Confederation of Indian Industry

CII-Sohrabji Godrej Green Business Centre

Detailed Energy Audit

At
K R Pulp & Papers Limited
Shahjahanpur

June 2014

Confederation of Indian Industry

CIISohrabji Godrej Green Business Centre

CONTENTS

Chapter
No.

Description

Page
No.

Executive Summary

Introduction

II

Acknowledgment

III

List of Energy Saving Proposals

IV

Energy Saving Proposals

Management Aspects And Conclusions

50

Annexure

53

Backup Calculations

75

Total No of Pages: 117

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EXECUTIVE SUMMARY
K R Pulp & Papers Limited is among Indias leading manufacturers of ecofriendly paper enriched with the expertise and experience of around two
decades in making paper from non conventional raw material i.e. Bagasse, a
residue of sugar cane.
Incorporated in 1995, the company has two fully integrated pulp and paper
manufacturing facilities situated in Shahjahanpur district in the state of Uttar
Pradesh in India. The Unit-1 is used to manufacture Kraft paper while Unit-2 is
used to manufacture White paper.
CII has conducted the Detailed Energy Audit at K R Pulp & Papers Limited,
Shahjahanpur Plant from 10th to 17th April, 2014. A detailed presentation was
made to the plant team covering various energy conservation opportunities on
17th April, 2014. The combined efforts of K R Pulp & Papers Limited and CIIGodrej GBC team have together identified, annual energy saving potential of
Rs. 434.10 Lakhs, based on present energy cost.:
No. of
Proposals

Annual
savings in
Lakhs

23

434.10

107.30

Annual savings with investment (Rs. Lakhs)

19

326.80

Investment Required

19

183.90

Months

Details

Total Annual savings (Rs. Lakhs)

Annual savings without investment
(Rs. Lakhs)

Average payback period for capital proposals

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SPECIFIC ACTION PLAN

a) Specific target date for implementation of proposals should be made within
30 days from submission of this report.
b) The plant should prioritise the above proposals and implement them in a
phased manner.
c) In our opinion the following proposals can be implemented within next
three months straightaway and should be on top priority.
(ESP Nos. 1, 2, 13 & 16)
The above proposals do not require any investment and no detailed
verification.
As a second priority and after detailed verification the following proposals
should be implemented.
(ESP Nos. 3, 4, 5, 7, 9, 10, 12, 14, 15, 17, 18, 19, 21, 22 & 23)
As a third priority and after detailed verification the following proposals
should be implemented.
(ESP Nos. 6, 8, 11 & 20)
d) The plant had already done commendable jobs in Energy conservation. CII
strongly feels that, the plant team should form an energy management
committee which involves senior persons from all departments and the
committee should continue the work and progress towards World Class
Energy Efficient Unit.

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CHAPTER - I

INTRODUCTION
K R Pulp & Papers Limited, Shahjahanpur evinced interest in availing the
services of Confederation of Indian Industry for conducting a detailed energy
audit in their factory.
This report on the detailed energy audit carried out at K R Pulp & Papers
Limited, Shahjahanpur, is in accordance with CIIs proposal, agreed by K R
Pulp & Papers Limited, Shahjahanpur vide their work order No.
KRPL/UNIT-2/2013-14/260274 dated 28th February 2014.
The detailed energy audit comprised of the following activities:
Detailed data collection of power consuming equipments, production
capacities of major equipment, operating parameters and section wise
specific power consumption.
Power measurements of major electrical energy consumers.
Measurement of efficiency of major power consuming equipment such as
fans etc.,
A detailed training programme on energy management was conducted to
seek more inputs from the plant personnel
Analysis of collected data and measurements to develop specific energy
saving proposals.
Discussion with the plant personnel on the identified proposals.
Presentation on the findings of detailed energy audit to plant personnel.
We are pleased to mention that all the identified energy savings proposals
have been discussed with plant executives concerned before finalising the
Projects.
The contents of the report are based on the data provided by K R Pulp &
Papers Limited, Shahjahanpur plant personnel during the detailed energy
audit.
The plant personnel should implement the suggestions made in the report
after verifying safety aspects. It is the responsibility of the plant personnel to
observe statutory regulations, if any, as applicable to the factory.

