Energy Audit Report Banswara Syntex Ltd - September 2024 PDF

Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara SALIENT POINTS MANDATORY ENERGY AUDIT BANSWARA SYNTEX LTD. BANSWARA September 2024 ENERGY...

Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara SALIENT POINTS MANDATORY ENERGY AUDIT BANSWARA SYNTEX LTD. BANSWARA September 2024 ENERGY AUDIT SERVICES, 1116, SECTOR – 17, FARIDABAD – 121002 HARYANA MOB : 09811229516, 09811627972 EMAIL :[email protected] Energy Audit Services - Faridabad Page1 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara We have carried out the assignment for Mandatory Energy Audit Under PAT Cycle of BEE. We have covered Entered Energy in Totality Elaborate Measurement have been carried out to evaluate the energy efficiency, In various Energy consuming Plants and Machinery including Utility. Various Option for Energy Saving have been worked out on the most practical lines. Towards the end of Field work, we had very openminded discussion with the management team, regarding all our observation as well as various option for energy saving.  ELECTRICITY CONSUMPTION Electricity (the only Energy) has two sources – Year 2023-24 Annual consumption Sources % of Total (Lac Units) RSEB 161.46 22.8% TPP 412.07 71.8% 100% Total 573.53 Energy Audit Services - Faridabad Page2 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara PIE CHART # A ANNUAL ELECTRICITY CONSUMPTION Annual Electricity Consumption 2023-24 22.80% 71.80% RSEB TPP 132 KV Power Supply Project work is under progress for the 132 KV Power supply from the grid. Input Energy Gate to Gate  Grid Power Supply – Power consumption in colony, ETP etc. is subtracted from KWH consumption in from Grid Power. Input Energy is worked out taking Electricity @ 860 Kcal/Unit.  TPP – Power  Energy Calculated @ 3650 Kcal per Unit.  All data tabulated in Table #1 Energy Audit Services - Faridabad Page3 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara  Option for Energy Saving Load on 4 nos. Transformers on RSEB side should be increased (even by 4-5 %) for better performance in PAT Cycle. Table # 1 Gate to gate Annual Electricity Consumption Year – 2023-24 Qty. GCV Million Sl. No. Particulars % Lac Units Kcal per Unit Kcal 1. Electricity 412.07 3650 150,406 92.35 from TPP 2 Electricity (RSEB) 144.80 860 12,452.8 7.65 (Without Colony) 3 Total 573.53 - 100% Annual Input Energy = 16,285.9 TOE Energy Audit Services - Faridabad Page4 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Electricity Consumed in exempted areas Colony & Others Sl. Qty. Areas Remarks No. (Units) 5,15,555 1 Staff &Labour colony Water supply for 2 87,615 Staff &Labour colony 9,03,432 3 PNB Bank, ADMN etc Base line year 4 MBBR 1,59,347 also exempted 0 5 Tube Well for TPP 16,65,949 6 Total Energy Audit Services - Faridabad Page5 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara SECTION # 1 ELECTRICAL ENERGY 1.1 Sources for Electrical Energy There are two main sources for Electrical Energy. I) Banswara Thermal Power Plant II) Grid Power including IEX III) 1.1.1 Thermal Power Plant This is the main source of Power Supply. Power supply is received at 11 KV. There are 4 nos. Step Down Transformers for LT Power Supply. These Transformers are dedicated for Power Supply from this source of Power Supply Only. 1.2 Monthly Electricity Consumption Month – wise, Electricity procured from different sources is tabulated in Table # Power supply from Banswara Thermal Plant amounts to be @ 71.8% of the total annual Electricity Consumption. Energy Audit Services - Faridabad Page6 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Monthly Power Consumption (Year 2023-24) Total Intake Month RSEB TPP KWH Apr-23 2122890 3122800 5245690 May-23 2015190 3287400 5302590 Jun-23 2128140 3121300 5249440 Jul-23 2018835 3186200 5205035 Aug-23 2130135 3081300 5211435 Sep-23 819840 3620400 4440240 Oct-23 694215 3521800 4216015 Nov-23 