Final Draft DEA Report Asian Paints LTD Patancheru

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

At
Asian Paints Limited,
Patancheru
June 2014

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
66
VI
Annexure
70
VII
Back-up Calculations
90
Total Pages: 116

EXECUTIVE SUMMARY
Asian Paints is one of the India's largest paint companies which manufacture
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.
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)
The above proposal doesnt require any investment.
e) 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
4
5
6
7
8
9
10
11
12
13
14

Replace The 2x36W T8 Lamps With
1x20 W LEDs
Replace 2 x 36W CFLs with 18W LEDs
Renewable energy for lighting (long
term)
Optimize the excess air supply in resin
house thermopac TP-405 for
improving combustion efficiency
house revomax boiler RXA06 for
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
industrial 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
0.9
31
1.8
13
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
LIGHTING SYSTEM AT ASIAN PAINTS LIMITED,PATANCHERU

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.
The lighting at Asian Paints, Patancheru was done by CFL, FTL, HPMV and
HPSV lamps.
LATEST DESIGN TREND IN LIGHTING
The latest trend in lighting is to utilize the right amount of pupil lumen. The
pupil lumen also considers the variation in sensitivity of the eye in relation to
the environment. The sensitivity of the eye varies between daytime lighting
and night time lighting as shown in the figure below.
The scotopic curve and photopic curve mention the day-time lighting and
night-time lighting respectively. The eye colour is more sensitive towards the
green colour for photopic curve and is correspondingly for blue colour in the
case of scotopic vision. This data of relative sensitivity of eye helps us in
designing the correct colour of the lamp required for different lighting
conditions. The scotopic vision is well suited for night environment such as
street lights, basements, closed rooms where sunlight is not available. The
photopic on the other hand will be closer to day-time environment.
The earlier system of lighting wherein the quantity of light delivered was
mentioned in lumen and not in pupil lumen considered only the photopic
curve.
Comparison of Lamps
The table below shows a brief comparison of all the lamps. LED is the latest
energy efficient technology in lighting. Compared to the conventional lamps, it
offers significant advantages in terms of energy consumption along with other
benefits. The latest trend is to go for LED lamps. These LED lamps have very
high scotopic to photopic ratio of 2.4. This is very well suited for lighting in
dark surroundings. Eg: street lighting, Closed rooms with low sunlight.
S.No Parameter
LED
HPSV
CFL
Metal
Halide
FTL T8
15,00020,000
Hours
60008000
Hours
10,00012,000
Hours
8000 Hours
Life
50000
Hours +
Lamp
Efficacy
90-100
90-140
60-65
65 to 90
60-68
30% @
Lumen
50,000
Depreciation
Hours
Upto
40% @
15000
Hours
1520%
till end
of life
Upto 40% @
12000
Hours
15-20% till
end of life
CRI
70-90
22- 25
65-85
65-90
60-72
Color
Variety
Yellow
White
White
White
Color
temperature
210010000K
2100K3000K
30006000K
4000-5000K
3000-6500K
S/P Ratio
Upto
2.4
0.62
1.3-2.2
1.6
1.3
Warm up
time 90%
Lumen
Instant
4
minutes
1
minute
5 minutes
10-50
Seconds
Flicker free
yes
No
No
No
No
Advantages of LEDs
As identified from the above table, LED lamps offer the following advantages
Lower energy consumption
High S/P ratio
Longer life time
Faster switching
Greater durability and reliability
Good Colour Rendering Index (CRI)
More focused light and reduced glare
Does not contain pollutants like mercury
Highly compatible for solar lighting as low-voltage power supply is sufficient
for LED illumination
Higher Light Output Ratio (LOR): The Light Output Ratio indicates the actual
amount of light that can be obtained after considering the losses in
luminaire. As can be seen from the figure below, the light output also
depends on the light fixture. In the first fixture, certain amount of light is
lost. The second fixture has a mirror finish reflecting the light lost to the
ceiling in the first case is directed downwards and the loss of light is low in
comparison to the fixture on left. The light fixtures that house LED lamps
are latest and hence the loss of light is low. LED fixtures have an LOR close
to 100%.
Replacement methodology of lamps with LEDs

T8 lamps with LEDs
The following methodology can be adopted when replacing a lighting fixture
with LEDs. The photopic efficacy of the present lamp can be obtained by
multiplying the lamp efficacy and S/P ratio of the lamp. Photopic efficacy is
indicated in pupil lumen/Watt. This photopic efficacy should be multiplied with
the Wattage of the lamp to obtain the pupil lumen. This pupil lumen should be
multiplied with LOR to get the actual amount of pupil lumen. Divide the pupil
lumen obtained with 240. 240 is the pupil lumen/Watt of LED. The required
Watt of LED lamp will be obtained. Choose the lamp closest to the above Watt
that is available commercially.
A sample calculation for replacement of T8 lamps with LEDs is also indicated.
Say for a T8 lamp: The lamp efficacy is 60 lumen/Watt. The S/P ratio is 1.3
and the pupil lumen/Watt will be 78. Considering a 72 W T8 lamp and an LOR
of 90%, the Pupil lumen is 5054. The wattage of LED required for replacing the
above T8 lamp is 20 W.
The comparison for T8, CFL, MH, HPMV and HPSV lamps is indicated below.
The approximate replacements can be considered based on the table below.
These values for exact calculation can be taken from supplier.
10
Type
of
Lamp
Luminous
Wattage
efficacy
of lamp
(lumen/Watt)
Correction
Photopic
factor
efficacy
(S/P
(pupil
ratio)
lumen/Watt)
Pupil
lumen
Can be
replaced
with
LED
Watt
T8
72 W
60
1.3
78
5616
20 W
CFL
72 W
65
1.3
84.5
6084
18 W
HPSV
70 W
90
0.62
55.8
3906
18 W
HPSV
150 W
90
0.62
55.8
8370
30 W
HPM
V
70 W
54
0.8
43.2
3024
18 W
MH
150 W
65
1.6
104
15600
70 W
MH
250 W
65
1.6
104
26000
100 W
Not all fixtures can be retrofitted with LED lamps directly and the fixtures may
need modification. The above methodology can be followed when considering
any future replacement of existing lamp fixtures.
Strategy for lighting fixture replacement
The following strategy can be adopted when replacing the existing lamps with
LEDs. During the audit, it was noted that the plant team has installed LEDs at
some locations on a trial basis. CII congratulates the plant team for the
excellent initiative taken. CII along with the plant team identified further
potential to replace the existing lamps with LEDs.
The lamps can be replaced in a phase-wise manner, prioritizing the ones with
higher energy savings and minimum pay back. These energy saving proposals
and the benefits were explained below.
1. Replacement of HPSV and HPMV lamps for street lighting
2. Replacement of T8 lamps with LEDs
3. Replacement of CFL lamps with LEDs
4. Opting renewable energy for street lighting
11
ENERGY SAVING PROPOSAL No. 1
REPLACE THE EXISTING 2X36W

