IIT Madras

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Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras

KMB-IIT-GN-11.11.22-01

The subject plant is located in Himatnagar district of Gujarat and falls under NIC Category-52101. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2022.

General Info

Principal Product

Cold Storage

Plant Area (Sq.ft)

2,00,000

No. of Employees

250

Production Hours

8,400

Annual Production

15,00,000

Annual Sales

₹10,00,000

Assessment Summary

Total Energy Costs(per year)

₹67,75,000

Total Recommended Investment(one time)

₹1,06,73,500

Total Recommended Savings(per year)

₹31,96,114

Energy Costs Calculation
Electricity

Annual Usage

9,21,711

Unit

kWh

Unit Cost

₹7

Annual Cost

₹64,51,977

Total Energy Costs(per year)

₹67,75,000

Observations & Recommendations
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Compressor Motors taking more power when there is partial loading on compressorUse VFD with the motor reduce the power consumption (Motor rated-120kW)-Avg. Running Time: 24 hrs for 2 months28,424₹1,98,968₹3,30,00020
Compressor Motors taking more power when there is partial loading on compressorUse VFD with the motor reduce the power consumption (Motor rated-75kW)-Avg. Running Time: 20hrs for 9 months1,13,949₹7,97,643₹2,10,0003
Compressor Motors taking more power when there is partial loading on compressorUse VFD with the motor reduce the power consumption (Motor rated-55kW)-Avg. Running Time: 14hrs for 4 months29,149₹2,04,040₹1,75,00010
Compressor Motors taking more power when there is partial loading on compressorUse VFD with the motor reduce the power consumption (Motor rated-90kW)-Avg. Running Time: 20 hrs for 9 months75,326₹5,27,285₹2,50,0006
Reduction in Maximum Contract DemandBy using VFD , Contract demand reduction happens for the same Chiller Load without altering maximum demand contract (37 kVA)₹66,600
Unbalance Current in Compressor Motor and line current varies nearly by 20 ampereConvey the issue with DISCOM
TR - Transformer
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Voltage and current Harmonics receiving from outside (source)Install Active Harmonic filter₹500000
Voltage sag found, and especially in night hoursConvey the issue with DISCOM
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Algae Formation over the cooling pipelineRemove the algae from pipe by painting of pipe and use chemical to reduce the formation of algae and also do proper cleaning of pipe and check the nozzle opening and proper water spray from nozzle (by reducing 1 deg C)18527.57₹129693₹500005
High TDS waterMaintain TDS level of cooling tower sump water helps in reduction of nozzle clogging (Blow down properly)
CHR - Chiller
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Losses due to insulationNeed to do proper insulation on pipeline44823₹313761₹100004
LT - Lighting
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Incandescent Lamp at all areaChange incandescent lamp by LED (Each Cold store Hall having 25 bulbs on average on each floor and operating time ( for 3 months one hall luminance for 12 h per 3 months & remaining 8 month anyone of the hall luminance for 8 h per day ) so operating hours=(12x30x3x1) & (8x30x8x1) all bulbs are 40W so replace the bulb with LED of 9W with same luminance13,950₹9,72,000₹58,5007
ALS - Alternate Source of Power
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Only depending on State ElectricityInstall Solar PV of 200 kWp capacity after studying the demand pattern and after implementation of all saving measures2,43,000₹9,72,000₹90,00,00010 years