441225 3474700 3915925 Dec-23 795300 3933700 4729000 Jan-24 898020 3847600 4745620 Feb-24 1106670 3380200 4486870 Mar-24 975090 3629800 4604890 573,52,750 Total 161,45,550 412,07,200 Energy Audit Services - Faridabad Page7 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara PIE CHART # B Electricity from Different Sources Electricity from Different Sources IEX, 0.00% Grid, 28.15% Banswara Thermal Grid IEX Banswara Thermal, 71.85% 2. Monthly Electricity Billing Monthly Electricity Billing has been studied for the year 2023-24 Summary of the following parameters – has been tabulated in TABLE # I) Consumption Month II) KWH procured from grid III) Average Power Factor IV) Actual Maximum Demand – KVA V) Billing Demand – KVA VI) KWH purchased through IEX VII) Total Billing Amount VIII) P.F. rebate or Penalty Energy Audit Services - Faridabad Page8 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara 1.5 Data Analysis Power Factor Graph 1.01 1.00 0.99 0.98 P.F. 0.97 0.96 0.95 0.94 Months  Power Factor # Very well Managed Monthly Electricity Billing 1. Power Factor - Very Good. 2. Average Billing Rate – Rs. 7.98 per unit, 3. Annual P.F. Bonus = Rs. 31.08 Lac very well managed. Energy Audit Services - Faridabad Page9 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Monthly Electricity Billing Sr. Consumed Consumed Contract Actual Max Billing P.F Month P. F No. KWH KVAH Demand Demand Amount Rebate 1 Apr-23 2122890 2142255 0.99 4995 3942 18310354 389292 2 May-23 2015190 2026110 0.99 4995 4629 18313803 419061 3 Jun-23 2128140 2142840 0.99 4995 3951 15166769 429441 4 Jul-23 2018835 2033085 0.99 4995 4352 14322867 395381 5 Aug-23 2130135 2149635 0.99 4995 4317 15306553 390678 6 Sep-23 819840 826635 0.99 4995 4646 10313520 179949 7 Oct-23 694215 698085 0.99 4995 1824 6902433 167053 8 Nov-23 441225 447825 0.99 4995 2436 4944488 78197 9 Dec-23 795300 797475 1.00 4995 1928 7679742 208462 10 Jan-24 898020 899955 1.00 4995 2074 8484961 74478 11 Feb-24 1106670 1108770 1.00 4995 2475 10115994 297869 12 Mar-24 975090 981540 0.99 4995 2706 9119696 78119 Total 16145550 16254210 0.993 1389,81,180 31,07,980 Energy Audit Services - Faridabad Page10 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara SECTION # 2 POWER SYSTEM 2.1 Brief Description Power Supply from Thermal Power Plant is received at 11 KV. There are 4 nos. Step Down Transformers for LT Supply. Rated Capacity Sl. No. TR # Remarks (KVA) 1 TR # 1 1500 2 TR # 2 1600 3 TR # 3 2000 4 TR # 4 2500 2.2 Power Measurement Data Following power parameters were measured for all the 4 nos. Transformers: - I) LT Main Voltage II) Load Current III) Power – KW IV) P.F. V) Power – KVA Summary of all the measurement data is tabulated in TABLE # Energy Audit Services - Faridabad Page11  Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # TPP Transformers Power Measurement Data TR # 1 TR # 2 TR # 3 TR # 4 Sr. Parameters (TPP) (TPP) (TPP) (TPP) No. Location LT room - 2 LT room - 2 LT room - 2 LT room - 2 1 Make Uttam Voltamp Voltamp Voltamp 2 Rated, KVA 1500 1600 2000 2500 3 Voltage (HT) 11KV/433 11KV/433 11KV/433 11KV/433 4 Measured Voltage (V) 415 434 424 421 5 Measured Current 1146 946 1157 1950 6 Measured Power – KW 740 670 825 1361 7 Power Factor 0.922 0.943 0.983 0.958 8 Power - KVA 793 715 847 1418 9 V - THD % 10.6 12.5 9.7 6.6 10 A - THD % 15.5 29.3 15.5 1.9 11 Tap Position 3 4 4 4 5th 5th 5th 5th 12 Remarks Harmonics - Harmonics - Harmonics - Harmonics - 14.3% 24.7% 12.9% 0.5% Energy Audit Services - Faridabad Page12  Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # RSEB Transformers Power Measurement Data TR # 1 TR # 2 TR # 3 TR # 4 Sr. Parameters (RSEB) (RSEB) (RSEB) (RSEB) No. Location LT room - 1 LT room - 2 LT room - 2 LT room - 3 1 Make Nissen MPT VOLT AMP KEL 2 Rated, KVA 1500 1500 750 1500 3 Voltage (HT) 11KV/440 11KV/440 11KV/433 11KV/433 4 Measured Voltage (V) 440 415 416 428 5 Measured Current 1302 1650 806 1803 