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CHAPTER - II

ACKNOWLEDGMENT
CII acknowledges with thanks the co-operation and the hospitality extended to
the CII energy audit team during the detailed energy audit at K R Pulp &
Papers Limited, Shahjahanpur.
The interactions and deliberations with K R Pulp & Papers Limited team
were exemplary and the whole exercise was thoroughly a rewarding
experience for CII.
The arrangements and support during the energy audit were excellent. We
deeply appreciate the interest, enthusiasm and commitment of K R Pulp &
Papers Limited, Shahjahanpur team towards the energy conservation.
We would also like to place on record our sincere thanks and appreciation for
all the senior plant executives.

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CHAPTER - III
LIST OF ENERGY SAVING PROPOSALS
Sl.
No

Energy Saving Propsals

Annnual Savings
(Rs.Lakhs)

Investment
Required
(Rs.Lakhs)

Payback
Period
(Months)

100.00

Reduce the Frequency of Turbo Generator 1 to 49 Hz

Reduce One Tap Setting of Transformer 5

2.10

Optimize the Lighting Voltage in the Plant

5.00

2.00

Install Variable Frequency Drives in Identified Pumps In

Pulp Mill

56.80

47.40

10

Install Variable Frequency Drives in Centricleaner

Pumps in Pulp Mill

8.80

8.0

11

Install Variable Frequency Drives in Identified Pumps in

Paper Machine

8.40

10.00

15

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Install Variable Frequency Drives in Centricleaner

Pumps in Paper Machine

43.00

19.50

Avoid the Pressure Drop Across Feed Control Valve By

Operating Bfp With Vfd in Unit 1

4.00

4.50

14

Avoid Passing Through Minimum Recirculation Line By

Installing Multistage Drag Valves For Boiler Feed Pump
in Unit 1

9.00

5.00

10

Avoid the Pressure Drop Across Feed Control Valve By

Operating Bfp in Auto With Vfd in Unit 2

27.00

1.00

11

Avoid Passing Through Minimum Recirculation Line By

Installing Multistage Drag Valves For Boiler Feed Pump
in Unit 2

4.80

8.0

20

12

Avoid Recirculation of Condensate By Installing Vfd And

Reducing Speed of Condensate Extraction Pump

2.40

1.00

13

Reduce Air Ingress in Unit-1 Boiler Flue Gas Path

2.0

14

Operate All the Cooling Tower Fans And Reduce the

Speed By Installing Vfd For All Fans in Unit-2 Power
Plant

4.00

3.00

15

Reduce Excess Flow Through Heat Exchangers in Unit-2

Power Plant

32.00

8.00

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16

Switch off One Condensate Extraction Pump Completely

in Unit-2 Power Plant

3.20

17

Avoid Pressure Drop Across Hot Well Level Control

Valve And Maintain Hot Well Level Directly By Installing
Vfd

2.00

1.50

18

Avoid Operating One Pump By Pumping Dm Water

Directly to Deaerator After Passing Through the Flash
Steam Heat Exchanger in Paper Mill Section

3.20

1.00

19

Optimize the Operation of Instrument Air Compressors

in Unit -2

16.40

10.00

20

Optimize the Operation of Instrument Air Compressors

in Unit -1

6.00

5.00

15

21

Optimize Vacuum Pump Operation in Unit-2

55.20

25.00

22

Replace V Belt With Cogged Flat Belt in Identified

Equipments

34.40

20.00

23

Optimize the Condensate Recovery Circuit in Paper And

Evaporator Section

4.40

4.00

11

434.10

183.90

Total

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Confederation of Indian Industry

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Chapter IV
Energy Saving Proposals

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ENERGY SAVING PROPOSAL NO. 1

REDUCE THE FREQUENCY OF TURBO GENERATOR 1

TO 49 Hz
During the detailed energy audit at K R Pulp and Papers Limited,
energy conservation by reducing frequency of the turbo generator was
explored in detail as the alternator was isolated from the grid.
During the detailed energy audit at K R Pulp and Papers Limited ,
energy conservation by reducing frequency was explored in detail. In
order to look at this possibility a detailed study was carried out for the
loading of the motors along with the plant team.
Present Status
The rating of the Turbo generator is given below for reference.
Rating of the alternator

15000 kVA

Number of phase

3 phase

Number of poles

4 pole

Rated voltage

11 kV

Rated current

787 A

Rated Power

12000 kW

Rated Power factor

0.8 pf

Rated speed

1500 rpm

The rating of the Turbo generator is given below for reference.

