Energy audit at Krishna Engineering Works, Coimbatore
STUDY BACKGROUND
Krishna
engineering was started in the year 1960. They are the manufacturers of rice
washer, instant dosa batter machine, chutney masala machine, grinding machines,
pulverizers .
SCOPE OF WORK
- Electrical energy survey and load assessment
- Electrical energy survey of driven
equipment such as pumps, fans and compressors
- Any other area that would impact
the energy consumption.
LOAD
ESTIMATION
|
S.No.
|
Load
|
Wattage (W)
|
No.
|
Hours
|
Wh
|
kWh
|
|
1
|
Lathe
|
1492
|
3
|
5
|
22380
|
22.38
|
|
2
|
Band saw cutting machine
|
746
|
1
|
6
|
4476
|
4.476
|
|
3
|
Milling machine
|
2238
|
1
|
2
|
4476
|
4.476
|
|
4
|
Radial drilling machine
|
746
|
1
|
2
|
1492
|
1.492
|
|
5
|
Ordinary drilling machine
|
746
|
2
|
2
|
2984
|
2.984
|
|
6
|
Welding machine
|
2550
|
1
|
3
|
7650
|
7.65
|
|
7
|
Hand drilling machine
|
1500
|
1
|
1
|
1500
|
1.5
|
|
8
|
Angle grinder
|
1500
|
3
|
4
|
18000
|
18
|
|
9
|
Tool
post grinder
|
746
|
1
|
4
|
2984
|
2.984
|
|
10
|
Flexible
grinder
|
746
|
2
|
2
|
2984
|
2.984
|
|
11
|
Slotting
machine
|
746
|
1
|
3
|
2238
|
2.238
|
|
12
|
Compressor
|
3700
|
1
|
8
|
29600
|
29.6
|
|
13
|
Generator
|
17000
|
1
|
3
|
51000
|
51
|
|
14
|
1.5
ton A.C.
|
1500
|
1
|
8
|
12000
|
12
|
|
15
|
Fan
|
60
|
9
|
8
|
4320
|
4.32
|
|
16
|
Tube
light
|
40
|
20
|
4
|
3200
|
3.2
|
|
17
|
CFL
|
27
|
4
|
4
|
432
|
0.432
|
|
18
|
Filament
bulb
|
60
|
3
|
4
|
720
|
0.720
|
|
19
|
UPS
|
680
|
1
|
|
2720
|
2.72
|
EB BILL
This
industry has two EB lines separate for lighting load and other loads.
ENCON MEASURES
ENERGY MANAGEMENT SUGGESTIONS
FOR LATHE
- Actual power consumed = 22.38 kWh
- Replacement of energy efficient
motors for lathe
- Reduction in wattage = 292 W
- Savings/year = Rs.9438
- Investment = Rs.5500
- Payback period = 7 months
ENERGY MANAGEMENT
SUGGESTIONS FOR MILLING MACHINE
- Actual power consumed = 4.476 kWh
- Replacement of energy efficient
motors for milling machine
- Reduction in wattage = 438 W
- Savings/year = Rs.2196
- Investment = Rs.7000
- Payback period = 3.2 years
ENERGY MANAGEMENT
SUGGESTIONS FOR COMPRESSOR
- Actual power consumed = 29.6 kWh
- Installation of VFD for compressors
- Reduction in wattage = 1500 W
- Savings/year = Rs.25308
- Investment = Rs.20000
- Payback period = 10 months
ENERGY MANAGEMENT
SUGGESTIONS FOR A.C.
- Actual power consumed = 12 kWh
- Installation of aircosavers
- Reduction in wattage = 450 W
- Savings/year = Rs.6180
- Investment = Rs.2800
- Payback period = 6 months
ENERGY MANAGEMENT
SUGGESTIONS FOR CEILING FANS
- Actual power consumed = 0.432 kWh
- Replacement of conventional fans
with superfans
- Reduction in wattage = 450 W
- Savings/year = Rs.7080
- Investment = Rs.27000
- Payback period = 4 years
ENERGY MANAGEMENT
SUGGESTIONS FOR LIGHTING
- Actual power consumed = 0.432 kWh
- Replacement of Filament bulbs with
CFL.
- Reduction in wattage = 40 W
- Savings/year = Rs.744
- Investment = Rs.360
- Payback period = 6 months
SETBACKS
Replacement
of energy efficient motors for other machines will practically provide not much
change in the power consumption as their capacity is too low. Hence providing
solutions for high capacity appliances prove to be a feasible option.
FINAL REPORT
|
ENCON options
|
Actual wattage (W)
|
New wattage (W)
|
Units saved (kWh)
|
Savings/year (Rs.)
|
Investment
(Rs.)
|
Payback period
|
|
Energy
efficient motors in lathe
|
1492
|
1200
|
4.38
|
9438
|
5500
|
7
months
|
|
Energy
efficient motors in milling machine
|
2238
|
1800
|
0.876
|
2196
|
7000
|
3.2
years
|
|
VFD
for compressor
|
3700
|
2200
|
12
|
25308
|
20000
|
10
months
|
|
Aircosaver
in A.C.
|
1500
|
1150
|
2.8
|
6180
|
2000
|
6
months
|
|
Superfan
(30W)
|
60
|
30
|
3.24
|
7080
|
27000
|
3.9
years
|
|
CFL
for filamnet bulb (20W)
|
60
|
20
|
0.192
|
744
|
360
|
6
months
|
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