6 Measured Power – KW 945 1145 548 1335 7 Power Factor 0.951 0.964 0.945 0.980 8 Power - KVA 996 1193 580 1357 9 V - THD % 4.9 12.3 7.9 4.3 10 A - THD % 23 24.2 33.4 17.7 11 Frequency - Hz 49.91 49.92 50.02 12 Tap Position 9 3 6 5 5th 5th 5th 5th 13 Remarks Harmonics - Harmonics - Harmonics - Harmonics - 21.4% 23.1% 31% 16.1% Energy Audit Services - Faridabad Page13 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara CONCLUSIONS 4. Power Factor - Very Good. For all the practical purposes 5... RSEB Supply Transformers – 4 nos 1. Current Harmonics – Very High 2. Power factor can be improved marginally  PROPOSAL Detuned type Capacitor Banks should be provided to improve Power Factor as well as control Current harmonics. Energy Audit Services - Faridabad Page14 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara SECTION # 3 AIR COMPRESSORS 3 nos. IR Make, Centrifugal type, Air Compressors Particulars IR # 1 IR # 2 IR # 3 Rated Capacity 3430 CFM 3430 CFM 3744 CFM CFM Motor (KW) 574 574 660 KW Estimated annual power consumption = 88 Lac Units = @ 15.4 % of Total power consumption Energy Audit Services - Faridabad Page15 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara During Field work IR # 1 & IR # 3 operating. Performance data Parameters IR # 1 IR # 3 Rated CFM 3429 3714 Actual Output- FAD 2480- 3410 CFM Very Low Power – KW 490 524 Operating Prs – Kg/cm2 7.2 7.3 Spec. Power – Watt/CFM 198 154 Remarks Very High Spec. O.K. Power Consumption  DATA ANALYSIS for IR # 1, Air Compressor On analysis, one set of suction filters observed to be fully choked and as such, no Air entering the Compressor. Filter Was cleaned After filter cleaned, performance recheckedrechecked, once again. After rechecking Sl. No. Parameters Before After 1 Output 2480 CFM 3142 CFM 2 Power Consumption – KW 524 523 3 Spec. power Consumption 198 154  Very Good improvement after cleaning of the Filter. Energy Audit Services - Faridabad Page16 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara  Conclusion After the corrective steps in suction filter – Spec. Power Consumption improved from 198 watt/CFM to 154 watt/CFM Power Saving (Specific) achieved = @ 22 %  Proposal 1. Filter maintenance schedule to be improved. 2. Flow meters have been provided. Output CFM to be analyzed on weekly basis. 3. IR # 1 & IR # 3 All the measurement data and performance data is tabulated Data Analysis 1. Total compressed Air (FAD) = 3142 + 3396 CFM = 6539 CFM 2. Total Power = 1016 KW 3. Venting IR # 3 - Venting to the tune of 7 to 10 %, This is Total waste of Power = 41.8 KW 4. Auto drain Valve system – defective – compressed Air Leakage observed to be alarming magnitude. 5. Estimated @ 500 CFM – To be rectified and necessary assistance needed from I. R. 6. IR # 3 – operating in current mode, It should be operated in pressure – control mode – IR help needed. 7. Energy Audit Services - Faridabad Page17 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Expected Power Saving. = 8 % of IR # 3 + 500 CFM x 154 Watt/CFM = 8 % of 523 KW + 500 x 154/1000 KW x 70 = 41.8 + 53.9 KW = 95.7 KW Expected annual saving = 95.7 KW x 8000 Hrs = 7.656 Lac Units @ Rs. 7.50 per unit = Rs. 57.42 Lac Option # 3 IR # 3 should be stopped IR # 1 & IR # 2 – identical. IR # 3 is consuming 32 KW HIGHER Power compared to IR # 1 Compressor. To be operated in pressure control mode. Power saving in operating IR # 2 in place of IR # 3 = 32 KW Expected annual saving = 32 KW x 8000 Hrs. = 2.56 Lac Units @ Rs. 7.50 per unit = Rs. 19.20 Lac Energy Audit Services - Faridabad Page18 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Compressor Measurement data – Recheck (23.09.2024) Energy Audit Services - Faridabad Page19 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara TABLE # Air Compressor IR # 01 Power Measurement Data Sl. Air Comp # 1 Parameters Air Comp # 1 No. (Recheck) 1 Make IR - CENTAC IR - CENTAC 2 Model C35 - MX3 C35 - MX3 