1. ENERGY MANAGEMENT SYSTEM
ENERGY CONSERVATION & MANAGEMENT
ENERGY MANAGEMENT SYSTEM
Energy consumption Measurments
Utilities Supply
P .F.MANAGMENT
Analyasis
DSM
Benchmark
TOD
Energy cons.projects

2. Various production group
ENERGY CONSERVATION
Electric bill
Energy Management
system
Real time measurement of consumption of Electric power through SCADA system
Power Factor
Various production group
Demand management
Extruder
Utilityes
T.O.D. terrif
Mixing
Compressed air system
socketing
Load Factor
Chilled Water System
Rework
Vaccum system
Others

3. Energy Management System
The entire manufacturing activity has been divided into different sub activities depending on nature of operations.
Each power consuming equipment has been provided with multifunctional meter and at present approximately 200 multifunctional meter are deployed.
Thus equipment wise and shift wise power consumption data is available at SCADA station.
The energy balance is also checked at various levels of power distribution system.
With this system it is possible to measure losses at various levels of power distribution system.
The equipment wise power consumption data helps in evaluating the specific energy consumption of each equipment thus enabling the user to under take gap analysis and formulating improvement plans.
Maximum demand controller helps in monitoring and controlling the bill demand.

4. Energy Management System
132 kv MD
Controller
Energy
Management
System
(E.M.S.)
PVC Pipe (11 kv)
HDPE/PPR (11kv)
C & P (11kv)
LTPCC
LTPCC
LTPCC
Extruder
Grinder
Utility
PVC
CPVC
ROTO
HMF
Canteen
Statistical
Analysis
Extruder
Mixer
Grinder/
Pulveriser
Objective :-
Energy
conservation
Extruder
Mixer
Socketing
Grinder/
Pulveriser
Utility
Capacitors
Spares

5. Energy Management Report
Daily Power Consumption
PVC
CPVC
Units
Production
Units / Kg
For the day
Cumulative
HDPE
PPR
Units
Production
Units / Kg
For the day
Cumulative
Roto Moulding
HMF
C&P XF
Total Units
For the day
Cumulative

6. Areawise Power Consumption Allocation
Areawise Power Consumption Allocation
S N
Sub sections
PVC
CPVC
HDPE
PPR
ROTO
HMF
C&P XF 1
Extruders 2
Mixer 3
Utility 4
Socketing 5
G/P 6
Others
a) Plant Lighting
b) Yard Lighting
c) .Offices
d) Common Facility
e) 11 KV Transformer Losses
Total
Energy Management Report

7. Energy Management Report1
Areawise allocation
Daily Variance
Cumulative Variance 2
MSEDCL units 3
MD Controller Units 4
132 KV I/C ( 1 OR 2) 5
11 KV O/G # 1 6
11 KV O/G # 2 7
11 KV O/G # 3 8
MSEDCL MD 9
MSEDCL (PF for Day)

8. Energy Management Report
PVC Performance of Specific Energy Consumption
Sr No.
U/Kg (Target)
U/Kg (For the day)
U/Kg (Cumulative) 1
Extrusion 2
Mixer 3
Utility 4
Socketing 5
G/P 6
Other
Total

9. ENERGY CONSUMPTION FOR THREE YEAR
PPRC
C/P
HDPE
CPVC
UPVC

10. PROJECTS FOR ENERGY CONSERVATION 2010-11 Energy Saving Proposal
S.N.
Energy Saving Proposal
Investment in Rs
Remark 1
Use of PIR sensor for material conveying blowers room to switch off lights
5000 2
Control hot water flow in mixer and cooling water flow in cooler jackets to optimize cycle time and optimize Specific power - hot water from air compressors discharge / solar water system
378000
Trial conducted on Heater mixer, HM-111 insulated on dated 10/5/ Saving observed units/kg. 3
Change the layout such that air is blown at the bottom & behind all root blowers (auto mixer conveyor blower room) so as to carry the heat out through the other diagonally opposite opening at the top of the room. 1 blower can be removed and VFD for one bl
100000
Work in progress to be completed in last week of May-10. 4
Use of ADSC (Auto Delta Star Converter) for Mixer-2/10/11/15/211 cooler motor
65000
Trial of auto start delta conducted at cooler mixer no-11 on dated 12/5/10 5
Optimization of Higher Specific power of mixers -2, 8,11,15 & 17 by maintenance etc
Work in progress, blade set to be ordered. 6
Power analyzer for energy conservation purpose.
80000
For in-house energy audit. 7
Ultrasonic air Leak Detector
300000
For in-house checking of all air Leakages in the plant. 8
Stop use of blowers or optimize blower air flow used on heaters of Extrusion machines
525000
Implemented on 35 nos machine with controller setting. Saving units/kg , remaining extruder requires temperature controller of make "SELECTRON" 9
Install close loop VFD on Vacuum pumps of vacuum tank at Extrusion machines PVC plant
Implemented on machine no-11. Saving 1.86 units/hr observed.