Rating of the alternator

15000 kVA

Number of phase

3 phase

Number of poles

4 pole

Rated voltage

11 kV

Rated current

787 A

Rated Power

12000 kW

Rated Power factor

0.8 pf

Rated speed

1500 rpm

The 12 MW Turbo alternator TG1 in K R Pulp and Paper is operating

isolated from the grid and is
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The current operatingOperated at a frequency of the TG1 is 50 Hz. A

detailed load study was carried out in the plant to explore the possibility
of reducing frequency of alternator. Through motor study, it was found
that the motors in the plant are operating mostly in the range of 60 80
%.
Majority of the process equipment will not be affected in production as
most of the process equipment hasveve a VFDs installed and reducing
their speed will not hamper production. .
Majority of the process equipment also had margin in equipment
requirement and operating conditions. For example the pumps in the
plant were throttled with valves significantly to meet the operating
requirements. The pumps also delivers energy to cater the pressure loss
across the valve. Reducing the frequency of the alternator will avoid this
pressure loss across the valve and reduce the energy consumed by
pumps.
Proposed system
Due to this available margin between operation and requirement, there is
a good potential to optimize the frequency of the plant.A detailed study
was carried out along with the plant team to understand the loading of
the motors to explore opportunity of frequency rediuction. As mentioned
earlier in the proposal the loading of the motors in the plant are found to
be in the range of 60 80%. Based on the loading of the motors the
frequency can be reduced to 49 Hz safely without overloading the motors.

Proposed system
We recommend to reduce the frequency and operate it at 49 Hz. The
reduction in frequency will majorly reduce the power consumed by
centrifugal equipment. The power consumed by centrifugal equipment are
is proportional to cube of speed and the power consumed by positive
displacement equipment arepower consumed by positive displacement
equipment is proportional to the speed. WithAlso, by reducing the the
reduction in frequency the power consumed by individual motors also
reduce, due to the reduction in no load losses of the motor. In order to
obtain the savings on a conservative basis only 40% of centrifugal
equipment are considered for calculation of energy savings.
Since the alternator TG1 is operating isolated from the grid and also due
to the margin available in the equipment, there is a good potential to
optimize the frequency of the plant to 49 Hz.
A small variation in speed will lead to appreciable reduction in the power
consumption of the plant. The frequency reduction is only possible for the
situation when plant is running without synchronization with grid.
Steps involved in frequency reduction

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1
2
3The frequency of the alternator can be reduced by reducing the turbine
speed. In K R Pulp and Paper a trial was taken along with the plant team
and the frequency was reduced to 49.5 Hz. CII congratulates the plant
team on the excellent effort.
With the reduction in frequency the power consumed by individual
motors also reduce, due to the reduction in no load losses of the
motor. The turbine rpm can be reduced to 10545 rpm to maintain
the alternator frequency as 49 Hz.
Abstract of Trial Taken at siteTrial to reduce alternator frequency
to 49.5 Hz
A trial was taken with discussions from the plant team and the frequency
was reduced to 49.5 Hz from 50 Hz. CII thanks the plant team for helping
extending all the support in taking the trial. us take the trial.
The speed of the prime mover corresponding to 50 Hz of operation is
10760 rpm, which in turn corresponds to 1500 rpm of the alternator. This
rpm was reduced from 10760 rpm to 10653 rpm. The speed of the prime
mover and correspondingly the frequency of the alternator was reduced
from 50 Hz from 49.5 Hz.
When the frequency of the alternator was reduced from 10760 50 to
10653 49.5 rpmHz, the power produced by the alternator showed an
immediate reduction of 180 kW. This reduction of 180 kW of
reductionobserved is instantaneous, as the frequencies of VFDs readjust
itself to the required frequency of operation within few cycles. Also, during
this reduction in power produced by the alternator, a reduction of 1.55
TPH of steam consumption was also observed.
The immediate change of values observed during the trial arechange of
values/results observed during the trial is mentioned in the table below:
Parameter

