39
Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605 Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date: 31-01-2017 Page 1 of 39 POST IMPLEMENTATION AUDIT REPORT SUPPORTING NATIONAL PROGRAM ON ENERGY EFFICIENCY IN SMES FOR INDORE (FOOD) CLUSTERJagdish Prasad Hansraj 25/A, Industrial Area, Maksi Road Ujjain Madhya Pradesh January 2017 Submitted to BUREAU OF ENERGY EFFICIENCY 4 th Floor, Sewa Bhawan, R K Puram, Sector-I, New Delhi -110066 Submitted by DEVELOPMENT ENVIRONERGY SERVICES LTD 819, Antriksh Bhawan, 22 Kasturba Gandhi Marg, New Delhi -110001 Tel.: +91 11 4079 1100 Fax : +91 11 4079 1101; www.deslenergy.com

POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

  • Upload
    others

  • View
    0

  • Download
    0

Embed Size (px)

Citation preview

Page 1: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 1 of 39

POST IMPLEMENTATION AUDIT REPORT “SUPPORTING NATIONAL PROGRAM ON ENERGY EFFICIENCY IN SMES FOR INDORE (FOOD) CLUSTER”

Jagdish Prasad Hansraj

25/A, Industrial Area, Maksi Road Ujjain

Madhya Pradesh

January 2017

Submitted to

BUREAU OF ENERGY EFFICIENCY

4th Floor, Sewa Bhawan, R K Puram, Sector-I, New Delhi -110066

Submitted by

DEVELOPMENT ENVIRONERGY SERVICES LTD 819, Antriksh Bhawan, 22 Kasturba Gandhi Marg, New Delhi -110001 Tel.: +91 11 4079 1100 Fax : +91 11 4079 1101; www.deslenergy.com

Page 2: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 2 of 39

DISCLAIMER

This report (including any enclosures and attachments) has been prepared for the exclusive use and benefit of

the addressee(s) and solely for the purpose for which it is provided. Unless we provide express prior written

consent, no part of this report should be reproduced, distributed or communicated to any third party. We do

not accept any liability if this report is used for an alternative purpose from which it is intended, nor to any

third party in respect of this report.

Page 3: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 3 of 39

ACKNOWLEDGEMENT

DESL places on record its sincere thanks to Bureau of Energy Efficiency (BEE) for vesting confidence

in DESL to carry out the assignment “Conducting Post implementation audit in Indore SME food

clusters” under their national project “Supporting National Program on Energy Efficiency in SMEs for

Indore (Food) cluster”.

As a part of this assignment, work in Indore and Ujjain food cluster was awarded to DESL, and DESL is

grateful to BEE for their full-fledged coordination and support throughout the study.

The study team is indebted to Mr. Jitendra Rathi, Owner, for showing keen interest in the energy

audit and also thankful to the management of Jagdish Prasad Hansraj Poha factory for their

wholehearted support and cooperation for the preparation of this Post implementation audit report,

without which the study would not have steered to its successful completion. Special thanks to other

members of the unit for their diligent involvement and cooperation.

It is well worthy to mention that the efforts being taken and the enthusiasm shown by all the plant

personnel towards energy conservation and sustainable growth are really admirable.

Last but not the least, the interaction and deliberation with Mr. Mayank Patel, Secretary, Poha

Parmal, Nirmata Sangh, Ujjain, technology providers, and all those who were directly or indirectly

involved throughout the study were exemplary. The entire exercise was thoroughly a rewarding

experience for DESL.

DESL Team

Page 4: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 4 of 39

DESL Team

Project Head Mr. R. Rajmohan Chief Executive Officer

Team leader and co-coordinator Mr. Suparno R Majumdar Consultant

Team Members Mr. Mithlesh Priya Analyst

Mr. Abhisheka Nand Jha Analyst

Mr. Amit Kumar Yadav Analyst

Page 5: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 5 of 39

CONTENTS

EXECUTIVE SUMMARY ............................................................................................................................................ 9

Replacement of existing Poha chalna, Paddy cleaning, Dhaan chalna and roaster motor with EE motor ....... 10

1 INTRODUCTION ............................................................................................................................................ 12

1.1 Background and Project objective ...................................................................................................... 12

1.2 Methodology ....................................................................................................................................... 12

1.2.1 Boundary parameters ..................................................................................................................... 12

1.2.2 General methodology ..................................................................................................................... 12