11. ENERGY CONSUMPTION FOR FOUR YEAR

12. 10
Use of Automatic Voltage Regulator (AVR) at Lighting feeder-PVC plant
400000
1 no. unit for hall # 1 to 5 , no. unit for hall # 7 to 12 of PVC / CPVC plant. 11
Insulation of chilled water lines & Calibrator vacuum tank to save surface cooling losses
160000
Implemented on M/C no-10 on dated 11/5/2010. To be implemented on balance vacuum tanks. 12
Use of Genie energy saver with timer controller
11000
To be tried on one A.C., then implement on balance A.C.'s 13
Use of VFD for Air compressors at PVC rework division.
110000 14
Use of VFD for ventilation blower at PVC grinder plant and open discharge damper fully
75000 15
Use of VFD for Dust collection blower -1 at PVC grinder plant and open discharge damper fully
90000 16
Use of VFD for Air compressors E-45 / E-22 17
Use of VFD for Air compressors E-15

13. 18
Use of VFD for Air compressors at ROTO/HMF division.
110000
Implemented in June-10 19
Use of photo sensors / timer controller for street light feeders-12 locations
10000
To be tried on one location, then implement on balance locations. 20
Use of VFD for Aspirator blowers - 1 & 2 at PVC mixer plant and suction damper fully opened.
180000
Trial conducted. 21
Installation of Sandwich Energy Efficient Flat belt transmission system on main motor at Extrusion machines or Direct coupling of main motor to gear box and avoid belt system to save power as extruder is operated with VFD.
43077
To be tried on one machine then implement on balance extruders. 22
Replace motor and gear box for vertical screw feeder motors with PMSM at extrusion machines (13 nos)-PVC plant.
10154
To be tried on one machine then may be implemented on balance extruders. 23
Replace motor and gear box for Haul off motors with PMSM at extrusion machines (13 nos)-PVC plant.
11692
To be tried on one machine then implemented on balance extruders. 24
Modifications to present raw water system at Raw water treatment plant at PVC plant.
75000 25
Use of Energy Efficient Vac blow air guns for cleaning.
275000 26
Thyristorized control system for electrical heaters at extrusion machines - PVC plant.
70000
To be implemented on M/C no-10, after successful results it can be implemented on balance extruders. 27
Use of premafrost for Air conditioners.
---
Offer awaited 28
Installation of flat belt transmission system on Pulveriser motors to save power consumption.
150000 29
Installation of cogged belt transmission system on Grinder motors to save power consumption
210000
TOTAL

14. ENERGY SAVING PROJECTS 2011-12
MODIFICATION IN CALIBRATOR TO REDUCE AIR CONSUMPTION(5 EXTRUSIO LINE)
1.5
Monitoring the energy saving on continuous basis. 2
COOL MIXER JACKET INSULATION
0.40
Reduce Heat load of Chiller. 3
VFD FOR COOLER MIXRE MOTOR- Qty-14 Nos
7.00
Energy saving by reducing speed of motor during idle run. 4
INSTALLATION OF FLAT BELT SYSTEM ON Extruder no--2 &10
1.3
3 to 4% Power saving due to improved transmission effeciency. 5
RESCHEDULING OF CAPACITOR BANK IN CRTAEs &PALLET(25 KVAR-2000T/25 KVAR-2400 T
0.1
IMPROVE P.F AT LOAD END 6
FIXED CAPACITOR BANK-50 KVAR ON CRATE &PALLET TRANSFORMER
REDUCED TRANSFORMER LOSS 7
APFC PANEL WITH HARMONIC FILTERATION-100 KVAR(ROTO)
ROTO MOULDING-improve P.f at load end; 8
APFC PANEL -150 KVAR GRINDING SECTION(Grinder/Pulvariser)
1.0
Grinder / Pulvariser dept -improve P.f at load end;