LAMPS WITH 1X20 W LED LAMPS
T8
FLUORESCENT

Background
Presently at Asian Paints, Patancheru, 2034 Nos. of T8 lamps were 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 72 watts. The table given
below indicates the T8 lamp quantities and total power consumption of the
fixtures
S.No
Location
Watt
Quantity
Power in
kW
Operating
Hours
Other Offices
36w x 2
746
53.71
2432
Engg Store
36w x 2
40
2.88
2432
Production Blocks
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
Based on the description earlier, considering factors like S/P ratio and LOR,
there is a good potential to replace these 2X36 W T8 lamps with 1X20 W LED
lamps.
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.
It is recommended to replace the T8 lamps in a phased manner. The lamps
with higher operating hours can be replaced first for higher savings. Based on
the results, the lamps at the other locations can also be subsequently
replaced. The lamps in the DC, BSR, and PMG can be replaced first followed by
other areas. LEDs can be considered as priority when replacing a failed lamp.
12
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.
13
ENERGY SAVING PROPOSAL NO. 2
REPLACE THE EXISTING 2 X 36 W CFL LAMPS WITH 18

W LED LAMPS
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 72 Watts
Based on the factors like S/P ratio and LOR, these lamps can be replaced with
18 W LED lamps. Light Emitting Diode (LED) is the latest technology. As
discussed earlier, LEDs offer the advantages of Lower energy consumption,
high S/P ratio, longer life time, faster switching, greater durability and
reliability, good CRI, more focused light and reduced glare.
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.
14
LONG TERM ENERGY SAVING PROPOSAL NO. 1
INSTALL SOLAR WIND HYBRID SYSTEM FOR STREET

LIGHTING
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 each lamp is 70W and
the total power consumption is around 10.5 KW.
Proposed Technology
Light Emitting Diode (LED) is the latest energy efficient technology in lighting.
As discussed earlier, LEDs offer the advantages of Lower energy consumption,
high S/P ratio, longer life time, faster switching, greater durability and
reliability, good CRI, more focused light and reduced glare. There is a good
potential to replace these HPMV and HPSV lamps with LEDs and to tap solar
energy for street lighting.
It is recommended to replace these HPMV and HPSV lamps with 1X18 W LEDs.
A 3 KW capacity solar wind hybrid system can be installed and the
requirements of street lighting can be met through renewable energy.
The solar wind hybrid system for 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 wind hybrid system for street lighting: To go one step further for
energy conservation opportunity, it is recommended to install a 3 kW capacity
solar wind hybrid system and the requirements of street lighting can be met
through renewable energy.
15
Solar Wind Hybrid System

A Solar wind hybrid system 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
It is recommended to replace the existing 70 W HPSV and HPMV lamps with
1X18 W LEDs. A 3 KW capacity solar wind hybrid system 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 wind
hybrid system for street lighting is Rs. 2.81 lakhs. The investment required is
Rs. 13.00 lakhs.
16

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 to identify, 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 in continuous operation and is operating 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
APH
O2: 7.5 %
Flue gas:
6556 m3/hr
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 and plant team and the
results are tabulated below:
17
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)
Effect of excess oxygen

Controlled supply of combustion air is an important criteria 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 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
gaseous fuels have better combustion properties, the optimum quantity of
excess air to be supplied should not exceed 10%. This corresponds to oxygen
concentration of 2% in the flue gas.
Higher air quantity supplied above recommended levels will result in increased
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 Carbonmono-oxide. High air quantity additionally leads to higher combustion air
blower power consumption also.
The above figure clearly indicates higher combustion air is being 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.
Recommendation
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.
18
Ensure that the following at the end of this trial

O2 level should be maintained at less then 2% in flue gases
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/hr 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 regulate the frequency for capacity
control.
The analyzer can be fed with an auto set point of O 2 % which would be
always maintained by feedback signal to the combustion air blower.
Minimum saving of 6.48 Kg of LPG/hr can be achieved by optimization of
the combustion air supply and reduction of blower power consumption by
2.5 KW.
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 2 % O 2 at exit
flue gases would result in an annual savings of Rs. 21.75 lakhs. The
investment required for procuring a gas analyzer would be Rs. 2.00 lakhs
which would have a very attractive pay back of 1 month.
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 2 % O 2 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. 3.50
lakhs which would pay back on 2 months.
19

REVOMAX BOILER RXA06 FOR IMPROVING COMBUSTION
EFFICIENCY
and operational modulation of the burner in Revomax boiler RXA 06 (0.6 TPH)
was studied in detail to identify possible energy savings opportunities.
Present Status
The Revomax boiler already has a burner with on and off modulation based on
the exit gas temperature set point. The oxygen level (O 2 level) was measured
during the detailed energy audit. The CO level was also found to be within the
limits.
The schematic of the Revomax boiler RXA 06 is as below. The results of flue
gas analysis are also tabulated. The above figure clearly indicates higher
combustion air is been supplied leading to excess of oxygen in boiler outlet.
The CO levels was found to be less than 43 ppm, which indicate good condition
for combustion. The Revomax boiler utilizes LPG/HSD as fuel.
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
Boiler RXA 06
% O2
CO (ppm)
Boiler outlet
6.5
43
Temperature
(Deg C)
196
20
Effect of excess oxygen