1.2.3 Project specific audit methodology ................................................................................................ 14

2 ABOUT THE MSME UNIT ............................................................................................................................... 15

2.1 Particulars of the unit .......................................................................................................................... 15

2.2 Manufacturing process ....................................................................................................................... 16

2.2.1 Process & Energy flow diagram ...................................................................................................... 16

2.2.2 Process description ......................................................................................................................... 16

3 POST IMPLEMENTATION ENERGY AUDIT OUTCOME AND RESULT .............................................................. 17

3.1 Installation of IE3 induction motors .................................................................................................... 17

3.1.1 Baseline Scenario ............................................................................................................................ 17

3.2 ENERGY SAVING AND COST ECONOMIC ANALYSIS ............................................................................. 19

3.2.1 EPIA 2: Replacement of Roaster FD fan motor with energy efficient motor ...................................... 19

3.2.2 EPIA 3: Replacement of elevator motor with energy efficient motor ................................................ 22

3.2.3 EPIA 4: Replacement of poha chalna, paddy cleaning, dhaan chalna and roaster motor with energy

efficient motor .................................................................................................................................................. 24

4 Unit Photo graphs ......................................................................................................................................... 28

ANNEXURE-1 ......................................................................................................................................................... 29

ANNEXURE-2 ......................................................................................................................................................... 31

ANNEXURE-3 ......................................................................................................................................................... 38

ANNEXURE-4 ......................................................................................................................................................... 39

Page 6: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 6 of 39

List of figures

Figure 1 General Methodology ............................................................................................................................. 13

Figure 2 Project implementation methodology ................................................................................................... 14

Figure 3: Production flow diagram ....................................................................................................................... 16

Figure 4 New efficiency classes of motors ............................................................................................................ 18

Figure 5 Roaster FD fan motor ............................................................................................................................. 22

Figure 6 Conveyor motor ...................................................................................................................................... 23

Figure 7 Poha Chalna motor ................................................................................................................................. 26

Figure 8 Plant Cleaning Blower Motor .................................................................................................................. 26

Figure 9: Dhaan Chalna Motor.............................................................................................................................. 27

Figure 10: Roaster Motor ..................................................................................................................................... 27

Figure 11 Roaster .................................................................................................................................................. 28

Figure 12 Dhaan Chalna ........................................................................................................................................ 28

Page 7: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 7 of 39

List of Tables

Table 1: Details of Unit ........................................................................................................................................... 9

Table 3 Energy audit instruments ......................................................................................................................... 13

Table 4: General particulars of the unit ................................................................................................................ 15

Table 4 Roaster FD fan motor ............................................................................................................................... 20

Table 4 Conveyor motor ....................................................................................................................................... 22

Table 4 Poha chalna, paddy cleaning, dhaan chalna and roaster motor .............................................................. 24

Page 8: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 8 of 39

ABBREVIATIONS

Abbreviations Expansions

APFC Automatic Power Factor Correction

BEE Bureau of Energy Efficiency

CEA Comprehensive Energy Audit

CFL Compact Fluorescent Lamp

CRV Chromium Vanadium

DESL Development Environergy Services Limited

DG Diesel Generator

EE Energy Efficiency/ Energy efficient

EPIA Energy Performance Improvement Action

FO Furnace Oil

GEF Global Environment Facility

HSD High Speed Diesel

HVAC Heating Ventilation and Air Conditioning

LED Light Emitting Diode

LT Low Tension

MD Maximum Demand

MS Mild Steel

MSME Micro, Small and Medium Enterprises

MT Metric Tons

MTOE Million Tons of Oil Equivalent

MV Mercury Vapour

No. Number

PF Power Factor

PID Proportional-Integral-Derivative

PNG Piped Natural Gas

R & C Radiation & Convection

RE Renewable Energy

SEC Specific Energy Consumption

SEGR Specific Energy Generation Ratio

SLD Single Line Diagram

SME Small and Medium Enterprises

UNIDO United Nations Industrial Development Organization

VFD Variable Frequency Drives

Page 9: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 9 of 39

EXECUTIVE SUMMARY

Bureau of Energy Efficiency (BEE) is implementing a project titled “Supporting National Program on

Energy Efficiency in SMEs for Indore (Food) cluster” The objective of the project is to provide

impetus to energy efficiency initiatives in small and medium enterprises (SMEs) of Indore food

Cluster in India.