15. 11
USE OF PMSM MOTOR HAUL OFF EXTRUSION MACHINE-No-02 & 10
0.2
2 MACHINE 12
USE OF PMSM MOTOR EXTRUDER FEEDER MOTOR. MACHINE no2 &-10
0.18 13
USE SYNTHETIC OIL FOR SCREW COMPRESSOR
0.15
Monitoring the Benefite as well as life of consumables(oil filter & separatos) for six month period & then decide for other compressors. 14
CONTROL OF WATER PRESSURE FOR SEC.CHILLER & SEC PROCESS CENTRALLISIED EATER SYSTEM BY USING VFD & PLC
5.5
Order to be released in the first week of Nov 2011. 15
CONTROL OF HINGNA PUMPING STATION (Man Less Operation)
6.5 16
WATER TREATMENT SYSTEM WATER PUMP -7.5 H.P (EEC SERIES)- 04NOS
1.32
Using of Energy efficient water pumps. 17
600KVR HT CAPACITOR FILTER BANK FOR 132KV SUBSTATION
5.25
1) Improve P.F of sub station.2)Quotation & technical discussion with supplier in progress. 18
OPTIMIZE THE TRANSFORMER LOSSES 132 KV BY LOAD SHARING
---
Minimse No load losses. 19
USE VFD FOR DUST COLLECTION SYSTEM FOR HALL NO-07 TO 11 & MIXER AUTOMATION HALL NO-02 TO-03 - Qty - 03 nos.
6.0
Energy saving due to speed control during low output requirment. 20
OFF LINE SOCKETING MACHINE (HEATING LOSS MINIMISATION)- Qty - 09 nos
0.36
Energy saving due to reduction in heat losses 21
GLAND TYPE PUMP CONVERTED INTO MECH SHAFT SEAL -QTY-25NOS
0.75
3% energy saving. 22
INCREASE SUN LIGHT TO REDUCE LIGHTING IN DAY TIME FOR ALL MIXER HALL
Energy saving by eliminating the use of lights during late evening hours.

16. 23
REDUCE THE HEIGHT OF STREET LIGHT ON BOUNDARY Qty - 30 nos.
0.15
Improve the lux level & reduce the no. of lamps. 24
INSULATION FOR DIE ZONE HEATERS TO REDUCE THE HEAT LOSSES. Qty - 64 lines UPVC
3.2
Energy saving due to reduction in heat losses 25
INSTALLED DEMAND CONTROLLER IN CRATE &H.D.P.E DIVISION
0.8
Control of Individual division max,demand 26
Alluminium Fins provided to BZ3 zone for control friction heat. Qty - 02 nos.
0.54
Save energy & Improve productivity. B
AWARENESS OF T.O.D UTILZATION FOR FOLLWING SECTIONS 1)Roto Moulding division- Extruder, Grinder & Pulveriser 2) UPVC & CPVC,HDPE/PPR divisionGrinder & Pulveriser Total Qty - 25 nos.
2.00
Energy & Hour meter providing for indivdual equipment for assessing specific energy consumption during various time slots.
35.92

17. Salient features
As policy, we have decided that we will buy efficiency 1 motor with all new machinery.
we will be replacing the existing motors with efficiency 1 motors at opportune times.
We have introduced conditioning chemicals for water treatment. The parameters like STD, COC and LSI are being continuously monitored. This has resulted in drastically reducing the frequency of acid descaling of heat exchangers. The better heat transfer at heat exchangers of chillers has resulted in achieving optimum SPC of chillers.
Waghur river water lifting pumping station is run on MSEB power supply as far as possible despite the fact that power feeder is a rural one having very high load shedding cycles.
this has resulted in minimum use of D.G. power & hence substantial saving in power cost.
Solar lighting was provided at truck terminus. The performance is being assessed for wider applications.

18. Rating Output kW Full Load Speed Min Rev /Min
Current Max. Amps. (415V)
Efficiency
(equal or above)
Effi. 2
Effi. 1
0.37
1330
1.4
66.0
73.0
0.75
1360
2.2
82.5
1.5
1380
3.8
78.5
85.0
3.7
1410
8.1
84.0
88.3
5.5
1420
11.4
85.7
89.2
7.5
1430
15.4
87.0
90.1
11.0
1440
22.0
88.4
91.0
18.5
36.0
90.0
92.2
30.0
1450
56.0
91.4
93.2
45.0
1460
92.5
93.9
75.0
1470
134.0
93.6
94.7
164.0
95.0
110.0
1480
204.0
94.4
95.2
125.0
234.0
95.5
132.0
247.0
160.0
288.0
95.8
Source :-Values Of Performance Characteristic Of 4 Pole Energy Efficient Induction Motors IEEMA –