Before Trial @50

Hz

After trial @ 49.5

Hz

Frequency of the
Alternator

50 Hz

49.5 Hz

Operating RPM of the

turbine

10760 rpm

10653 rpm

Generation MW

10.97 MW

10.79 MW

Capacity TPH

79.42

77.87

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The value mentioned above is an instantaneous value and cannot be

considered for energy savings directly. In order to monitor the reduction
in energy produced by the alternator the monitoring of power
consumption has to be monitored for a longer duration to realize the
energy savings achieved.
The VFDs will adjust the voltage and frequency to operate at the desired
values based on the feedback given to the VFD. Due to this the effect of
frequency reduction will have no effect on the equipment which have
VFDs. In the future the plant team may plan on installing VFDs for
equipment in the plant for energy savings. Overall the effect of frequency
reduction may be reduced by installing VFDs and the margin of energy
savings may reduce by installing more VFDs. Eventhough the margin of
energy savings reduces it is still recommended to reduce the frequency of
the alternator and operate at 49 Hz.
Recommendation
We recommend
to To reduce the frequency of TG1 to 49 Hz from 49.5 Hz in steps of
0.2 Hz. .
On a Cconservatively basis 40% of load is assumed as centrifugal.
Atleast 250 kW can be saved by implementing this proposal.
Benefits
Annual energy savings of Rs 100.00 Lakhs can be achieved by reducing
the energy savings. The investment required for the project is NIL.

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ENERGY SAVING PROPOSAL NO. 2

REDUCE ONE TAP SETTING OF TRANSFORMER 5

During the Detailed Energy Audit conducted at KR Pulp and Papers
Limited, Shahjahanpur the opportunity to optimize the voltage of plant
was studied.
Present Status
The induction motors in the plant are rated for 415V. The tap settings
were maintained to obtain a voltage 427V for Transformer 5. The loading
of motors in the plant were ranging from 70-85%.
The graph shown in Fig below is drawn for an induction motor on a pu
basis. It shows the effect of stator terminal voltage to total motor losses
for various per unit loading for an induction motor. The no load curve on
the graph shows that the no load loss reduces as the stator terminal
voltage reduces. The No load losses of a motor are directly proportional
to square of the applied voltage.

Fig Applied voltage (pu) vs total motor losses

The graph shown above is drawn for loading at , , and full load. For
each loading of the motor there is an optimum voltage point where the
total motor loss is at minimum for that condition of loading. Reducing the
voltage below the optimum point, the motor capacity gets derated and
the current flowing through the motor increases i.e. voltage below the
optimum point derates the motor.
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The motor has to draw a fixed amount of power to satisfy the shaft power
for specific loading conditions. Since, the terminal voltage of the motor
reduces the current is increased to meet the shaft power. This causes an
increase in current and hence increases copper losses in the stator and
the rotor and during this condition of low voltage the no load loss is lower
as compared to the higher voltage applied to the motor.
The voltage drop at the motor terminals should be seen based on the
length of the cable, size of the cable installed, based on the power factor
of the motor and also due to any loose connections in lugs or the wiring of
the motor. According to IEC 60038 a 415V motor can be safely operated
with a range 230/400V +10% and -6% at the MCC and also 4% voltage
drop is allowed at the supply terminals. The motors are generally
designed to handle a voltage variation of 10% from the rated value.
Motors consuming low power factor may have higher voltage drop and
can be compensated by installing capacitor banks at the motor terminals
or motor DBs. Care should be taken while installing capacitor banks at the
motor terminals, that the installed kVAR of the capacitance should not
exceed the no load kVAR of the motor.
Since the voltage maintained at the motor terminals may lie below the
optimum voltage point as explained above, the current consumed by the
motors may increase, which may increase the copper losses in the motor.
But the reduction of voltage reduces the magnetization losses of the
motor and can be significantly reduce the energy consumed in the plant.
The loading of the motors in the plant has been observed to be 70 85%,
the current consumed by the motors will not exceed the full load current
of the motor, due to the reduction in voltage and the motor can be safely
operated.
Proposed system
In general for an AC induction motor operating at a higher voltage than
rated, the no load losses can be reduced by reducing the voltage to the
rated value. As a thumb rule there is 1% reduction in power consumption
for every 4% reduction in voltage. Based on this the thumb rule of 1%
reduction in power consumption for every 4% reduction in voltage, power
savings of 6 kW can be achieved in the plant by reducing one tap setting
of the distribution transformers(11kV/433V).
Taps setting of the Transformers and corresponding HT and LT
Voltages
Tap Position