As part of this project, DESL has been engaged to implement the project in the SME food cluster at

Indore and Ujjain in Madhya Pradesh. There are about 200 units scattered over Indore and Ujjain.

The major products processed in these food industries includes poha (rice flakes) and various types

of pulses – toor, masoor, chana, arahar, moong etc.

The project awarded to DESL consists of 18 major tasks:

Conducting pre–activity cluster workshop defining the agenda of this engagement

Conducting initial walk through energy audits within 8 selected units of the cluster

Identifying and proposing two energy efficient process technologies to BEE

Identifying at least 5 local technology/service providers for above technologies in the cluster

Identifying 20 SME units willing to implement and demonstrate the above two technologies

Assistance to BEE for entering into contract with each of the 20 shortlisted SME units

Conducting Comprehensive Energy Audits in 20 SME units

Development of technology specific case studies (Audio, Visual and Print) for each technology

Developing best operating practices(BOP) document for the top 5 energy equipment/processes

in the industry cluster

Enumeration of common regularly monitorable parameters at the process level which have

impact on energy performance and listing of appropriate instrumentation for the same.

Conducting post energy audit in each of the above 20 units to verify energy savings.

Verification and submission of relevant documents (Evidence of implementation and

Commissioning of EE technology )to the BEE

Assisting BEE in conducting five post energy audits

Submission of progress report in hard and soft versions (Word, presentation) to BEE

Submission of draft document to BEE within seven days from issue of LOI by BEE

Brief Introduction of the Unit

Table 1: Details of Unit

Name of the Unit Jagdish Prasad Hansraj Constitution Private Limited MSME Classification Small No. of years in operation NA Address: Registered Office Plot No:25/A, Industrial area Maksi road,Ujjain

Administrative Office Plot No:25/A, Industrial area Maksi road,Ujjain Factory Plot No:25/A, Industrial area Maksi road,Ujjain Industry-sector Food Products Manufactured Poha (Rice flakes) Name(s) of the Promoters / Directors Mr. Jitendra Rathi

Page 10: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 10 of 39

The production process of the unit

The production process description is as follows:

Paddy used as raw material for production of poha is purchased from nearby food grains markets.

The purchased paddy is cleaned in mega and vibro cleaners to remove the large-sized and small-

sized sand particles which come along with the paddy. The cleaned paddy is then soaked in water for

1 day. The soaked paddy is roasted in rotating tunnel roaster for moisture reduction and to soften it.

The softened paddy is then manually fed into the poha (press) machines where it is flattened and

the husk cover of the paddy is removed by machining. These rice flakes are then cleaned in cleaners

and finally packed and dispatched.

Energy efficient technology implemented vis-a-vis baseline energy audit recommendation

Technology recommended as per baseline energy audit (as

approved by steering committee)

Technology implementation and cross-verified during post implementation

energy audit

Replacement of poha machine motor with energy efficient

motor EE motors (7.5 HP X 7)

Replacement of roaster FD fan motor with energy efficient

motor

EE motors (1 HP X 1)

Replacement of elevator machine motors with EE motor EE Motors (1 HPX2)

Replacement of existing worm motor, Paddy cleaner motor,

Poha cleaning chalna, Poha chalna (khatkhata) and cyclone

motor with EE motor

EE motor( 1HPX1, 1 HPX1, 1.5HPX1,

1HPX1, 7.5HPX1)

Cost economic Analysis: Projected (As per baseline) Vs. Actual

EPIA Estimated Energy Savings (%)

Savings (kWh/y)

Investment (Rs Lakh)

Simple Payback Period (Years)

Replacing poha machine motor with Energy Efficient Motor

Baseline Project (Projected) (20HPX1, 20HPX1, 30HPX1)

20% 17566.4 1.4 1.04

Post Implementation (Actual) (7.5HPX7)

45% 30,822.5 4.60 1.95

Replacing FD fan motor of roaster with Energy Efficient Motor

Baseline Project (Projected) (1HPX1)

13% 277.51 0.1 4.7

Post Implementation (Actual) (1HPX1)

15% 336.62 0.07 2.85

Page 11: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 11 of 39

Replacing Elevator motor with Energy Efficient Motor

Baseline Project (Projected) (1HPX2)

6% 277 0.20 4.73

Post Implementation (Actual) (1HPX2)

