 to 0.17 kW/cfm
 Air compressor

Compressor loading time, % 67

Compressor unloading time, % 33

Estimated leakage, % 67- 15 = 52% (250 cfm)

Energy loss, kW 40
 Ring forming section
Cooling Water Pump
Parameters Unit Design Operating
Flow rate m3/h 62.4 45.1
Head m 10.5
Motor Power kW 3.7 6.0

• CT pump, water velocity – 6.69 m/s (pipe size- 50 mm)

• 11 nos of pumps has installed for water circulation to butt wielding (8 nos),
Press machine ( 10 nos) and Trimming machine (3nos)
• Design cooling water required- Max 50 lpm (3m3/hr), Min 30 lpm (1.8m3/hr)
• Actual combined water flow rate – 68.1m3/hr
combined pumps power – 31 kW

It is recommended to install single high capacity pump with VSD, which is

circulate water to all machines and return back to cooling tower inlet.

Estimated energy saving – 16.7kW

Ring forming section
 Tank- 1
Induction Hardening m/c 4512/13

Cooling tower pump

Water flow- 36 m3/hr (5.2 m/s)
Power- 4.81kW

Cooling water circulation pumps (2 nos)

Water flow- 25.11 + 24.89 = 50 m3/hr
Power- 3.8 + 8.1 = 11.9kW

Design flow required for the machine – 900 lpm (54 m3/hr)

Recommended to install single pump, which is circulate water to

machine 4512/13 and return back to cooling tower.

Estimated energy saving – 3.2kW

 Tank- 2
Induction Hardening m/c 4503/04, 4507/08

CT Pump 4503/04 4507/08

Flow, m3/hr 36 (5.2m/s) 35 (5.05m/s)
Power, kW 3.5 3.4

Cir Pump 4503/04 4507/08

(single pump) (2 nos pumps)
Flow, m3/hr 33.29 10.8 +9.26= 20
Power, kW 11.3 4.1+ 3.7= 7.8

Design flow required to machine- 600 lpm (36 m3/hr)

Also, Two pumps has installed for Tempering Furnace – 6.62+5.5= 12.12m3/hr

Recommended to install single pump for each machine, which is

circulate water to machine and return back to separate cooling
tower.

Estimated energy saving – 4.4kW

 Tank- 3
Induction Hardening m/c 4501/02, 4505/06

CT Pump 4501/02 4505/06

Flow, m3/hr 20.9 (3.01m/s) 28.73 (4.14m/s)
Power, kW 5.9 11.5

Cir Pump 4505/06

(3 nos pumps)
Flow, m3/hr 47
Power, kW 17.5

Design flow required to machine- 600 lpm (36 m3/hr)

Recommended to install single pump for each machine, which is

circulate water to machine and return back to separate cooling
tower.

Estimated energy saving – 15kW

 Cooling Towers

Description Unit Ring Tank-1 Tank-2 Tank-3 Separate

forming CT
Machine No 4512/13 4502/03, 4501/02, 4509/10
07/08 05/06
Design Parameters
3
Flow m /hr 54 54 54 54 54
0
Range C 4.2 4.2 4.2 4.2 4.2
0
Approach C 3.9 3.9 3.9 3.9 3.9
Capacity TR 60 60 60 60 60
Actual Parameters
3
Flow m /hr 45.1 36 71 49.63 35
0
Range C 1.3 2.4 1.4 1.6 2.1
0
Approach C 0.8 2 2 2.4 2.2
Capacity TR 19.4 28.6 32.9 26.3 24.3
Effectiveness % 62% 55% 41% 40% 49%
3
Evaporation loss m /day 2.15 3.17 3.65 2.92 2.70
3
Drift loss m /day 0.27 0.22 0.43 0.30 0.21
3
Total Water loss m /day 2.42 3.39 4.08 3.21 2.91
 Cooling Tower

• It is suggested to replace Aluminum fan blade with FRP type blade. It will
reduce fan power consumption by around 10-15%.

• Recommended to install thermostat controller to cooling tower - depend on

sump temperature cooling tower fan will switch On / off.
Thank You