Controlled supply of combustion air is an important criteria 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 quantity of excess air
near to stoichiometric 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 gaseous/liquid fuels have better
combustion properties, the optimum quantity of excess air to be supplied
should not exceed 10%. Since LPG is a gaseous fuel the excess air
requirement is low and maximum O2 level of 2% can be easily maintained.
HSD being a liquid fuel will have lower mixing of fuel and air, and an O2 level
of 3% can be maintained.
Higher air quantity supplied above recommended levels will result in increased
carryover of heat from the. 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 Carbonmono-oxide.
The O2 level of 6.5% clearly indicates higher combustion air is being supplied
leading to excess amount of air in comparison to the recommended level of
3%. 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
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 O 2
at exit and observe the performance and reduce further to reach a level of
3 % 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
O2 level should be maintained at less then 3% in flue gases
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 or HSD per hour can be achieved by
optimization of the combustion air supply.
21
Benefits
Optimizing the combustion air supply to the boiler by reducing the combustion
air by modulating the inlet damper and maintaining 3 % O 2 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.
22

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
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.
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 pump still has to cater to the loss of
pressure across the valve and some energy supplied to the pump is lost across
the valve. There is a good potential to avoid the valve throttling by installing a
VFD for the Thermic fluid pump.
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.
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 by reducing the pump speed using
VFD.
Whenever the quantity of thermic fluid requirement reduces due to reduction
in heat demand 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 pumping power consumption.
The schematic of the TP 405 thermic fluid circulation circuit is as below
23
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 up to 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.
24

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. These blowers are installed for maintaining the
inside air quality and venting out VOC content from the area for providing safe
working environment.
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 the flow and pressure measurements of
all the blowers in Industrial paint block and the reading 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 of specific energy consumption (SEC), the rated flow
was considered to obtain the energy savings conservatively.
The specific energy consumption of the blowers were measured and are
compared with the specific energy consumption of high efficiency blowers of
same capacity.
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.
25
Recommendation
Phase I
Replace the discharge blower VSP 301 & 302 with 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.
Considering the new operating SEC of 0.35 W/CFM, the saving potential
for phase I blower would be 9.9 KW.
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.
26
WBU SECTION COOLING TOWER OPERATION

During the detailed energy audit at Asian Paints Limited., Patancheru Unit
the operation of the cooling tower in WBU section was studied in detail.
The WBU cooling tower is used to cater to the cooling requirement of 3 kL, 5
kL, LDVs and Chiller condensers. During the audit the cooling requirement of
each of the user was studied.
The reactors, cooling water circulation is needed for only 4hrs per batch (batch
cycle time 8hrs) & for LDVs, it is 2hrs per batch (batch cycle time - 4hrs).
The chillers were primarily used for monomer cooling and TSDs. The chiller
will switch off once the monomer temperature maintained.
Sometimes due to insufficient cooling, chilled water from the chiller is used to
cool the cooling water obtained from the cooling tower. This method of utilizing
chilled water for cooling will in turn increase the load on the chiller. The
increase in load on the chiller will require additional heat to be rejected on the
condenser side, which is rejected in the cooling tower. Thus this process will
further increase the load on the cooling tower.
Heat load for each user was studied during the audit and the details are as
shown in the table:
Cooling load
S.No
User
3 kL Reactor
50
5 kL Reactor
46
LDV
15
70TR Chiller condenser
90
Total
200
(TR)
The operation of the users of the WBU cooling tower usually do not overlap
and one or two users of the cooling tower are in operation. But sometimes the
users of the cooling tower overlap and is as indicated by the usage of chilled
water for cooling tower water.
The installed capacity of the cooling tower in this section is only 120TR, which
is not sufficient to meet the maximum heat load. Since there is some risk that
all or many of the users may operate at the same time, it may be considered
to install an additional cooling tower of 120 TR capacity. Installing an
27
additional cooling tower of 120 TR will solve the issues related to cooling when
the operation of the users of the cooling tower overlap.
It has been understood from the plant team that there is issue of obtaining
lesser cooling from the cooling towers and increasing the duration of cooling
for reactors and LDV. This is an indication that the cooling tower heat rejection
is not sufficient when more users are in operation. If the cooling tower return
water temperature increases there is a possibility that the chiller may trip due
to high pressure.
In the subsequent proposals of optimizing the cooling water for reactors and
LDV, the cost of installing a 120TR cooling tower is considered for the reactors.
The cooling water to the reactors and LDV can then be optimized to obtain
sufficient cooling with lower flow and optimized T. The details of these are
also explained in the proposals.
28
OPTIMIZE THE OPERATION OF WBU COOLING WATER

PUMPS
the cooling water pumps in WBU section were studied in detail for identifying
energy saving opportunity.
Present status
In WBU section, there are two nos of reactors of capacities 3 kL & 5 kL. Raw
materials will be fed to these reactors and heated using steam. Monomers are
continuously added to based on the product requirement. Then, the material is
cooled and sent to LDV. Approximate batch cycle time in each reactor is 8hrs.
Monomer addition in the reactor is an exothermic reaction, which takes place
for 4 hrs. Jacket cooling is required during this phase. 5kL reactor has three
jackets and 3kL reactor has two jackets. Two seperate pumps were installed to
circulate the cooling water through the reactors. Out of these two pumps, one
pump is dedicated for 3kL reactor & the other pump is dedicated for 5kL
reactor. 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 due to the
29
failure of non return valve. The stand by pump of 5 kL was observed to be