HT Voltage (V)

11650

2(Recommended)

11275

3(Current)

11000

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LT Voltage (V)

10725

10450

10175

9900

433

Proposed system
In general for an AC induction motor operating at a higher voltage than
rated, the no load losses can be reduced by reducing the voltage to the
rated value. As a thumb rule there is 1% reduction in power consumption
for every 4% reduction in voltage. Based on this the thumb rule of 1%
reduction in power consumption for every 4% reduction in voltage, power
savings of 6 kW can be achieved in the plant by reducing one tap setting
of the distribution transformers(11kV/433V).
The tap settings of Transformer 5 are mentioned in the table above. The
current tap setting of the transformer is at 3 rd tap. The current tap setting
maintains a voltage of 427 V. This voltage can be reduced closer to 415 V,
at which the motors in the plant are designed. This gives us a good
opportunity to reduce the plant voltage to 415 V.
The tap settings of Transformer 5 are mentioned in the table below. The
current tap setting of the transformer is at 3 rd tap. The current tap setting
maintains a voltage of 427 V. This voltage can be reduced closer to 415 V,
at which the motors in the plant are designed. This gives us a good
opportunity to reduce the plant voltage to 415 V.
Recommendation
Currently all the distribution transformers are rated for 11kV/433V. The
tap position is in the normal tap of 43. It is recommended to reduce the
tap settings of Transformer 5 4th to 3rd tap in order to:
Maintain 415 420 V as the distribution transformer output voltage

Reduces magnetization losses in the motors

Atleast 6 kW can be saved by reducing one tap setting in the
transformers
Benefits
Optimizing the voltage in distribution transformers will result in an annual
energy saving of Rs. 2.10 Lakhs. There is no investment required for
this proposal.

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ENERGY SAVING PROPOSAL NO. 3

IMPROVE
THE
POWER
FACTOR
OF
PURCHASED FROM ELECTRICITY BOARD

POWER

During the Detailed Energy Audit conducted at KR Pulp and Papers

Limited, Shahjahanpur the opportunity to improve the EB power factor
was explored in detail.
Background
The grid power in KR Pulp and Papers is used mainly for operating the
plant during the failure of any power generation sources in the plant
(Emergency conditions). The power is used to charge the transformers for
no load condition only. The billing system used is in terms of kVAh and the
load utilized was very low maintaining a power factor of 0.97 at the grid.
The kVAh consumed in the grid was around 2, 48, 000 kVAh, the kWh
consumption is 2, 36, 000 kWh, leading the power factor of operation to
be 0.95.
There is a good potential to optimize the power factor of operation to be
0.99. The power factor of EB can be improved by installing capacitor
banks. Based on the EB consumption the required amount of capacitor
banks required to maintain 0.99 pf is also calculated.
Recommendation
It is recommended to improve the EB power factor to reduce the kVAh
charges. Approximately 9600 kVAh can be saved per month.We
recommend
To install capacitor banks and improve the EB power factor to 0.99
Around 9600 kVAh can be saved

Benefits
Annual energy savings of Rs 5.00 Lakhs can be achieved. The
investment required for the capacitor banks are Rs 2.00 Lakhs, which is
paid back in 5 months.

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ENERGY SAVING PROPOSAL NO. 4

INSTALL
VARIABLE
FREQUENCY
IDENTIFIED PUMPS IN PULP MILL

DRIVES

IN

During the Detailed Energy Audit conducted at K R Pulp & Papers Ltd.,
Shahjahanpur, the pumping systems were studied for energy saving
potential.
Present Status
Many of the pumps in the pulp mill in Unit-II were found to be controlled
through control valves. The flow requirement in the below mentioned
pumps varies on the basis of production levels and the consistency to be
maintained in the respective chests. The pumps would have been
designed for maximum production and hence the flows are generally
controlled through valves.
Closing of the valve creates an artificial resistance to the flow, additional
to the system resistance. This pressure drop across the valve is a
mechanical energy loss which is also included in the work done by the
pump. It is estimated that about 10-40% of the pump power consumption
is lost across the valve.
All these pumps as mentioned below operates at varying load depending
upon the rate of production. The present method of controlling the flow is
through valve throttling which is an inefficient way of controlling the flow.
This energy loss can be prevented saved by varying the capacity flow of
the pump according to the requirement. The flow of the pump can be
varied by varying the speed of the pump using a Variable frequency drive.
By reducing the speed of the speed of the pump, the required flow can be
maintained without closing the throttle valves. As pump power is directly
proportional to the operating head of the pump, there is good potential to
for saving power.
The details of the various pumps operated with valve throttling is as given
below
Valve
Power
Opening
kW
%