19. Power factor incentive prompt payment incentive
MSEDCL Power cost Statement-2011 to 2012
Date:- 25/5/2012
Month
Units consumed
Amount paid
Billed Max. demand
Rs/Unit with E.D
Rs/UnitWithout E.D.
Power Factor
Load factor
Power factor incentive
load factor incentive
prompt payment incentive
July
6263
6.60
6.02
1.00
48%
Nil
174637
Aug
7850
86%
308919
Sept
6.15
58%
207190
Oct
7050
6.70
6.11
225297
Nov
7800
6.82
6.22
73%
307277
Dec
8350
6.8
6.16
0.99
351423
Jan
8500
6.95
6.31
83%
365609
Feb
8050
6.94
6.30
80%
354769
Mar
8366
6.73
82%
295107
Apl
8327
5.49
4.87
87%
391144
May
8154
6.61
5.99
84%
365405
Jun
8194
6.51
5.89
371639
Total
1) Power factor incentive Rupees- 2,23,60,055 /-
2) Load factor incentive Rupees - 1,81,08,275 /-
3) Prompt Payment Discount Rupees- 33,46,777/-
Total Rupees- 4,38,15,107 /-

20. Maintenance Dept.(PVC Div.)
The Supreme Ind. Ltd.
Maintenance Dept.(PVC Div.)
Year

21. Electrical Sub station for PEB hall 10 & 11-1000KVA capacity. 1 No.
Sr.
Item Specification
Qty
Benefits 1
Electrical Sub station for PEB hall 10 & KVA capacity.
1 No.
To take care for additional load & minimise the breakdown due to overloading of existing transformer. 2
Errection & commissining of KVA transformer.
Job
Standby transformer against 9 nos 3
Power cable extension for PDB 8/9/10
Due to additional of load in Extrusion /mixer area ,to avoid overloading of existing cables. 4
DG power back up for X-film,Crates,Commercial office,HR,main gate & knowledge center etc.
Provision for continues Emergency power supply 5
Street light (Golf area side) monkey ladder provision for maint purpose
To improve the safe working condition by 100% 7
Eurotherm make temp.controller for extrusion machines-for 60 machines.
150 Nos
Improvement in 1% of Heating load process with properties & Power saving purpose. 8
Seperation of Electrical Panel for Herbold Grinder/Pulverisor .
3 Nos 9
Automatic power factor control panel for controlling power factor of electrical system.
15 Nos
For monitaring unity power factor & benefit of power factor incentive in MSDCL Billing.also Automatic power factor control. 10
Emergency light for PVC,CPVC,Utility area.
Improved in safe working conditions. 11
Remote monitering & controlling of waghur water lifting pump station at Hingane
job
To eliminate operating & human error also reduction in manhours. 12
Replacement of Zeplin make PLC ( non repairable )of vaccum loader by Selectron make
10 Nos.
Import substitution & reduction in breakdown. 13
Variable frequncy drive for cooler mixer
8 Nos.
Reduction in B/D & energy saving ,also eliminate kick to reduction in max. demand in peak period 14
To procure of LED lights for plant lighting
Energy saving by 35 % in plant lighting due to LED illumination. 15
To procure of Green Magic Energy Saver for plant lighting.
Energy saving by 15 % in plant lighting due to voltage controlling method.

22. Annual SAVING IN (Lacs)
S.N.
NAME OF ACTIVITY
Annual SAVING IN (Lacs)
STATUS
REMARKS 1
Control the maximum demand & maintain power factor at unity on day to day basis.
458.47 …
Benefit in MSEDCL monthly bill for ) Load incentive 2) P.F. incentive. 2
Daily Energy Monitaring (KWH) in Utility Area,& Run Optimum Utility to achive the target of U/kg
37.68
Energy consumption for utility in year was 0.75 U/kg.Annual saving accrued is U/kg as compared to last year In Rs-(0.005*114000*1000*6.61= /-) 3
Develope auto control system for centralized chilled & process water system through controling water pressure by using VFD & PLC
2.24
Completed on Dec-2011
Achived 2.5% energy saving against actual consumption 8500 units / day for water pumps i.e.212 units / day.Benefits accrued in annual saving (160*212*Rs-6.61)= Rs /- 4
Low air pressure ckt for Cutter & Barrel Vaccum by using PRV for the same application against actual working air pressure.(i.e.4.8 kg/sq.cm to 3.0 kg/sq.cm ) for cleaning purpose.
1.6
Completed on Oct
Achived energy saving due to reduction in air pressure.Assumption 180CFM air is utilized for cleaning.reduction in pressure from 4.8 to 3.0 kg/sq.cm i.e 15% CFM is saved ( 27 CFM *0.156 kw=4.2 units/hr saved ) Annual saving 4.2*24*240*6.61=Rs /- 5
Use synthetic oil for screw compressor.
0.67
Completed on Oct 2011.
Achived the energy saving 2% (28kwh/day) of compressor daily running units 1419 Kwh/day;Also got benefit in improved life of consumables. 6
Gland type Pump Converted into Mech Shaft Seal -QTY-25 Nos.
1.2
Completed on Dec-2011
2-% energy saving is achived i.e. ( 5.5 kw*80%*25*24*350*6.61=120000/-) & effeciency of pumps improved.