17% 729.65 0.32 5.67

Replacing Other motor (Worm motor, Paddy cleaner motor, Poha cleaning chalna, Poha chalna khatkhata and Cyclone)

Baseline Project (Projected) (1HPX1) (Worm)

6% 138.57 0.07 6.36

Post Implementation (Actual) (1HPX1) (Worm)

22% 484.84 0.06 1.55

Baseline Project (Projected) (1HPX1) (Paddy Cleaner)

6% 138.57 0.07 6.59

Post Implementation (Actual) (1HPX1) (Paddy Cleaner)

19% 405.96 0.06 1.86

Baseline Project (Projected) (1.5HPX1) (Poha Cleaning Chalna)

10% 311.78 0.03 1.26

Post Implementation (Actual) (1.5HPX1) (Poha Cleaning Chalna)

20% 661.50 0.10 1.98

Baseline Project (Projected) (1HPX1) (Poha Chalna khatkhata)

6% 138.57 0.07 6.36

Post Implementation (Actual) (1HPX1) (Poha Chalna khatkhata)

16% 353.37 0.06 2.13

Baseline Project (Projected) (7.5HPX1) (Cyclone)

5% 866 0.15 2.26

Post Implementation (Actual) (7.5HPX1) (Cyclone)

17% 2,798.93 0.20 0.95

Page 12: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 12 of 39

1 INTRODUCTION

1.1 Background and Project objective

Bureau of Energy Efficiency (BEE) is implementing a project titled “Supporting National program on

Energy Efficiency in SMEs for Indore (Food) cluster”. The objective of the project is to provide

impetus to energy efficiency initiatives in micro small and medium enterprises (MSMEs) sector in

Indore and Ujjain food cluster in India.

The objectives of this project are as under:

Identifying energy efficient process and technologies that can be implementable by units in

the Indore food cluster;

Identifying 20 MSME units within the cluster that are willing to implement and demonstrate

the above technologies in their units;

Facilitate Bureau of Energy Efficiency (BEE), New Delhi to sign tri-partite Memorandum of

Understanding (MOUs) with the 20 MSME units of Indore food cluster (that are willing to

implement the energy efficient technologies) and their cluster association

Conduct Baseline Energy Audits in 20 MSME food units of the Indore food cluster who have

signed MOUs with BEE;

Establish baseline energy efficiency scenario for the 20 units against which energy savings

shall be computed post implementation

Facilitate the 20 MSME units to implement the proposed energy efficient technologies in

their units.

Conduct post implementation energy audits in the 20 MSME units to establish the actual

energy savings in those units

Development of technology specific case studies (audio-visual and print) for each technology

(during pre-implementation, implementation and post implementation stages).

1.2 Methodology

1.2.1 Boundary parameters

Following boundary parameters were set for the baseline audit:

Audit covered all the identified energy intensive areas and equipments for which energy

efficiency improvement measures were proposed

All appropriate measuring systems including portable instruments were used

The identified measures normally fall under short, medium and long-term measures

1.2.2 General methodology

Following flow chart illustrates the methodology followed for carrying out the project:

Page 13: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 13 of 39

Figure 1 General Methodology

The study was conducted in fallowing stages:

Stage 1: Identification of units and conducting walk through energy audit in 5 units to understand

the process and its energy intensiveness, identification of energy saving technologies, assessment of

the measurement system, proposing energy efficient technologies to BEE and units for acceptance,

Stage 2: Identification of vendors for implementation of energy efficient technologies and facilitate

BEE to sign tripartite MOUs with the units that is willing to implement the EE technology and its

cluster association

Stage 3: Formation of project team for conducting baseline energy audits (DEA) in the units that

have signed MOUs with BEE; and conduct DEA in those units – carry out on-site measurement of

energy parameters, collection of historical energy use data for analysis.

Stage 4: Data analysis, quantification of energy savings (in the processes / equipment) post

measurements, and preparation of baseline energy audit report.