Name of Pump

Tag
Name

Screw Press Chest

Pump

PU 76

57

Continuous Digester
Dilution Pump

PU 74

48

kW
Saving

Flow
m3/hr

35-60

11

440

35

14

72.8

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Wet Dilution Pump BSW1

PU 119

60

12

18

400

Back Shower Pump BSW1

PU 100

17

50

120

Wet Dilution Pump BSW 2

PU 96

66

25

19.5

500

Back Shower Pump BSW 2

PU 101

17

50

130

Washed HD Tower
Pump

PU 116

71

80

HD Dilution Pump

PU 126

54

50

16

Secondary Screen
Pump

PU 132

21

30

Screened HD Tower
Pump

PU 146

24

50

LC Chest Pump

PU 150

24

15

Screened HD Tower
Dilution Pump

PU 165

54

25, 14

16

EOP VAT Dilution

Pump

PU 169

15

28

4.5

EOP Washer Dilution

Pump

PU 171

54

60

10.5

Thus there is excellent potential to save energy by installing VFDs for the
pumps and varying flow as per requirement.
Recommendation
We recommend the following:
Install Variable Frequency Drives for the identified pumps
Operate these pumps with suggested VFD feedback
Vary speed of pump to maintain required flowOptimize the power
consumption
Benefits

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The annual savings of Rs. 58.60 Lakhs can be achieved by implementing

this project. The investment required is Rs. 47.40 Lakhs which is paid
back in 10 months.

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ENERGY SAVING PROPOSAL NO. 5

INSTALL
VARIABLE
FREQUENCY
DRIVES
CENTRICLEANER PUMPS IN PULP MILL

IN

During the Detailed Energy Audit conducted at K R Pulp & Papers Ltd.,
Shahjahanpur, the pumping systems were studied for energy saving
potential.
Present Status
The Centricleaner pump in the pulp mill in Unit-II was found to be
controlled through a control valve. The flow requirement in the pump
varies on the basis of production levels.
2.6 bar

0.6 bar

To Screen Washer

Primary Centricleaner
Primary Centricleaner
Standpipe

40% open

3.4 bar

PU 128

84 kW

Closing of the valve creates an artificial resistance to the flow, additional

to the system resistance. This pressure drop across the valve is a
mechanical energy loss which is also included in the work done by the
pump. The necessity for controlling the valve could be due to higher
design head or design flow.
There is pressure loss of 0.8 bar across the valve for primary Cetricleaner
pump which accounts to more than 30 % of the pump head. As pump
power is directly proportional to the operating head of the pump, there is
good potential to save energy.

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This energy loss can be prevented by varying the capacity of the pump
according to the requirement. This can be achieved by installing variable
frequency drive to the pump. The flow of the pump can be varied by
varying the speed of the pump using a Variable frequency drive. By
reducing the speed of the speed of the pump, the required flow can be
maintained without closing the throttle valve.
Recommendation
We recommend the following:
Install Variable Frequency Drives for the primary centricleaner pump in
pulp mill
What is the feedback to the VFD???????????????
Vary speed of pump to maintain required flow
Benefits
The annual savings of Rs. 8.80 Lakhs can be achieved by implementing
this project. The investment required is Rs. 8.0 Lakhs which is paid back
in 11 months.

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ENERGY SAVING PROPOSAL NO. 6