rotating in opposite direction without any electrical input. Similarly, when only
3kL pump was running, recirculation of 15 m 3/hr (12%) was observed through
5kL pump also due to the failure of non return valve. Therefore, minimum
recirculation in the circuit is 15m3/hr when any one reactor is in operation.
Recirculation is a loss in the system. Pump is handling the recirculated volume
also, which is not being used in process. We can understand that the power
consumed by the pump in handling that amount of recirculated volume is lost
completely. There is a good potential to save energy by avoiding recirculation
due to failed NRVs.
Plant team have already replaced existing NRVs with new ones. CII
congratulates the plant teams efforts in replacing passing NRV to
avoid recirculation.
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 against the installed cooling tower
capacity of 120 TR. The installation of an additional cooling tower of 120 TR
has been discussed in WBU SECTION COOLING TOWER OPERATION.
The range of 1.50C was being achieved by the cooling tower. Generally, cooling
towers are designed to give a range of 6-8 0C. By switching on the fans and
running them continuously with a VFD, cooling tower can give minimum range
of 40C i.e., range will get doubled and the cooling water flow can be halved.
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.
Each equipment runs at a different batch cycle time. When all the equipment
run simultaneously, the cooling requirement is maximum, i.e., 200TR.
After installing an additional cooling tower of 120TR, a trial can be taken by
throttling the pumps in steps of 10% till temperature difference of 4 0C is
achieved across the reactor. Simultaneously, the reactor bulk temperature has
to be monitored, as it is critical.
After conducting a trail and after installing an additional cooling tower of
200TR for meeting the load requirement the reactor cooling water flow can be
controlled by combination of VFD for the pump as feedback and the auto
control valves installed for reactors. The VFD can be given a feedback to
maintain pressure of 2.5 kg/cm 2 at discharge and auto control valves can be
given the reactor temperature as feedback.
It is recommended to operate only one pump for both the reactor, due to the
available margin in quantity of flow, the investment for VFD is considered for
only one pump. In case plant team is planning to operate stand by pump
and switch off the running pump, the same VFD can be utilized with a
changeover switch.
30
Recommendation
We recommend to
Step 1:
Avoiding recirculation
Avoid recirculation by installing new NRV
Plant team have already replaced existing NRVs with new

ones
Step 2:
Increasing the capacity of cooling tower
Install a separate cooling tower of 120TR for chiller condenser and

avoid using chilled water to cool return water during summer
Step 3:
Optimizing the flow
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 trial by reducing the flow by
throttling the pump in steps of 10% till temperature difference of
40C is achieved across the reactor
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.
31
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
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. There are two LDVs installed in WBU section. Only one LDV
will be in service at a time. 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, which opens and closes based on the
material temperature.
The schematic layout of the operation is shown as below:
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 reduced.
32
Flow can be reduced by throttling the pump or installing VFD and operating it
with pump discharge pressure as feedback. Controlling the flow by throttling
leads to partial energy savings. Some of the power will be lost in overcoming
the pressure drop across the throttle valve. Controlling the flow by reducing
the speed of the pump by installing VFD will save more power.
Before installing VFD, trail can be taken by throttling the pump in steps till the
temperature difference of 40C is achieved & simultaneously monitoring the
material temperature.
Recommendation
We recommend to
Install additional cooling tower of capacity 120TR (same included in

proposal no.8 also)
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
33
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 Design Design
Flow
Head
Power Eff Running
2
flow
head
(m3/hr) (kg/cm ) kW (%)
hours
3
2
(m /hr) (kg/cm )
1
490
64
2.92
49
0.4
7.1
8.3
3500
491
64
2.92
25
0.2
5.0
2400
492
64
2.92
71
1.2
4.41
58.5
5500
470
91
5.0
74
2.6
21.3
27
160
481
125
3.2
28
8.7
39
100
482
125
3.2
64
3.7
12.3
58
1300
483
125
3.2
3500
The following observations can be made from the measurements

During the audit it was observed that two out of 490,491 and 492 were found
in operation. 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. From the discussions with the plant team, this must be due to
worn out impeller.
The plant team has started working on the failed impeller replacements. Pump
492 is delivering the flow which is being delivered by the pumps 490, 491
together. Therefore, by operating only 492 pump for the maximum hours and
avoiding operating 490 & 491, power of 5kW can be saved.
Pump 482 was found to operate at higher efficiency than pump 481.
Therefore, 482 pump can be operated for the maximum hours to save power
consumption. The efficiency of pumps 490, 491, 470 and 481 were found low.
34
Since the running hours of pump were low, replacement with energy efficient
pump was not viable.
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
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.
35
OPTIMIZE THE OPERATION OF INDUSTRIAL COOLING

TOWER FANS & COOLING WATER PUMPS
the industrial cooling water pumps in industrial paint section were studied in
detail for identifying energy saving opportunity.
Background
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. Currently, the temperature feedback to the fan to switch on and
off has failed and the cooling tower sump temperature of 32 oC has been
observed, instead of desired temperature of 25oC.
The energy saving by switching on and off the cooling tower fan is partial. The
cooling tower requires good air water contact to achieve a good approach.
There is a good potential to install VFD for the Cooling tower fans and operate
with a feedback based on cooling water leaving temperature. The desired
temperature of the cooling tower sump can be given as feedback to the VFDs
of cooling tower fans. Currently, the process parameters are not affected by
the cooling water temperature of 32oC. Thus 32oC of cooling water
36
temperature can be maintained and the calculations have been considered for
32oC. If the temperature of 25 -27 oC is considered, the energy savings will be
lower.
When measurements were taken, CT fans were in OFF condition. The range of
20C was being achieved by the cooling tower. Generally, cooling towers are
designed to give a range of 6-80C. By switching on the fans and running them
continuously with a VFD, cooling tower can give minimum range of 4 0C i.e.,
range will get doubled and the 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.
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
We recommend the following
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.
37
REPLACE INEFFICIENT
EFFICIENT PUMPS
PUMPS
WITH
NEW
ENERGY
the performance of the water pumps in the plant were studied in detail for
Background
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
21.00
24
6.15
24
18
33.00
10*
2.4
41
23.5-9.5
11-39
21.00
32
5.79
34
marked pumps head is estimated value as provision for measuring pressure

was not available.
*
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.
The below diagram shows how efficiency of the pump reduces with mismatch
between design and operating parameters
38
Characteristic curve
Operating point
*
Design point
*
Iso efficiency curves
Head
60%
50%
40%
Power
When the operating

parameters are different from design parameters,
consumption
operating point falls into low efficiency region.
Therefore, it is recommend to install energy efficient pumps designed to
operate at best efficiencyFlow
for operating parameters.
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
Efficiency
:
:
25 m
> 70%
Specifications of 70TR chiller hot well pump:

Flow
35 m3/hr
Head
pressure guage
Efficiency
has to be decided after installing
> 70%
Specifications of Pump house P504:

Flow
25 m3/hr
Head
Efficiency
:
:
35 m
> 70%
Benefits
39
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.
40
REDUCE THE GENERATING PRESSURE

COMPRESSORS IN THE PLANT
OF
THE
AIR
Present status
During the detailed energy audit of Asian Paints Limited, Patancheru Unit,
a detailed study of all the compressed air units was carried out for possible
The plant has installed a centralised compressed air system consisting of two
screw compressors which maintain the pressure of the receiver at 5.7 bar. This
centralized compressed air system supplies air to all the sections of the plant
viz. Water Based Unit, Solvent Based Unit, Industrial Paint Unit, Resin Block
and the Monomer block.
Monomer
Tank
P405
587 CFM
5.7 bar
5.6 bar
5.5 bar
Refrigerant
Drier
10m3
Receiver
Water Based Unit
P406
587 CFM
5.5 bar
Industrial Based Unit
Phase I & II
5.5
bar
Resin
Block
5.4
bar
Solvent Based Unit

& Workshop
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
It was observed that when the plant is in full load operation, one compressor is
continuously running and the second compressor is running for 10 % of the
time. This compressor has been set in such a way that if it is in unload for
more than 10 minutes it automatically switches off. The limit of switching on
and off for a 110 kW motor is not more than four times in an hour.
41
During the detailed energy audit of the plant, a comprehensive compressed air
distribution study was carried out to understand the compressed air
requirement at the end users and the pressure drop at the farthest point in the
plant. During the compressed air user study of the plant, it was observed that
the compressed air pressure drop at the farthest point from the generation
was not more than 0.2 bar.
The compressed air pressure being maintained at different applications in the
plant is as follows:
Purpose of Compressed Air
Pressure Maintained
Open/Close valves
4.0 bar
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 observed that in most of the end users the pressure setting being
maintained was between 3.0 bar to 4.0 bar. The only operation which requires
a pressure of 5.0 bar is the Lid pressing operation in packer area. The
manufacturer has advised a pressure setting of 6.0 bar considering a safety
margin but the plant is running the packer machine successfully maintaining a
pressure setting of 5.0 bar. It was also observed that these packing machines
were already 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.
Here is a good opportunity to utilise this booster compressor so that it supplies
high pressure compressed air to the packer machine and reduce the
compressor air pressure at the generation end itself.
Proposed System
The compressed air pressure maintained for most of the applications in the
plant is not more than 4.0 bar. Only the lid pressing operation in the packing
42
machine requires a higher compressed air pressure requirement of 5.0 bar.

These packer machines are already installed with booster compressors. We can
use these booster compressors in such a way that when we give an input of
4.0 bar compressed air, it gives an output of air at a pressure of 5.0 bar.
Utilizing this booster compressor we will be able to cater to the pressure
requirement of 5.0 bar for the lid pressing machine and at the same time we
will be able to reduce the pressure of the compressed air at the generation end
to less than 4.5 bar average pressure which is sufficient for all the other
compressed air applications.
When we utilize this booster compressor, it increases the amount of
compressed air usage as it increases the pressure of the incoming air and
produces high pressure air. But this increase in compressed air consumption is
not as significant when compared to the savings we will achieve by reducing
the compressed air generation pressure.
Recommendation
Step 1:
Firstly, we recommend to reduce the compressor pressure by 0.2 bar at the
generating point and at the same time adjust the compressed air pressure
setting in the booster compressor of all the packing machines such that
these booster compressors gives an output of 5.0 bar compressed air to the
packer machines.
Run the plant in normal operation for a few days.
Step 2:
If there is no issue with the operation of the plant, keep on reducing the
generation pressure in steps of 0.2 bar until the generating pressure is set
to an average pressure of 4.5 bar and utilizing the booster compressor in
the packing machines so that the required pressure of 5.0 bar is
continuously maintained in the packing machines.
keep on reducing it until the generating set points are:
Load point
- 4.2 bar
Unload point
- 4.7 bar
The above set points have been suggested on a conservative basis and there is
still further scope for the plant team to reduce the generation air pressure.
By reducing the generating pressure of compressed air, energy savings of
around 29 kW is possible.
Benefits
The annual energy savings achieved by implementing this project is Rs. 9.9
Lakhs. This does not require any major investment.
43
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.
The compressed air leakages in the distribution system are difficult to find out
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:
Make sure no user is in operation.
Make sure that no one is using compressed air for cleaning purpose.
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.
As discussed in the previous proposal, the plant has installed a centralized
compressed air system which maintains the air pressure in the receiver at 5.7
bar.
The leakage test was carried out in the plant and significant leakage in the
distribution system was observed. First, the leakage test was carried out for
the whole plant and then each block was isolated and the amount of leakage
was calculated individually for each block.
Generally, valves and flanges are more prone for leakages.