The energy instrument used in post implementation audit is tabulated below:

Table 2 Energy audit instruments

Sl. No. Instruments Make Model Parameters Measured

01 Power Analyzer – 3

Phase (for un balanced

Load) with 3 CT and 3

PT

Enercon and

Circutor

AR-5 AC Current, Voltage, Power Factor,

Power, Energy, Frequency, Harmonics

and data recording for minimum 1 sec

interval

Page 14: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 14 of 39

1.2.3 Project specific audit methodology

The BEE’s national program on energy efficiency and technology up gradation at Indore food cluster followed

the following implementation methodology:

Figure 2 Project implementation methodology

Page 15: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 15 of 39

2 ABOUT THE MSME UNIT

2.1 Particulars of the unit

Table 3: General particulars of the unit

Sl. No. Particulars Details

1 Name of the unit Jagdish Prasad Hansraj Poha factory

2 Constitution Private Limited

3 Date of incorporation / commencement of business

NA

4 Name of the contact person Mobile/Phone No. E-mail ID

Mr. Jitendra Rathi +91 – 9425332670 [email protected]

5 Address of the unit Plot No: 25/A, Industrial area Maksi road,Ujjain

6 Industry / sector Food

7 Products manufactured Poha (Rice flakes)

8 No. of operational hours 10

9 No. of shifts / day 1

10 No. of days of operation / year 310

Page 16: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 16 of 39

2.2 Manufacturing process

The following flow chart shows the typical process employed at manufacturing of rice flakes in Dharmesh

industries.

2.2.1 Process & Energy flow diagram

Figure 3: Production flow diagram

2.2.2 Process description

JP Hansraj Poha factory, Ujjain is a poha manufacturing unit. The process description is as follows:

Paddy is used as raw material for production of poha. Raw material is purchased from nearby food-

grain markets. Purchased raw material is conveyed to mega cleaner to remove huge sand particles

which come along with the paddy from fields. After removal of larger-sized sand particles in the

mega cleaner, the smaller-sized sand particles are removed from the paddy in a vibro cleaner. Post

cleaning, the paddy is soaked in water for 24 hours. The soaked paddy is heated in a roaster for

removal of moisture and to soften it. The roasted paddy is transferred manually to the poha

machines where the paddy is flattened and the husk is removed from the softened paddy. Then the

material is processed to the cleaner to produce poha (rice flakes) which is then packed and

dispatched.

Page 17: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 17 of 39

3 POST IMPLEMENTATION ENERGY AUDIT OUTCOME AND RESULT

During DEA of the plant, all energy consuming equipments and processes were studied. The analysis

of all major energy consuming equipments and appliances were carried out. Based on the analysis,

Energy Performance Improvement Actions (EPIA) had been identified in which EE motor

replacement was the major one is explain below:

3.1 Installation of IE3 induction motors

3.1.1 Baseline Scenario

During the baseline energy audit, M/s JP Hansraj were using less efficient motors which were

installed when plant commissioned. Now these days it is categorized in inefficient motors due to

enhancement in new technology available in the market.

The international organization which prepares & publishes international standards for all electrical,

electronics & related technologies is known as IEC.

The IEC (International Electrotechnical Commission) publishes IS:12615-2011 which is based on IEC

60034-30 (2008) ) which defines New Efficiency Classification for single speed, three phase,

induction motors.

The IS:12615-2011 covers single speed, three-phase, 50Hz, cage induction motors that:

have rated voltage ≤1000V;

have a rated output 0.37kW ≤ PN ≤ 375kW;

have either 2, 4 or 6 poles;

meet frame size to output relation as stipulated in IS:1231 (for outputs covered by IS:1231);

are rated on the basis of either duty type S1 (continuous duty) or S3 (intermittent periodic

duty) with rated cyclic duration factor of 80% or higher;

are capable of operating direct on-line;

are designed for operation on virtually sinusoidal and balanced voltage conditions as defined

in 7.2.1 of IS/IEC 60034-1;

designed for an ambient temperature not exceeding 40°C and altitude not exceeding

1000m;

have degree of protection IP44 or superior;

have method of cooling IC411 in accordance with IS 6362 / IEC 60034-6;

have service factor not exceeding 1.0.

The Efficiency classes defined are:

IE1 - Standard Efficiency

IE2 - High Efficiency

IE3 - Premium Efficiency

Page 18: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 18 of 39

The IS: 12615-2011 also stipulates that for motors to be classified as “Energy Efficient”, these must

meet at least IE2 efficiency values.

Figure 4 New efficiency classes of motors

During DEA of the plant, the recommended EE measures & outcome of the implementation i.e.

energy saving & cost economics analysis (Post implementation) is shown below:

Page 19: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 19 of 39

3.2 ENERGY SAVING AND COST ECONOMIC ANALYSIS

During DEA of the plant, all energy consuming equipments and processes were studied. The analysis

of all major energy consuming equipments and appliances were carried out. The energy saving and

cost economic analysis after post implementation audit is discussed below:

3.2.1 EPIA 1: Replacement of poha machine motor with energy efficient

motor

In the material handling section, five numbers of motors were studied during baseline audit, i.e.