3 Type Centrifugal Centrifugal 4 Type of Cooling Water Cooled Water Cooled 5 Rated CFM 3430 3430 6 Rated KW 574 574 7 Voltage 413 412 8 Current 748 752 9 Power (KW) 490 493 10 P.F. 0.91 0.912 11 Operating Pressure (Bar) 7.24 7.25 12 Pressure Set point 7.2 7.25 13 By Pass Valve (Open) 0.000 0.000 14 2nd Stage Temperature 120 120 BSL Flow 2600 CFM 4th Number Fully 15 Remarks & After Filter Filter Chocked Changed Energy Audit Services - Faridabad Page20 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara TABLE # Air Compressors IR# 01 Performance Measurement Data Sl. Air Comp # 1 Parameters Air Comp # 1 No. (Recheck) 1 Make IR - CENTAC IR - CENTAC 2 Model C35 - MX3 C35 - MX3 3 Type Centrifugal Centrifugal 4 Type of Cooling Water Cooled Water Cooled 5 Rated CFM 3430 3430 6 Rated KW 574 574 7 Power - KW 490 493 8 Operating Pressure (Bar) 7.248 7.248 9 Area 0.52 0.69 10 Measured Velocity (Mtr/ Sec) 2.3 2.2 11 Calculated CFM 2480 3142 12 Volumetric efficiency - % 72% 92% 13 SPC (KW / CFM) 0.198 0.157 14 Inlet Valve (Open) 100% 100% 15 Pressure Set point 7.255 7.255 16 By Pass Valve (Open) 0.000 0.000 17 2nd Stage Temperature 120 120 BSL Flow 2600 18 4th Number Fully CFM Remarks Filter Chocked & After Filter Changed Energy Audit Services - Faridabad Page21 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara TABLE # Air Compressors # 03 Performance Measurement Data Sl. Air Comp # 3 Parameters Air Comp # 3 No. (Recheck) 1 Make IR - CENTAC IR - CENTAC 2 Model C39 - MX3 C39 - MX3 3 Type Centrifugal Centrifugal 4 Type of Cooling Water Cooled Water Cooled 5 Rated CFM 3714 3714 6 Rated KW 660 660 7 Power (KW) 524 523 8 Operating Pressure (Bar) 7.345 7.345 9 Area 0.69 0.69 Measured Velocity (Mtr/ 10 2.4 2.4 Sec) 11 Calculated CFM 3410 3396 12 Volumetric efficiency - % 92% 91% 13 SPC (KW / CFM) 0.154 0.154 14 Inlet Valve (Open) 55% 55% 15 Pressure Set point 7.255 7.255 16 By Pass Valve (Open) 7 - 8% 7 - 10 % 18 2nd Stage Temperature 118 118 BSL Flow 19 Remarks 2350 CFM Energy Audit Services - Faridabad Page22 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara 9.5.1 Pressure Drop Measurement Table # 7 Pressure Drop Study Pressure Description Location (Kg/Cm2) Dryer # 1 Input 7.3 Dryer # 1 Output 7.1 Dryer # 3 Input 7.3 Dryer # 3 Output NA Dryer # 4 Input 7.2 Dryer # 4 Output 7.0 PRESSURE DROP – O.K.  Operating Pressure can be reduced to the level of 6.5 bar.   Reduction in operating pressure from 7.0 bar to 6.5 bar will save Power  @ 4.5 % Power. This aspect would be covered under Energy Audit Report. Energy Audit Services - Faridabad Page23 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara SECTION # 4 Humidification Plants 4.1 Supply Air Fan & Return Air Fan Power parameters measured for all the S.A. Fans & R.A. Fan. Summary of all the measurement data has been tabulated in Table # 4.2 Data Analysis All the measurement data has been analyzed for Energy saving.  Main Observation All SAF & RAF Fans are provided with VFD & Speed is being controlled very effectively. Potential For Power Saving  Step # 1 Certain SUPPLY AIR FANS operating for the same ducting but operating at different speed. Would be tabulated in Audit report Step # 2 Some of SAF Fans (Identical Fans ) – operating at same speed, but consuming different power – Energy Audit Services - Faridabad Page24 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Impeller – specially pitch – angle to be checked & Set – right. The list of all such fans would be provided in ‘Energy Audit Repor’t. Energy Audit Services - Faridabad Page25  Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # S.A. & R.A. Fans # Power Measurement Data Recheck Sr. Name Of Motor Plant Ref. Voltage Current KW P.F. VFD No. Drive KW KW VFD Winding (TFO & 1 SAF # 1 15 410 23.5 16.12 0.94 50 Hz 16.12 50 Hz A/C) (Mill No. # 01) Loom Fabricated-1 2 SAF 15 406 20.8 9.5 0.65 48 Hz 9.53 48 Hz (Mill No. # 01) Loom Fabricated- 3 SAF 15 406 17.9 9.2 