INSTALL
VARIABLE
FREQUENCY
DRIVES
IDENTIFIED PUMPS IN PAPER MACHINE

IN

During the Detailed Energy Audit conducted at K R Pulp & Papers Ltd.,
Shahjahanpur, the pumping systems were studied for energy saving
potential.
Present Status
Many of the pumps in the paper mill in Unit-II were found to be controlled
through control valves. The flow requirement in the below mentioned
pumps varies on the basis of production levels and the consistency to be
maintained in the respective chests. The pumps would have been
designed for maximum production and hence the flowsflows need to be
controlled to meet the operating production levels. The flow is being
controlled are generally controlled through valves.
Closing of the valveValve throttling creates an artificial resistance to the
flow, additional to the system resistance. This pressure drop across the
valve is a mechanical energy loss which is also included in the work done
by the pump. It is estimated that for these pumps about 10-40% of the
pump power consumption is lost across the valve.
This energy loss can be prevented saved by varying the capacity flow of
the pump according to the requirement without creating any artificial
resistance. This can be achieved by installing variable frequency drive to
the pump.The flow of the pump can be varied by varying the speed of the
pump using a Variable frequency drive. By reducing the speed of the
speed of the pump, the required flow can be maintained without closing
the throttle valves. As pump power is directly proportional to the
operating head of the pump, there is good potential to for saving power.
Name of Pump

Tag
Power
Valve
kW
Flow
Name
kW
Opening Saving m3/hr
%

Refined SW Chest Pump

PM
181

< 10

28

22

Broke Chest Pump

PM
190

19

48

5.5

77

Bagasse Pulp Chest

Pump

PM
194

24

76

215

Machine Chest Pump

PM
185

45

50

13.5

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CII Sohrabji Godrej Green Business Centre

Thus there is excellent potential to save energy by installing VFDs for the
pumps and varying flow as per requirement.
Recommendation
We recommend the following:
Install Variable Frequency Drives for the identified pumps
Vary speed of pump to maintain required flow as per the process
requirement
Optimize the power consumption of the pumping system
Benefits
The annual savings of Rs. 8.40 Lakhs can be achieved by implementing
this project. The investment required is Rs. 10.00 Lakhs which is paid
back in 15 months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 7

INSTALL
VARIABLE
FREQUENCY
DRIVES
CENTRICLEANER PUMPS IN PAPER MACHINE

IN

During the Detailed Energy Audit conducted at K R Pulp & Papers Ltd.,
Shahjahanpur, the pumping systems were studied for energy saving
potential.
Present Status
The Centricleaner pumps in the paper mill in Unit-II were found to be
controlled through control valves. The flow requirement in the pumps
varies on the basis of production levels.
2.9 bar

0.8 bar

To Primary Screen
through PM 234
2 bar

0.5 bar

Primary Centricleaner

From CL Box

40% open

40% open

4 bar
PM 100

234 kW

3.5 bar
PM 42

75 kW

Closing of the valve creates an artificial resistance to the flow, additional

to the system resistance. This pressure drop across the valve is a
mechanical energy loss which is also included in the work done by the
pump. The necessity for controlling the valve could be due to higher
design head or design flow.
There is pressure loss of 1.1 bar across the valve for primary Cetricleaner
pump which accounts to more than 25 % of the pump head. Similarly,
there is a 1.5 bar pressure loss across the valve for the secondary
centricleaner pump which is more than 40 % of the pump head. As pump
power is directly proportional to the operating head of the pump, there is
good potential to save energy.
This energy loss can be prevented by varying the capacity of the pump
according to the requirement. The flow of the pump can be varied by
varying the speed of the pump using a Variable frequency drive. By
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reducing the speed of the speed of the pump, the required flow can be
maintained without closing the throttle valves .
Recommendation
We recommend the following:
Install Variable Frequency Drives for the identified Centri cleaner
pumps
Vary speed of pump to maintain required flow
Optimize the power consumption of the pumps
Benefits
The annual savings of Rs. 43.0 Lakhs can be achieved by implementing
this project. The investment required is Rs. 19.5 Lakhs which is paid
back in 6 months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 8

AVOID THE PRESSURE DROP ACROSS FEED CONTROL

VALVE BY OPERATING BFP WITH VFD IN UNIT 1
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur detailed study was carried out on the operation of boiler
feed pump in unit-1 for any possible savings.
The design specification of the boiler feed pump is as follows
Flow

30 m3/hr

Head

600 m

Rated Power

90 kW

No. of stages

9 stages

A schematic diagram of the existing setup is as shown:

Each feed control valve controls the quantity of the flow w.r.t the boiler
drum level. It is observed that the control valve open percentage is
varying from 45 to 50%.
The common header pressure is 60 kg/cm 2 and the drum pressure is
around 45 kg/cm2. Because of the severe throttling, there is huge
pressure drop across the feed control valve. Approximately, 10 kg/c m2 is
the pressure drop is taking place across the control valve .

