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WELCOME TO THE PRESENTATION ON ESCO FROM

SRI VASUKI POWER SYSTEMS PVT LTDAdugodi, Bangalore - 560 030

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❖ VASUKI established in the year 1999 by SURESH BABU.V Founder & CMD

of VASUKI Group of Companies.

❖ ISO 9001 -2015 ,14001 -2015 & OSHAS 18001 -2007 Certified Company

❖ CRISIL rated Company

❖ BEE Certified Company

❖ Channel Partners for MNRE to provide Solar rooftop Solutions and solar

Power Plant Integrations

❖ More than Two decades of Rich Experience in execution of Turn Key

projects , Operation and Maintenance services in the wide range of market

segment such as Corporate offices, Banks, Commercial Complex, Hospitals,

STPI, Data Centre, Hotels, Industries, Commercial complexes, Public sector

Organisations

❖ More than 430 Employees are serving the Company in various capacity

COMPANY PROFILE

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SCOPE OF ENERGY AUDIT :

❖Identify Energy consumption in the organization❖Estimate the scope of savings❖Setting up a reference point❖Optimize energy use❖Reduction In Carbon Emissions ❖Implementation procedure ❖Measurement & Verification

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Client -1

This Client is an early pioneer in IT outsourcing and theoffshore software development business. Helpingsoftware companies get more competitive throughinnovative product engineering models. HelpingEnterprise customers realize their business goals throughtechnology solutions in the realm of Collaboration,Mobility & Analytics. Help build Share Point basedintranets and extranets to increase productivity andcollaboration.

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❖ Energy Conservation Measures changing of CFL to LED ❖ 1x 18w CFL replaced by 9 w LED ❖ Implementation Framework/Business Model❖ Measurements & verification framework ❖ Challenges faced if any and how were they addressed

S. No. Present Status Recommendation Yearly SavingsApproximate

Investment

Simple

payback

period

kWh/year Rs./year Rs. Year

A

18W CFLs are used for

Work stations and

Lobby lighting.(80 No.)

These CFLs can be

replaced by 9W LED bulbs.38.9 20,480 12,000 0.6

b

2 x 36W FTLs are used

at some of the places

(70No.)

Replace these FTLs by 2

x18 W LED tube lights 133.3 60,620 1,40,000 2.3

c

2 x 28W FTLs are used

at some of the places

Replace these FTLs by 2

x18 W LED tube lights

119 785 1,800 2.3

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Apart from the above projects following suggestions aremade for further savings.❖Switching off computers, lighting and electrical loads

when not in use.❖Reduction in ventilation load by closing the air grills

wherever not necessary like in near windows and scrapdump area.

❖Reduction of current unbalanced load at the Main DBby correcting the balancing of circuits

❖Installing Roof Top Solar PV power plantThe office is having good shadow free roof top space nearCafeteria, installed Solar PV power plant and generateelectricity which is catering the lighting load

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CLEINT 2

This client is a part of the global Group. They are intomanufacturing of tungsten wires, sheet metal productsof tungsten, molybdenum and tantalum and machinedproducts of these materials. The products are widelyused in lighting, semiconductor applications and wireEDM.

The total electricity bill for the company is Rs. 224.9lakh per annum. Additionally, LPG cost is around 60 lakhand diesel for DG set is around 5 lakh per annum

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S. No. Present Status Recommendation Yearly Savings

Approxi

mate

Investm

ent

Simple

payback

period

kWh/year Rs./year Rs. Year

A Projects with low investment

1

Main air compressor of 90 kW

and a 11 kW air compressor

for H2N2 plant are operated

separately.

Use of compressed air from

main air compressor for H2N2

plant, instead of running a

separate air compressor for

H2N2 plant

65,505 4,32,066 75,000 0.2

2

Existing 2x 1000 lpd Solar

water heater panels are

oriented more towards east

than south reducing their

output

Reorient the panels properly to

due south and get the designed

output. This will reduce the

electricity consumption for hot

water generation

14,244 93,953

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B Medium term projects with little investment

3

The existing cooling tower

pump of 9.3kW is oversized

and outlet is throttled close to

50%.

Install a VFD to avoid throttling

losses18,144 1,19,676 60,000 0.5

4

Cooling Tower fan is

continuously operated without

any temperature feedback

Installed temperature controller

to switch on switch off the

cooling tower fan based on

temperature setting

7,740 51,052 25,000 0.5

5

18W CFLs are used for outdoor

lighting.(24 No.)These CFLs can be replaced by

9W LED bulbs.933 6,155 3,600 0.6

6

2 x 36W FTLs are used at some

of the places (12 No.)Replace these FTLs by 2 x18 W

LED tube lights 1,964 12,955 24,000 1.9

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C Long term and with considerable investment

7

The existing 90kW air

compressor is poorly loaded

at 38%. Even after considering

the usage of H2N2 plant its

loading will improve to 52%,

wasting lot of energy in

unload condition

Install a properly sized air

compressor of 55kW to

optimize the loading

percentage

1,57,341 10,37,802 14,00,000 1.3

8

The production area lighting is

done by 2 x 28W FTLs (799

No.)