Baramb motor, cyclone motor, Poha elevator motor, poha machine motor, Dhaan chalna motor,

Dhaan elevator motor, Poha chalna, khatka motor & FD fan blower. These motors were inefficient

and were consuming higher power. It was proposed to replace these motors with high energy

efficient motors.

The table below summarizes the post implementation energy consumption figures of the unit vis-à-

vis the baseline energy audit data.

Table 4 Poha machine motor

Parameter Unit Value

Baseline Scenario

Rating of poha machine motor-1 HP 20.00

Rating of poha machine motor-2 HP 20.00

Rating of poha machine motor-3 HP 30.00

Total motor rating kW 52.15

Present Power consumption by poha machine motor kW 28.33

Post Implementation Scenario

Rating of one poha machine motor HP 7.50

Total motor rating of 7 motors HP 52.50

Present Power consumption by poha machine motor kW 15.49

Savings

Reduction in power consumption kW 12.84

Page 20: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 20 of 39

Running hours / day hrs / day 8

Operating days / year days / y 300

Weighted avg. cost of electricity Rs / kWh 7.66

Annual energy savings kWh / y 30,822.57

Annual monetary savings Rs. Lacs / y 2.36

Estimated Investment Rs Lacs 4.60

Simple payback period y 1.95

Annual CO2 emission reduction tCO2/y 27.43

Assumption / conversion factors:

Emission factor kwh has been considered as 0.89kg CO2 per kWh

CO2 emission reduction calculation has been considered based on equivalent reduction

in CO2 emission

Inference

Energy cost saved per year is Rs. 2.36 Lac.

Actual investment made to implement the energy efficient motor is Rs. 4.60 lac.

The investment made will be recovered within 1.95 year.

Picture

3.2.2 EPIA 2: Replacement of Roaster FD fan motor with energy efficient

motor

The table below summarizes the post implementation energy consumption figures of the unit vis-à-

vis the baseline energy audit data.

Table 5 Roaster FD fan motor

Parameter Unit Value

Baseline Scenario

Rating of FD fan motor HP 1.00

Present Power consumption by FD fan motor kW 0.71

Post Implementation Scenario

Page 21: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 21 of 39

Rating of FD fan motor HP 1.00

Present Power consumption by FD fan motor kW 0.60

Savings

Reduction in power consumption kW 0.11

Running hours / day hrs / day 10

Operating days / year days / y 310

Weighted avg. cost of electricity Rs / kWh 7.66

Annual energy savings kWh / y 336.62

Annual monetary savings Rs. Lacs / y 0.03

Estimated Investment Rs Lacs 0.073

Simple payback period y 2.85

Annual CO2 emission reduction tCO2/y 0.30

Assumption / conversion factors:

Emission factor kwh has been considered as 0.89kg CO2 per kWh

CO2 emission reduction calculation has been considered based on equivalent reduction

in CO2 emission

Inference

Energy cost saved per year is Rs. 0.03 Lac.

Actual investment made to implement the energy efficient motor is Rs. 0.073 lac.

The investment made will be recovered within 2.85 year.

Picture

Page 22: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 22 of 39

Figure 5 Roaster FD fan motor

3.2.3 EPIA 3: Replacement of elevator motor with energy efficient motor

The table below summarizes the post implementation energy consumption figures of the unit vis-à-

vis the baseline energy audit data.

Table 6 Elevator motor

Parameter Unit Value

Baseline Scenario

Rating of elevator motor-1 HP 1.00

Rating of elevator motor-2 HP 1.00

Present Power consumption by conveyor motor kW 1.42

Post Implementation Scenario

Rating of elevator motor-1 HP 1.00

Rating of elevator motor-1 HP 1.00

Present Power consumption by conveyor motor kW 1.18

Savings

Page 23: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 23 of 39

Reduction in power consumption kW 0.24

Running hours / day hrs / day 10

Operating days / year days / y 310

Weighted avg. cost of electricity Rs / kWh 7.66

Annual energy savings kWh / y 729.65

Annual monetary savings Rs. Lacs / y 0.06

Estimated Investment Rs Lacs 0.32

Simple payback period y 5.67

Annual CO2 emission reduction tCO2/y 0.65

Assumption / conversion factors:

Emission factor kwh has been considered as 0.89kg CO2 per kWh

CO2 emission reduction calculation has been considered based on equivalent reduction

in CO2 emission

Inference

Energy cost saved per year is Rs. 0.06 Lac.