44
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:

Sl. No.
Solvent Based Paint Block Ground Floor
Mixer no.244 pigging line, Pneumatic valve leakage (Major)
VFM - P215 tub cut-off pneumatic valve leakage
Lid pressing machine LP P217 cylinder leakage
VFM P209 cut-off pneumatic valve leakage
Near mixer 219 pigging line, pneumatic valve leakage
LP 203 FRL leakage
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
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
17
Work centre 2, pneumatic valve leakage near FMT P202
18
Pneumatic valve leakage above drier tub 1
19
Behind sand mill 209 copper tube leakage

45
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
25
26
VSP 351, diaphragm pump pipeline leakage
27

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
40
FRV bottom
41
DLP 406 condensate cooling line Control Valve
42
Control valve vent line is open O/L

Resin House (2nd Floor)
46
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
47
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
Usually the norm is of maintaining compressed air leakage to less than 15% in
a plant. In some of the energy efficient plants, compressed air leakage was
observed to be as less as 6%. Therefore, here is a good opportunity to
conserve energy and minimize the leakages in the plant.
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
Increase the awareness among the operators and the workers on the value
of compressed air
Promote Red-tag system among the workers in the plant, wherein
whenever any worker identifies a leakage point, he will attach a red tag at
the leakage point
The maintenance staff then addresses the leakage with the help of the tag
and minimum leakages are maintained in the plant
Conduct leakage test during shut down time
Identify & arrest the leakages
Considering reduction in the leakage to 30% from the current values,
Benefits
48
The annual energy saving potential by arresting the compressed air leakage
points is Rs. 11.54 Lakhs. This does not require any major investment.
49
Observation
50
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
51
The lux measurements were carried out at various locations in the plant,
during the detailed energy audit.
The lux levels measured and the recommended values are mentioned below.
The lux levels were sufficient at the following areas:
Location
SBU Ground
floor
Time
Avg lux
Recommende
d Lux
Corridor
130
50
BOPT changing
area
270
100
Area
Day time
SBU Ground
floor
Day time
IPU- FF
Day time
Spray booth room

Ph - 2
189
100
IPU- FF
Day time
Lab area ph -1
103
100
IPU SF
Day time
Reactor area (355389)
545
100
RH- MF
Day time
stair case
1500
50
RH- SF
Day time
Walk way corridor
55
50
Avg lux
Recommende
d Lux
Pug Mill platform
23
100
Corridor- 1
28
100
Filling area
58
100
Pug Mill platform
23
100
Corridor- 1
20
100
The lux levels were low at the following areas:

Location
Time
Area
WBU - Ground
floor
Day time
Night time
52
Day time
WBU- First floor
Night time
Day time
WBU Second floor
Night time
Filling area
27
100
Filling vessels
18
100
Reactors area 101105
33
100
22
100
Process area
34
100
Pugmill area- 1
49
100
Pugmill area- 2
26
100
Liquid storage
25
100
Filling vessels
20
100
22
100
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
53
Walk away corridor
18
50
Hoppers
30
100
TSD
38
100
Storage area
20
75
53
100
61
100
70
100
77
100
56
100
56
100
80
100
89
100
Corridor
37
50
BOPT changing
area
27
100
Process stations
62
100
Below tanks &

filling stationscircle 1
Below tanks &
filling stationsDay time
circle 2
Below tanks &
Below tanks &
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
SBU
Day time
54
1
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
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
56
100
First floor
Night time
SBU MF
Day time
SBU - second
floor
Night time
Day time
IPU GF
Night time
IPU FF
Day time
Premixing area Ph1

55
Night time
Day time
IPU SF
Night time
RH GF
Day time
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 ph1
19
100
Mixer floor area

Ph-2
22
100
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 (355389)
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

tanks- left side
47
100
below and behind

tanks- right side
21
100
Corridor
37
50
MCC room
20
200
56
Night time
below and behind

tanks- left side
12
100
below and behind

tanks- right side
10
100
50
MCC room
17
200
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 area- right
36
100
Charging area
36
100
MCC room ph-1
31
200
MCC room ph-2
15
200
Reactor area- left
28
100
Reactor area- right
30
100
Walk way corridor
50
Charging area
15
100
MCC room ph-1
22
200
MCC room ph-2
20
200
Corridor
Day time
RH- MF
Night time
stair case
Day time
RH- SF
Night time
It is recommended to improve the lux levels in these areas, after conducting a

detailed study of lighting design. Instead of replacing the lamps with the same
no. of LEDs when replacing the existing T8, CFl lamps, the plant team may go
for slightly more no of lamps to improve the lux levels. Task lighting can be
57
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.
58
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.
Order of harmonics
WBU 1
I1= 187.2 A
WBU 2
I1= 193.5 A
IPU 1
I1= 95.6 A
59
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:
R-phase
Case
PF
Y-Phase
B-Phase
THD
V%
THD
I%
PF
THD
V%
THD
I%
PF
THD
V%
THD
I%
Main
Cap 0.93
bank
with
reactors
switched off
1.00
2.70
0.95
1.10
3.80
0.93
1.00
3.70
With
0.94
capacitor
panel MCCB
on
1.00
2.30
0.95
1.10
4.20
0.94
1.00
3.20
Manually all 0.99

C and L on
1.00
2.80
0.99
0.90
3.30
0.99
1.00
3.40
Auto Mode
1.00
2.80
0.99
0.90
3.20
0.99
0.90
3.10
0.99
60
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.
61
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
62
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.
63
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. The condensate at present is not being utilized back to boiler
due to higher TDS levels and is been sent to softening plant.
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.
By preheating the boiler feed water to boiler by 30 Deg C would result in fuel
savings of 0.67 kg of LPG per hour.
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:
64
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 x90% Boiler Efficiency
65
=
Running hours
Annual savings
0.67 kg of LPG
=
3000 Hours/Annum
=
0.67 kg x 3000 hrs/annum x Rs.
60/kg of LPG
=
Rs. 1, 20, 000
Say Rs. 1.20 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
Investment required
Rs. 4.0 Lakhs
Payback
Rs. 4.00 Lakhs x 12 months

Rs. 1.20 Lakhs
40 months
66
Chapter V
Management Aspects and Conclusions
67
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.
68
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.
69
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
70
Annexure
71
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
72
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
73
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
74
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)

75
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
76
SOLAR WIND HYBRID SYSTEM

1.
2.
JAIN IRRIGATION SYSTEMS

LTD
House No. - C-98,
Ground Floor, Niralanagar,
Lucknow (Uttar Pradesh)
Tel : +91 - 522 - 224 7886
+91 - 522 - 402 1067
Mob : +91 - 094530 07807
SUPERLITE LUMINAIRES
33, Guru Gobindsingh Estate,
Jay Coach, Goregaon (E),
Mumbai - 400 063. INDIA.
Tel : +91-22-26852822
Telefax : +91-22-26853027
Email: info@superliteindia.com
Contact person name
Mr Atul Lotia
Director
3.
ZENITH SOLAR SYSTEMS