Replace these fixtures by

2 x 18W LED tube lights.92,732 6,11,650 14,02,200 2.3

S. No. Present Status Recommendation Yearly Savings

Approx

Investme

nt

Simple

payback

period

kWh/year Rs./year Rs. Year

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9

Electric heaters are used in

hot water generation for

heating the water required

for chemical cleaning.

Solar water heating

system with heat

exchanger can be

provided to reduce the

power consumption.

72,000 4,74,903 20,00,000 4.2

10

Good roof top area is vacant

for harnessing Solar energy.

(Admin block – 715 m2 and

Production Area – 3666 m2 )

Roof top Solar PV power

plant to the tune of 400

kWp is possible

combining the Admin and

Production blocks.

5,78,160 38,13,473 3,20,00,000 8.4

Total10,08,764 66,53,685 3,69,89,800 5.6

S. No. Present Status Recommendation Yearly SavingsApprox.

Investment

Simple

payback

period

kWh/year Rs. /year Rs. Year

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Apart from the above projects following suggestions are made for furthersavings.❖ Reduction of compressor load pressure from 6.5 bar to 6.0 bar in 90 kW

compressor.

❖ The unload power of the 90kW is around 58kW, which is on higher side andhence needs to be checked from maintenance and setting point of view.

❖ Providing solar hot water to hot water generation section for top up andrefilling purposes. Presently this is used only in boiling section.

❖ Idle running of machines to be avoided by proper planning. This is leadingto huge losses over a year as the heaters of the machines will be On even ifthe production is not there to maintain the set temperatures.

❖ Insulation needs to be improves in machines especially in AS and 17Fmachines where heat losses are considerably high.

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❖ Reduction in ventilation load by closing the air grills wherever not necessary likein scrap dump area.

❖ Reduction of current unbalance at the Main transformer DB by correcting thebalancing down streams.

❖ The ammonia heater usage to be optimized by switching on the heater for the cylinder which is in service and switching off for the other two on standby.

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Power consumption trend

0

50000

100000

150000

200000

250000

300000

350000

Sep

-15

Oct

-15

No

v-1

5

De

c-1

5

Jan

-16

Feb

-16

Mar

-16

kWh

/ m

on

th

From the above graph, it is clear that there is steady increase in consumption due to increase in production as per the feedback

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Voltage profile of transformer

0

50

100

150

200

250

300

350

400

450

500

10

:50

:00

AM

11

:28

:00

AM

12

:06

:00

PM

12

:44

:00

PM

1:2

2:0

0 P

M2

:00

:00

PM

2:3

8:0

0 P

M3

:16

:00

PM

3:5

4:0

0 P

M4

:32

:00

PM

5:1

0:0

0 P

M5

:48

:00

PM

7:1

0:0

0 P

M7

:48

:00

PM

8:2

6:0

0 P

M9

:04

:00

PM

9:4

2:0

0 P

M1

0:2

0:0

0 P

M1

0:5

8:0

0 P

M1

1:3

6:0

0 P

M1

2:1

4:0

0 A

M1

2:5

2:0

0 A

M1

:30

:00

AM

2:0

8:0

0 A

M2

:46

:00

AM

3:2

4:0

0 A

M4

:02

:00

AM

4:4

0:0

0 A

M5

:18

:00

AM

5:5

6:0

0 A

M6

:34

:00

AM

7:1

2:0

0 A

M7

:50

:00

AM

8:2

8:0

0 A

M9

:06

:00

AM

9:4

4:0

0 A

M

Vo

ltag

e

RY YB BR RN YN BNMinimum Maximum Average

Phase to Phase voltage

RY 382.4 438.7 411.7

YB 384.5 439.8 413.2

BR 387.3 443.3 416.1

Phase to Neutral Voltage

R 221.2 254.3 238.4

Y 221.2 253.2 238.0

B 223.8 255.7 240.1

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Hot water and solution heater load

12.0

14.0

16.0

18.0

20.0

22.0

24.0

kW

10:50:00.000 AM

4/30/2016

1:48:00.000 PM

4/30/2016

35 min/Div

2:58:00 (h:min:s)

The total heater load varied from 12 kW to 24 kW with average of 18 kW

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Break up of electricity consumption

Machines33%

Cleaning heaters3%

HVAC12%

Air Comp13%

Chiller5%

H2N24%

Semicon9%

Admin1%

Lighting Shop floor4%

Out door lighting

0%CT2%

Ammonia heater1%

Others11%

Transformer lossses2%

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VASUKI Team

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Question & Answers

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Reach Us

Contact : Mr. V. Suresh BabuMobile : 98440 66511Phone : 080 22113447E Mail : sureshbabu@vasuki.in

info@vasuki.in Web : www.vasuki.in

mailto:sureshbabu@vasuki.inhttp://www.vasuki.in/

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