0.73 50 Hz 9.37 50 Hz 2(Mill No. # 01) Loom Fabricated- 4 SAF 20 407 29.4 14.4 0.69 48 Hz 14.41 48 Hz 3(Mill No. # 01) 5 SAF # 1 30 409 20.4 13.4 0.93 45 Hz 12.43 45 Hz Ring Frame (Mill No # 02) 6 SAF # 2 30 408 32.1 21.0 0.93 46.5 Hz 18.17 46 Hz 7 SAF # 1 15 426 15.7 9.3 0.81 50 Hz 7.8 46.8 Hz 8 SAF # 2 15 422 21.2 8.8 0.57 45 Hz 11.8 46.7 Hz TFO Dye House (Mill No # 04) 9 RAF # 1 22 413 21.0 10.8 0.72 45 Hz 10.4 45 Hz 10 RAF # 2 22 413 24.9 13.4 0.75 45 Hz 13.8 46 Hz Energy Audit Services - Faridabad Page26 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # S.A. & R.A. Fans # Power Measurement Data Recheck Sr. Name Of Motor Plant Ref. Voltage Current KW P.F. VFD No. Drive KW KW VFD 1 SAF # 1 15 420 21.5 15.3 0.97 50 Hz 14.2 50 Hz 2 SAF # 2 15 418 23.7 16.8 0.98 50 Hz 16.2 50 Hz 3 SAF # 3 15 417 3.9 2.4 0.85 30 Hz 8.7 50 Hz Mill - 04 Ring Frame 4 SAF # 4 15 416 12.3 6.0 0.69 5 Hz 18.0 48 Hz LR/6 (49 - 63) 5 RAF # 1 15 413 24.2 16.4 0.95 50 Hz 15.8 50 Hz 6 RAF # 2 15 412 14.9 10.2 0.96 50 Hz 10.3 42 Hz 7 RAF # 3 15 413 18.3 12.0 0.92 50Hz 12.0 50 Hz 8 SAF # 1 15 412 7.9 4.9 0.85 35 Hz 10.74 48 Hz Mill-04 Ring Frame 9 SAF # 2 R/F (20-24) & (35- 15 414 18.3 10.0 0.76 35 Hz 10.57 50 Hz 44) 10 SAF # 3 15 412 7.0 3.8 0.76 35 Hz 8.70 48 Hz Energy Audit Services - Faridabad Page27 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # S.A. & R.A. Fans # Power Measurement Data Sr. Motor Name Of Drive Plant Ref. Voltage Current KW P.F. VFD No. KW 1 SAF # 1 7.5 NA Winding (TFO 2 SAF # 2 & A/C) 30 426 20 14 0.95 45 Hz Mill # 01 3 RAF # 1 30 429 28 19 0.93 48 Hz 4 SAF # 1 Doubling 15 411 3.2 2.1 0.91 33.7 Hz Fabricated – 5 SAF # 2 Winding 15 411 3.0 1.97 0.92 32 Hz 7 SAF # 1 30 428 24.7 16.2 0.88 45 Hz 8 SAF # 1 30 426 22.4 15.9 0.94 45.2 Hz Preparatory 9 RAF # 1 30 427 37 25.1 0.94 48 Hz 10 RAF # 2 15 Not Operating Energy Audit Services - Faridabad Page28 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # S.A. & R.A. Fans # Power Measurement Data Sr. Plant Motor Name Of Drive Voltage Current KW P.F. VFD No. Reference KW 1 Pneuma Fan-2 30 426 48.7 25.2 0.71 Star Delta 2 Pneuma Fan-1 Ring Frame 426 24.1 13.2 0.75 No VFD 3 SAF # 1 15 432 9.9 4.4 0.59 35 Hz 4 SAF # 2 15 433 11.4 7.7 0.91 39 Hz 5 RAF # 1 Preparatory 15 430 14.6 10.2 0.93 45 Hz 7 RAF # 2 15 428 22.1 12.93 0.78 45 Hz 8 SAF # 1 22 405 6.7 3.7 0.79 36 Hz TFO Tower – 9 SAF # 2 22 406 7.6 4.4 0.82 36 Hz Mill # 02 10 RAF # 1 15 406 17.5 11.5 0.93 48 Hz Energy Audit Services - Faridabad Page29 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # S.A. & R.A. Fans # Power Measurement Data Sr. Name Of Plant Motor Voltage Current KW P.F. VFD No. Drive Reference KW 1 SAF # 1 Ring Frame 30 409 20.4 13.4 0.93 45 Hz 2 SAF # 2 Ring Frame 30 408 32.1 21 0.93 46.5 Hz 3 RAF # 1 Ring Frame 30 407 46.4 31 0.94 48 Hz 4 RAF # 2 Ring Frame 15 Not Operating from Last 2 Year 5 Pneuma Fan-1 Ring Frame Very Small Fan 6 Pneuma Fan-2 Ring Frame 30 404 53.1 28.9 0.78 No VFD 7 SAF # 1 Preparatory 30 422 26.1 15.4 0.80 45.1-Hz 8 RAF # 1 Preparatory 30 424 26 15.6 0.80 47.2-Hz Winding 9 SAF # 1 22 409 19.2 12.6 0.92 (TFO & A/C) Winding 10 RAF # 1 22 409 30.7 20.6 0.95 48.9-Hz (TFO & A/C) Energy Audit Services - Faridabad Page30 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Energy Audit Services - Faridabad Page31  Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Spray Water Pumps # Power Measurement Data Sr. Name Of Motor Plant Ref. Voltage Current KW P.F. VFD No. Drive KW Winding Mill- 1 Spray Pump 426 9.8 4.7 0.65 35 Hz 1 2 Spray Pump-1 Ring Frame 15 426 18.1 9.3 0.69 44 Hz 3 Spray Pump-2 Ring Frame 428 5.7 3.7 0.88 35 Hz TFO Tower 4 Spray Pump 405 7.9 4.6 0.83 45 Hz – Mill # 02 5 Spray pump Ring Frame 11 403 7.7 4.2 0.77 35-Hz 6 Spray Pump Winding 410 7.1 3.8 0.734 34.9-Hz Energy Audit Services - Faridabad Page32 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara SECTION # 5 Water Pumps 5.1 Cooling Tower Pumps for Air