Actual investment made to implement the energy efficient motor is Rs. 0.32 lac.

The investment made will be recovered within 5.67 year.

Picture

Figure 6 Conveyor motor

Page 24: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 24 of 39

3.2.4 EPIA 4: Replacement of worm motor, Paddy cleaner motor, Poha

cleaning chalna, Poha chalna khatkhata motor and cyclone motor

with energy efficient motor

The table below summarizes the post implementation energy consumption figures of the unit vis-à-

vis the baseline energy audit data.

Table 7 Worm motor, Paddy cleaner motor, Poha cleaning chalna, poha chalna khatkhata and Cyclone motor

Parameter Unit Value

Baseline Scenario

Rating of paddy cleaner motor HP 1

Present Power consumption by paddy cleaner motor kW 0.71

Rating of worm motor HP 1

Present Power consumption by worm motor kW 0.71

Rating of poha chalna (khatkhata) motor HP 1

Present Power consumption by poha chalna (Khatkhata) motor

kW 0.71

Rating of poha cleaning chalna motor HP 1.50

Present Power consumption by poha cleaning chalna motor kW

1.06

Rating of cyclone motor HP 7.50

Present Power consumption by cyclone motor kW 5.31

Total Power consumption by all motors kW 8.49

Post Implementation Scenario

Rating of paddy cleaner motor HP 1

Present Power consumption by paddy cleaner motor kW 0.58

Rating of worm motor HP 1

Present Power consumption by worm motor kW 0.55

Page 25: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 25 of 39

Rating of poha chalna (Khatkhata) motor HP 1

Present Power consumption by poha chalna (khatkhata) motor

kW 0.59

Rating of poha cleaning chalna motor HP 1.50

Present Power consumption by poha cleaning chalna motor kW

0.85

Rating of paddy cleaning motor HP

7.50

Present Power consumption by paddy cleaning motor kW

4.41

Total Power consumption by all motors kW

6.98

Savings

Reduction in power consumption kW 1.52

Running hours / day hrs / day 10

Operating days / year days / y 310

Weighted avg. cost of electricity Rs / kWh 7.66

Annual energy savings kWh / y 4,704.82

Annual monetary savings Rs. Lacs / y 0.36

Estimated Investment Rs Lacs 0.48

Simple payback period y 1.32

Annual CO2 emission reduction tCO2/y 4.19

Assumption / conversion factors:

Emission factor kwh has been considered as 0.89kg CO2 per kWh

CO2 emission reduction calculation has been considered based on equivalent reduction

in CO2 emission

Inference

Energy cost saved per year is Rs. 0.36 Lac.

Actual investment made to implement the energy efficient motor is Rs. 0.48 lac.

The investment made will be recovered within 1.32 year.

Page 26: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 26 of 39

Picture

Figure 7 Poha Chalna motor

Figure 8 Plant Cleaning Blower Motor

Page 27: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 27 of 39

Figure 9: Dhaan Chalna Motor

Figure 10: Roaster Motor

Page 28: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 28 of 39

4 Unit Photo graphs

Figure 11 Roaster

Figure 12 Dhaan Chalna

Page 29: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 29 of 39

ANNEXURE-1

Base Executive summary

Page 30: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 30 of 39

Page 31: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 31 of 39

ANNEXURE-2

Clearance by CA

Page 32: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 32 of 39

Page 33: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 33 of 39

Page 34: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 34 of 39

Page 35: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 35 of 39

Page 36: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 36 of 39

Page 37: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 37 of 39

Page 38: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 38 of 39

ANNEXURE-3 Completion Letter

Page 39: POST IMPLEMENTATION AUDIT REPORT Hansraj.pdf · Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0 Prepared by: DESL Date:

Client Name Bureau of Energy Efficiency (BEE) Project No. 9A0000005605

Project Name “Supporting national program on Energy Efficiency in SMEs for Indore(Food) cluster” Rev. 0

Prepared by: DESL Date: 31-01-2017 Page 39 of 39

ANNEXURE-4 GHG Emission Factor