23. Annual SAVING IN (Lacs) Total Saving Rs in Lacs-
S.N.
NAME OF ACTIVITY
Annual SAVING IN (Lacs)
STATUS
REMARKS 7
Rescheduling capacitor bank in Crate & pallet (25 KVAR- for m/c-2000T, KVAR- for m/c-2400T) …
Completed on Dec-2011
Improved power factor at load end 8
Fixed Capacitor bank 50 KVAR at LT side of Transformer of Crates & Pallet division.
Completed on Dec-2011
Reduced transformer losses during idle condition. 9
VFD for cooler mixer motor Qty-14 Nos
4.27
Completed on Dec-2011
Energy saving from to U/kg by reducing speed of motor during idle run (64539MT*0.001*1000*=64539 units*6.61 = Rs /-) 10
Use Vfd for dust collrection system for Hall no & Mixer Automation Hall no 2 to 33 - Qty - 03 nos.
0.59
Energy saving by reducing speed of motor during idle run.(50*180*6.61=Rs-59490/- ) 11
Installation of Flat belt system to Extruder no - 2 & 10
0.61
Completed on Jan-2012
Observed 3% Power saving due to improved transmission effieciency. (1050 units*3%=31*2*150*6.61=Rs-61473) 12
Increase sunlight to reduce the lighting in day time for Mixer hall 7 to 11
0.44
Completed on Feb-2012
Increased day light by installing transperent sheet for hall no.10.Also lighting fixture height minimised, due to this removed 10 nos fixtures (470 watt fixtures * 10 nos *12 hrs working = 55*120*6.61= Rs-43626/-) 13
Installed Demand Controller in Crate & HDPE Division..
Completed on Feb-2012
For Control of Maximum Demand at Individual division ( Pl. see Sr.no.1 )
Total Saving Rs in Lacs-
507.27

24. To procure of High Jet Pressure Pump. 1 No.
Mechanical 1
To procure of High Jet Pressure Pump.
1 No.
Efficient & proper physical descaling of chiller. 2
To procure of Stackers for overhead crane maintenance.
1No.
For improved safety work for maintenance of overhead plant lighting,street lighting & crane work. 3
To procure & replaced gear coupling for Cooler Gear Box
10 Nos
Reduction in breakdown of cooler gear box. 4
Auto chemical dosing with controller for condenser cooling tower water circuit.
For maintain accurate chemical dosing & benefit in improve the efficiency of chillersalso reduction in water consumption by 3 % with make up quantity. 5
Indo vacc make oil lubrication vaccum pump with receiver and piping systemfor hall no 7,8,9
5 Nos.
Energy efficient pump & less power consumption. 6
Conversoin of mechanical linkage in to Gear motor for 4 Jaw & 2 Jaw for Haul -of
4 Nos.
for reduction in breakdown & achive energy saving upto 2 % 7
Monorail Crane for individual mixer of Hall 10
To attend the breakdown immediately. 8
Dust collection system for manual mixers
3 Nos.
Maintain the Houskeeping & Improved human health. 9
Air booster for CPVC 06, Dust cllection , Hall no 1 Haul off
To minimise the slippages pipes in haul off due to low centralised air pressure. 10
Project on disposal of Cacl2 concentrate effluent (HMF)
To meet the pollution control board noms for trade effueint. 11
Refrigerant Air dryer-125 CFM for HDPE/PPR plant
To minimise the air losses & enegy saving. 12
Inhouse manufacturing of Hypochloride solution.
Job
To saving the Rs/-500 per day. 13
Recycle the drain/backwash water of Lamella clarifier /MGF /ACF
Reuse the water by recirculation ,through lamella clearifier & reduction in consumption. 14
To develop testing facility for manhole chambers in roto moulding division.
To avoid outsider agengy for testing purpose, thus save in time & money .

25. ENERGY CONSUMPTION FOR FOUR YEAR

26. Thank you