Compressors 7.1 Cooling Tower pumps for Air compressors reference Table, summary enclosed herewith– 7.2 Sl. No. Particulars Pump # 1 Pump # 2 1 Water pumps Old Pump New Pump 2 Motor 15 KW 15 KW 3 Power 18.0 KW 14.0 KW Consumption  CONCLUSIONS # New Water Pump is consuming 4 KW less Power. Proposal To replace cooling water pump # 1 also, as per pump # 2 Expected annual saving = 4 KW x 8640 Hrs = 34560 Units @ Rs. 7.50 per unit, = Rs. 2.59 Lac Estimated Cost = Rs. 1.25 Lac Energy Audit Services - Faridabad Page33 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Cooling Tower Pumps # Measurement Data Sl. Cooling Tower Cooling Tower Parameters No. Pump # 1 Pump # 2 1 Location Air Comp # 1 Air Comp # 3 2 Make KSB (Old) KSB (New) 3 Model KSB 080 KSB 080 4 Rated Capacity M3/H 100 100 5 Head – M 35 35 6 Motor – KW/RPM 15 15 7 Voltage 412 411 8 Current 28 24 9 Power (KW) 18 14 10 P. F 0.89 0.87 11 Discharge Pressure - Kg/cm2 3.0 3.9 12 Suction Pressure - Kg/cm2 0.5 0.5 Discharge Nil Nil 13 Throttling Suction Nil Nil 14 Flow – M3/H 96 98 15 Motor Efficiency 90% 92% 16 Total Head - (M) 25 34 17 Pump Efficiency - % 40.3 70.5 18 Remarks Energy Audit Services - Faridabad Page34 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara SECTION # 12 RING FRAMES 12.1Measurement data Following measurement data, operating data has been tabulated:- 1. Make & Model 2. Motor – KW 3. Voltage 4. Load current 5. Power – KW 6. P.F. 7. Nos. of Spindles 8. Count 9. TPI 10. TPM 11. Doff- % 12. Breakage of yarn Energy Audit Services - Faridabad Page35 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara 12.2 Summary of all the above data has been tabulated as following:- Mill # Ring Frames # Table # Remarks R.F. # 1 to Table # 23 R.F. # 11 Mill # 1 R.F. # 12 to Table # 23 A R.F. # 20 R.F. # 22 to Table # 24 R.F. # 33 Mill # 2 R.F. # 34 to Table # 24 A R.F. # 47 R.F. # 2 to Table # 25 R.F. # 10 Mill # 3 R.F. # 11 to Table # 25 A R.F. # 23 R.F. # 28 to Table # 26 R.F. # 39 Mill # 4 R.F. # 40 to Table # 26 A R.F. # 48 R.F. # 49 to Mill # 5 Table # 27 R.F. # 56 12.3 Data Analysis All the Ring Frames are provided with VFD. Ring Frames are operating efficiently. Energy Audit Services - Faridabad Page36  Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Ring Frame Power Measurement data Unit # 01 Sr. Motor Name Of Drive Model Spindle Voltage Current KW P.F. Count Speed VFD No. KW 1 Ring Frame # 1 LR9/AX 1056 66 418 62.2 45 0.97 30 20219 71.4 Hz 2 Ring Frame # 19 LR9/A 432 30 417 26.2 18 0.97 30 19894 64.0 Hz 3 Ring Frame # 12 LR6/S 560 30 421 32.3 21.5 0.91 28 20050 52.7 Hz 4 Ring Frame # 16 LR9/AX 480 30 415 15.4 11 0.96 16 14312 37.4 Hz 5 Ring Frame # 6 Riter 1056 66 411 75 47 0.89 30 20000 NA 6 Ring Frame # 2 Riter 1056 66 411 119 72 0.87 30 20000 NA 7 Ring Frame # 8 LR9/AX 528 30 416 32 21 0.95 18 18312 68.6 Hz Energy Audit Services - Faridabad Page37 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Ring Frame Power Measurement data Unit # 02 Sr. Name Of Drive Model Spindle Motor KW Voltage Current KW P.F. Count Speed VFD No. 1 Ring Frame # 20 LR6/S 560 30 428 35.5 24.4 0.95 30 20355 52.2 Hz 2 Ring Frame # 21 LR6/S 560 30 428 31 22 0.95 33 20580 52.0 Hz 3 Ring Frame # 31 LR6/S 560 30 407 27.5 18 0.94 30 18959 48.0 Hz 4 Ring Frame # 41 LR6/S 480 30 405 11.2 7.5 0.93 30 14047 35.0 Hz 5 Ring Frame # 37 LR6/S 560 30 406 16.1 11 0.93 30 18178 47.0 Hz 6 Ring Frame # 26 LR6/S 560 30 407 29.5 19.1 0.94 30 20000 47.3 Hz 7 Ring Frame # 27 LR6/S 560 30 405 37.5 25 0.95 30 20400 51.0 Hz 8 Ring Frame # 38 G5/1 496 30 408 29.5 20.11 0.95 28 18500 52.0 Hz 9 Ring Frame # 36 G5/1 496 30 409 27 17 0.92 28 19500 50.0 Hz Energy Audit Services - Faridabad Page38  Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Ring Frame Power Measurement data Unit # 03 Sr. Name Of Drive Model Spindle Motor KW Voltage Current KW P.F. Count Speed VFD No. 1 Ring Frame # 3 LR6/S 592 40 410 34.5 23.5 0.95 30 20894 55.0 Hz 2 Ring