15, Grihashilp Society, Delhi Gate
City :
Ahmednagar
State : Maharashtra
Country :
India
Pin Code :
414001
Tel :
+91-827-5033190
Mob : +91-9822093130
Contact person name
Mr. Amey Mudkavi
4.
HBL POWER SYSTEMS

Block A, Kubera Towers
Trimulgherry
Hyderabad- 500015, AP
Tel: +91 -40-27791641
+91 -40-27795434
Toll Free No: 18004252939
Email: hro@hbl.in
77
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
78
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
79
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
80
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
81
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 2x36w T8 Lamps With

1x20 W LEDs
28
31
13
Replace 2 x 36W CFLs with 18W LEDs
0.9
1.8
24
2.8
13
56
22.3
Sl.
No
0.31
Renewable energy for lighting (long

term)
house thermopac TP-405 for improving
combustion efficiency
house revomax boiler RXA06 for
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 industrial
paint block
13.45
14.5
13
Optimize the operation of WBU cooling

water pumps
1.97
19
Optimize the operation of LDV cooling

water pump in wbu section
0.44
0.6
17
3
4
5
6
Person/Depa
rtment
Responsible
Target
Date
Remarks
10
Optimize the operation of new bazaar

cooling water pumps
12
11
Optimize the operation of industrial

cooling water pumps
4.2
1.6
12
Replace inefficient pumps with new

efficient pumps
3.5
42
13
Reduce the generating pressure of the

air compressors in the plant
9.9
14
Minimise compressed air leakage

in the plant
11.54
98.81
75.0
Total
Backup Calculations
91
REPLACE THE 2X36W T8 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
Around 146 KW
Proposed
It is recommended to replace these T8 lamps with 1X20 W LEDs.
Power consumption of LEDs
=
2034 Nos X 20 W each
=
40.68 kW
Say 40 kW
Savings
=
146 - 40 kW
Say 106 kW
92
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.1500 for LED)
=
=
2034 X 1500
Rs. 30.51 Lakhs
Payback period
(Investment) X 12 months
(Savings)
Rs. 30.51 Lakhs X 12 Months

Rs. 28.30 Lakhs
=
12.9 Months
Say 13 months
93
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
=
=
108 X 18 W
1.94 kW
Savings in KW
=
7.78 1.94 kW
=
5.84 kW
Say 5.8 kW
Annual Savings in Rs.
=
=
=
5.8 kW X 2432 hrs X

Rs. 6.7/kWh
Rs. 94,507/Rs. 0.94 Lakhs
Investment (Rs. 2000 for LED)
=
=
=
108 Nos X Rs 2000/LED

2,16,000/Rs. 2.16 Lakhs
Payback period
Investment X 12 Months
Savings
Rs.2.16 Lakhs X 12 Months

Rs.0.94 Lakhs
28 months
94
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
=
=
150 X 70 W
10.5 kW
Energy consumption of LEDs
=
=
150 X 18 W
2.7 kW
A 3 KW solar wind hybrid system can be installed at the plant to tap 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 wind

hybrid system
Rs. 9 Lakhs
Total Investment
Say 13 Lakhs
Savings
10.5 kW X 4000 hrs

X Rs. 6.7/kWh
Rs. 2.81 Lakhs
95
Simple pay back period
=
=
Rs 13.0 Lakhs x 12
Rs 2.80 Lakhs
55 months
96

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/Nm3/DegC
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
1523.5
97
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. 2.00 Lakhs
Payback

Rs. 21.75 Lakhs
1 month
=
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
98
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. 3.50 Lakhs

Rs. 22.3 Lakhs
2 months
99

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 boiler 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/Nm3/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
100
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
* The investment for gas analyzer is not considered in this project as

the same is considered in earlier energy saving proposal No. 4.
101

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 considering the same heat being developed.
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
* The pump is already equipped with VFD.
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)
102

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
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
ducting. For calculation the specific energy consumption (SEC) the rated flow
was considered for comparing the savings possible. Saving potential can be
even higher then calculated due to non availability of exact discharge flow.
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
(9.5 + 9.25) KW
18.75 KW
Annual savings in Phase I
Annual savings
=
6.7/KWh
=
Rs. 8, 79, 375

Say Rs. 8.79 Lakhs
103
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
104
OPTIMIZE THE OPERATION OF WBU COOLING WATER

PUMPS
the cooling water pumps in WBU section were studied in detail for identifying
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

Present temperature difference
1.50C
Temp diff can be maintained
40C
% flow reduction possible
=
=
40C 1.50C x 100

40C
62.5%
=
=
60%x 7.7kW
4.6 kW
Power saving in 3kL pump
=
=
60% x6.3kW
3.7 kW
Total power saving
=
=
=
4.6kW + 3.7kW
8.3 kW
Say 8 kW
Annual saving
=
=
=
60% of the flow can be reduced,

Power saving in 5kL pump
8kWx10hrsx 330days x Rs 6.7/kWh

Rs 1, 76, 880/Rs 1.76 Lakhs
105
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
106
OPTIMIZE THE OPERATION OF LDV COOLING WATER

PUMP IN WBU SECTION
the LDV cooling water pumps in WBU section were studied in detail for
Saving calculation
Operating power of LDV pump
5kW
Present temperature difference
20C
Temp diff can be maintained
40C
% flow reduction possible
40C 20C x 100

40C
50%
=
50% of the flow can be reduced,
Annual saving
=
=
=
50%x 5kWx 7hrs x 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
107
OPTIMIZE THE OPERATION OF NEW BAZAAR COOLING

WATER PUMPS
the New bazaar cooling water pumps in WBU section were studied in detail for
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
108
OPTIMIZE THE OPERATION OF INDUSTRIAL COOLING