Frame # 4 LR6/S 592 40 406 32 22 0.96 40 20806 54.0 Hz 3 Ring Frame # 5 LR6/S 592 40 409 37.3 25 0.95 40 20872 55.0 Hz 4 Ring Frame # 17 New 480 30 410 27.6 18.5 0.91 20 18503 70.0 Hz 5 Ring Frame # 19 New 480 30 410 33 22 0.92 20 18999 72.0 Hz 6 Ring Frame # 9 LR6/S 592 37 411 33 22.2 0.95 40 20412 53.5 Hz 7 Ring Frame # 10 LR6/S 592 40 411 31 21 0.92 50 20795 52.0 Hz Energy Audit Services - Faridabad Page39  Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Ring Frame Power Measurement data Unit # 04 Sr. No. Name Of Drive Model Spindle Motor KW Voltage Current KW P.F. Count Speed VFD 1 Ring Frame # 32 LR9/AX 432 30 400 25.5 16.5 0.93 30 20911 79.0 Hz 2 Ring Frame # 46 LR6/S 480 30 402 36 22 0.87 28 20938 Star Delta 3 Ring Frame # 56 LR6/S 544 40 407 38 26 0.97 30 20800 55.0 Hz 4 Ring Frame # 55 LR6/S 544 40 417 30.8 22 0.96 40 21061 55.0 Hz 5 Ring Frame # 72 LR6/S 528 22 413 31.5 22 0.96 - 14828 52.0 Hz 6 Ring Frame # 64 LR6/S 544 40 420 34.5 23.5 0.93 40 20907 55.0 Hz 7 Ring Frame # 57 LR6/S 544 40 410 32 22.5 0.97 40 20893 55.0 Hz Energy Audit Services - Faridabad Page40 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara SECTION # 13 AUTO CONERS 13.1 Brief Description Suction Blower is the main load. Actual loading on suction blower is related to the nos. of repairs, at any time. As such, use of VFD with Pressure transducer has been very, very successfully. 13.2 Measurement Data Since, Power consumptions in suction Blower is variable, Power consumptions has been measured by Energy meter method for certain time duration. Summary of all the measurement data is tabulated and analysed.  SUMMARY Most of the Auto coners have been already changed. Only 3 nos. Auto Coners have been identified, consuming very much higher Power. Auto coner Rated KW Power Consumption (KW) A/C – 34 Make Savio - 15 KW - 14 KW A/C – 33 Make Savio - 15 KW - 11.9 KW A/C – 32 Make Savio - 15 KW - 15.4 KW Corrective steps necessary.  PROPOSAL Replacement of these three Auto Coners may please be considerd in future. Energy Audit Services - Faridabad Page41  Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Auto Coner # Power Measurement data Unit # 01 Number Sr. Name Make Model Motor KW of Voltage Current KW P.F. Speed Count. M/C Eff. VFD No of Drive Spindle 1 A/C # 4 Muratec 21-C 11 60 424 11 7.5 0.87 1300 30.5 70% 51.9 Hz 2 A/C # 5 Muratec 21-C 11 60 423 13 9.0 0.91 1300 30.0 76.3% 54.0 Hz 3 A/C # 6 Muratec 21-C 11 60 424 11 7.0 0.87 1300 30.0 71.2% 52 Hz 4 A/C # 3 Muratec 21-C 15 60 424 9.5 6.5 0.89 1300 30.0 65% 67 Hz 5 A/C # New Muratec 21-C 15 60 423 7.0 4.6 0.77 1350 30.0 71% 70 Hz Energy Audit Services - Faridabad Page42  Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Auto Coner # Power Measurement data Unit # 02 Number Sr. Name of Motor M/C Make Model Of Voltage Current KW P.F. Speed Count. VFD No Drive KW Eff. Spindle 6 A/C # 13 Muratec 21-C 11 60 417 9.1 6.4 0.97 1400 7 A/C # 11 Muratec 21-C 11 60 423 7.1 4.5 0.89 1400 30.0 81% 63-Hz 8 A/C # 9 Riter X/6 15 50 425 6.9 4.5 0.76 1350 30.0 77.1% 70-Hz Energy Audit Services - Faridabad Page43  Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Auto Coner #Power Measurement data Unit # 03 Number Sr. Motor M/C Name of Drive Make Model Of Voltage Current KW P.F. Speed Count. VFD No KW Eff. Spindle 9 A/C # 26 Muratec 21-C 11 60 418 14.6 8.4 0.84 1350 30 75% 54 Hz 10 A/C # 25 Muratec 21-C 11 60 421 14.7 8.7 0.86 1300 30.0 77% 54 Hz 11 A/C # 21 Riter X/6 15 58 421 14 7.5 0.83 1000 24.0 86.0% 70 Hz 12 A/C # 23 Saurer X/6 10 60 421 11.5 7.5 0.68 1250 30 80% 70 Hz Energy Audit Services - Faridabad Page44  Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Auto Coner #Power Measurement data Unit # 04 Number Sr. Name of Motor M/C Make Model of Voltage Current KW P.F. Speed Count. VFD No Drive KW Eff. Spindle 13 A/C # 34 Savio Espero 15 64 407 22 14 0.85 1200 30 76.5 No VFD 14 A/C # 33 Savio Espero 15 64 406 20 11.9 0.83 1200 30.0 79% No VFD 15 A/C # 32 Savio Espero 15 64 400 25 14.5 0.87 1250 40.0 72.3% No VFD 16 A/C # 31 Muratec 11 60 402 14.7 8.2 0.89 1350 40 77 54 Hz Energy Audit Services - Faridabad Page45 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara SECTION # 14 TFO 14.1 Power Measurement Data a) Power Measurement Voltage, Load Current, Power Consumption – KW and P.F. measured for all TFO machines. b) Following process – data also noted: - Count Nos. of Drums TPI Cut c) Drum speed also noted. Summary of all the measurement data is also tabulated in table # 14.2 Data – Analysis  CONCLUSIONS :- Very well managed Energy Audit Services - Faridabad Page46 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # TFO #Power Measurement data Unit # 01 Sr. Motor No. of Name Of Drive Voltage Current KW P.F. Count Speed VFD Hz No. KW Drum 1 TFO # 4 22 410 11.1 7 0.88 36 8052 39.5 Hz 2 TFO # 6 22 220 410 10.2 6.5 0.88 38 8028 39.1 Hz 3 TFO # 11 22 410 9.5 5.9 0.87 82 8043 39.1 Hz Energy Audit Services - Faridabad Page47 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # TFO # Power Measurement data Unit # 02 Sr. Name Of Motor No. of Voltage Current KW P.F. Count Speed VFD No. Drive KW Drum 4 TFO # 27 15 409 8.5 5.3 0.91 38 8046 39.2 Hz 5 TFO # 26 15 410 8 5 0.9 82 8028 39.2 Hz 6 TFO # 22 15 180 411 10.5 6.8 0.93 28 8012 39.35 Hz 7 TFO # 18 15 409 9.5 6.5 0.94 28 8027 39.25 Hz 8 TFO # 13 15 406 8.6 6 0.96 38 8085 39.5 Hz Energy Audit Services - Faridabad Page48 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # TFO #Power Measurement data Unit # 03 Sr. Name Of Motor No. of Voltage Current KW P.F. Count Speed VFD No. Drive KW Drum 9 TFO # 102 22 415 19 12.0 0.85 30 9612 No VFD 10 TFO # 105 22 144 416 26.1 12.6 0.67 30 9600 No VFD 11 TFO # 101 22 415 20.5 12.5 0.78 30 9600 No VFD 12 TFO # 99 30 420 19.7 12.5 0.87 30 8710 No VFD 13 TFO # 97 30 420 20.6 13.5 0.89 30 8630 No VFD 180 14 TFO # 95 30 419 27.2 13.5 0.88 30 8568 No VFD 15 TFO # 96 30 419 30.8 13.35 0.39 30 8576 No VFD Energy Audit Services - Faridabad Page49 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # TFO #Power Measurement data Unit # 04 Sr. Name Of Motor No. of Voltage Current KW P.F. Count Speed VFD No. Drive KW Drum 16 TFO # 35 15 415 12.5 6.5 0.73 28 8234 39.65 17 TFO # 33 15 180 414 18.4 11.5 0.84 50 9992 48 18 TFO # 31 15 414 11.6 6 0.71 82 8000 39 Energy Audit Services - Faridabad Page50 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # TFO #Power Measurement data Unit # 05 Sr. Name Of Motor No. of Voltage Current KW P.F. Count Speed VFD No. Drive KW Drum 19 TFO # 51 30 417 38.1 20.0 0.73 30 9970 No VFD 20 TFO # 52 30 192 415 40.0 22.5 0.77 18 9500 No VFD 21 TFO # 53 30 420 38.1 20.4 0.72 30 9703 No VFD 22 TFO # 55 30 420 19.1 10.4 0.74 28 7920 No VFD 23 TFO # 57 30 216 417 19.2 10.0 0.65 199 7945 No VFD 24 TFO # 56 30 415 18.5 10.0 7.2 28 7804 No VFD Energy Audit Services - Faridabad Page51 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara SECTION # 17 17.1 BORE WELL PUMPS There are 7 nos. Borewell pumps. Following data Tabulated 1. Borewell Pump 2. Motor – KW 3. Location 4. Flow – M3/H – measured 5. KW per 100 M3 worked out & tabulated. Following Borewells consuming much higher power for 100 M 3 output i. Borewell Pump # 2 ii. Borewell Pump # 3 iii. Borewell Pump # 5 These 3 nos. Borewells should be thoroughly checked for consuming higher power Energy Audit Services - Faridabad Page52 Mandatory Energy Audit Report Banswara Syntex Ltd - Banswara Table # Bore well Power Measurement Data SWA Sr. Name Of Rated Power, Flow Location (KW / No. Drive KW KW (m3/h) Flow) Guest 1 Bore well # 1 7.5 9.64 19 50.7 House 2 Bore well # 2 5.5 BSL Garden 7.58 8.5 89.2 Near - 3 Bore well # 3 7.5 7.6 7.8 97.4 Mandir 4 Bore well # 4 10.0 Godown - In 10.2 24 42.5 Godown - 5 Bore well # 5 7.5 8.5 9.7 87.6 Out 6 Bore well # 6 10.0 Farm - 1 14.5 24 60.4 7 Bore well # 7 5.5 5.7 13.7 38.0 Energy Audit Services - Faridabad Page53