TOWER FANS & COOLING WATER PUMPS
the industrial cooling water pumps in WBU section were studied in detail for
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
Investment for VFD
Rs 0.80 Lakhs
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
By switching off the pump 458,

Annual saving of the pump
By installing VFD to the pump 457
109
REPLACE INEFFICIENT PUMPS WITH NEW EFFICIENT

PUMPS
the performance of the water pumps in the plant were studied in detail for
Savings calculation for 70TR chiller hot well pump:
kW savings with pump of
efficiency 70%
6.15 6.15 x 24 %
70 %
=
4 kW
* 70% new pump efficiency is considered only for savings calculation.
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. 1.30 Lakhs
Investment for 4 new pumps
Rs. 3.5 Lakhs
Simple Payback period

Rs. 1.30 Lakhs
32 months
110
REDUCE THE GENERATING PRESSURE

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 which maintain the pressure of the receiver at 5.7 bar. This
centralized compressed air system supplies air to all the sections of the plant
viz. Water Based Unit, Solvent Based Unit, Industrial Paint Unit, Resin Block
and the Monomer block.
Monomer
Tank
P405
587 CFM
5.7 bar
5.6 bar
5.5 bar
Refrigerant
Drier
10m3
Receiver
Water Based Unit
P406
587 CFM
5.5 bar
Industrial Based Unit
Phase I & II
5.5
bar
Resin
Block
5.4
bar
Solvent Based Unit

& Workshop
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
It was observed that when the plant is in full load operation, one compressor is
continuously running and the second compressor is running for 10 % of the
time. This compressor has been set in such a way that if it is in unload for
more than 10 minutes it automatically switches off. The limit of switching on
and off for a 110 kW motor is times in an hour.
During the detailed energy audit of the plant, a comprehensive compressed air
distribution study was carried out for the compressed air requirement of the
111
end users and the pressure drop at the farthest point in the plant. During the
compressed air user study of the plant, it was observed that the compressed
air pressure drop at the farthest point from the generation was not more than
0.2 bar.
The compressed air pressure being maintained at different applications in the
plant is as follows:
Purpose of Compressed Air
Pressure Maintained
Open/Close valves
4.0 bar
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 observed that in most of the end users the pressure setting being
maintained was between 3.0 bar to 4.0 bar. The only operation which requires
a pressure of 5.0 bar is the Lid pressing operation in packer area. The
manufacturer has advised a pressure setting of 6.0 bar considering a safety
margin but the plant is running the packer machine successfully maintaining a
pressure setting of 5.0 bar. It was also observed that these packing machines
were already 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.
Here is a good opportunity to utilise this booster compressor so that it supplies
high pressure compressed air to the packer machine and reduce the
compressor air pressure at the generation end itself.
Proposed System
The compressed air pressure maintained for most of the applications in the
plant is not more than 4.0 bar. Only the lid pressing operation in the packing
machine requires a higher compressed air pressure requirement of 5.0 bar.
These packer machines are already installed with booster compressors. We can
112
use these booster compressors in such a way that when we give an input of
4.0 bar compressed air, it gives an output of air at a pressure of 5.0 bar.
Utilizing this booster compressor we will be able to cater to the pressure
requirement of 5.0 bar for the lid pressing machine and at the same time we
will be able to reduce the pressure of the compressed air at the generation end
to less than 4.5 bar average pressure which is sufficient for all the other
compressed air applications.
When we utilize this booster compressor, it increases the amount of
compressed air usage as it increases the pressure of the incoming air and
produces high pressure air. But this increase in compressed air consumption is
not as significant when compared to the savings we will achieve by reducing
the compressed air generation pressure.
Recommendation
Step 1:
Firstly, we recommend to reduce the compressor pressure by 0.2 bar at the
generating point and at the same time adjust the compressed air pressure
setting in the booster compressor of all the packing machines such that
these booster compressors gives an output of 5.0 bar compressed air to the
packer machines.
Run the plant in normal operation for a few days.
Step 2:
If there is no issue with the operation of the plant, keep on reducing the
generation pressure in steps of 0.2 bar until the generating pressure is set
to an average pressure of 4.5 bar and utilizing the booster compressor in
the packing machines so that the required pressure of 5.0 bar is
continuously maintained in the packing machines.
keep on reducing it until the generating set points are:
Load point
- 4.2 bar
Unload point
- 4.7 bar
Calculations
For Compressor P405:
Percentage Pressure reduction
Annual Savings
= (5.95 4.45) kg/cm2 x 100

(5.95 +1) kg/cm2
= 21 %
= 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
113

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
114
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
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
115
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
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

= {83/ (92+83)} 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(load kW)30(Unload kW)) 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
116

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Final Draft DEA Report Asian Paints LTD Patancheru

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Confederation of Indian Industry

CII-Sohrabji Godrej Green Business Centre

Detailed Energy Audit

Confederation of Indian Industry

List of Energy Saving Proposals

Energy Saving Proposals

Management Aspects and conclusion

Total Pages: 116

Confederation of Indian Industry

: 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

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Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

Confederation of Indian Industry

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LIST OF ENERGY SAVING PROPOSALS

Energy Saving Proposals

Confederation of Indian Industry

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Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

LIGHTING SYSTEM AT ASIAN PAINTS LIMITED,PATANCHERU

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Confederation of Indian Industry

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Confederation of Indian Industry

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Replacement methodology of lamps with LEDs

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Confederation of Indian Industry

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ENERGY SAVING PROPOSAL No. 1

REPLACE THE EXISTING 2X36W

During the course of detailed energy audit at Asian Paints Limited,

CIISohrabji Godrej Green Business Centre

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 2

REPLACE THE EXISTING 2 X 36 W CFL LAMPS WITH 18

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LONG TERM ENERGY SAVING PROPOSAL NO. 1

INSTALL SOLAR WIND HYBRID SYSTEM FOR STREET

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Solar Wind Hybrid System

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ENERGY SAVING PROPOSAL No. 4

Combustion air: 4284

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Air preheater outlet

Effect of excess oxygen