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Boiler drum level is being controlled by three element control valve. This
automatic flow based control valve operates based on the level of the
boiler drum. As per the drum level the open % of the control valve varies.
Flow controlling with the control valve is not an energy efficient
mechanism. The loss happening across the control valve can be
minimised / reduced by reducing optimizing thethe speed of the pump
with the help of VFD.
As the pump is already installed with VFD and running in manual mode.
Power consumption of the pump can be optimized by operating the VFD in
auto mode.
Recommendation
We recommend to
Operate the pump with a closed loop feedback to the VFD
o Option 1: Feedback can be same that of to the valve (3
element signal)
o Option 2: Feedback can be pressure difference of 2 kg/cm 2
across the control valve
Benefits
By implementing the above recommendation annual savings of Rs 4.0
Lakhs will be achieved. This requires an investment of Rs 4.50 Lakhs for
VFD, which will be paid back with in 14 months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 9

AVOID
PASSING
THROUGH
MINIMUM
RECIRCULATION LINE BY INSTALLING MULTISTAGE
DRAG VALVES FOR BOILER FEED PUMP IN UNIT 1
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur CII and plant team jointly taken the flow and pressure
measurements of all pumps was carried out for possibility of reducing the
power consumption in detail. The observations made during the energy
audit are given below.
Present status
One BFP is in continuous operation for supplying feed water to boiler
drum from the deareator. Automatic Recirculation valves (ARVs) are
installed to protect the pump when the flow happening through the pump
is less than 30% of its rated capacity. These valves open and discharge
high pressure feed water to de-aerator.
Because of higher operating pressure differences across these valves,
normal ARVs tend to erode faster. To ascertain if any erosion has taken
place for the ARVs for feed pumps connected to Boiler, CII and plant team
jointly measured the re-circulation flow is measured.
The measured re-circulation flow in BFP-1 is 10.0 m 3/hr & BFP-2 is 9
m3/hr. The percentage of passing is around 28%.

Re-circulation results in increased power consumption for the same useful

work done.
What is the solution????????????????
Recommendations
We recommend the following:
Install multi-stage pressure reduction drag valves in lieu of normal
ARVs. These are typically represented as shown below:

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 Pressure reduction for these valves takes place in 12 18 stages. This

purely depends on design.
The erosion rate will be very low for these drag valves and completely
eliminate recirculation for significant amount of time.
Benefits
By installing the multi stage drag reduction valve in the minimum
recirculation line of boiler feed pump will save Rs 9.0 Lakhs. This
requires an investment of Rs 5.0 Lakhs for new valve, which will be paid
back with a simple pay back period of 7 months.

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CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 10

AVOID THE PRESSURE DROP ACROSS FEED CONTROL

VALVE BY OPERATING BFP IN AUTO WITH VFD IN
UNIT 2
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur detailed study was carried out on the operation of boiler
feed pump in unit-1 for any possible savings.
The design specification of the boiler feed pump is as follows
Flow

106 m3/hr

Head

983 m

Rated Power

90 kW

No. of stages

9 stages

A schematic diagram of the existing setup is as shown:

Each feed control valve controls the quantity of the flow w.r.t the boiler
drum level.
The common header pressure is 95 kg/cm 2 and the drum pressure is
around 70 kg/cm2. Because of the severe throttling there is huge
appreciable pressure drop across the feed control valve. Approximately,
22 kg/cm2 is the pressure drop is taking place across the control valve.

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CII Sohrabji Godrej Green Business Centre

Boiler drum level is being controlled by three element control valve. This
automatic flow based control valve operates based on the level of the
boiler drum. As per the drum level the open % of the control valve varies.
Flow controlling with the control valve is not an energy efficient
mechanism. The loss happening across the control valve can be
minimised / reduced by reducing the speed of the pump.
As the pump is already installed with VFD and running in manual mode.
Power consumption of the pump can be optimized by operating the VFD in
auto mode.
Recommendation
We recommend to
Operate the pump with a closed loop feedback to the VFD
o Option 1: Feedback can be same that of to the valve (3
element signal)
o Option 2: Feedback can be pressure difference of 2 kg/cm 2
across the control valve
Benefits
By implementing the above recommendation annual savings of Rs 27.0
Lakhs will be achieved. This requires a marginal investment of Rs 1.0
Lakh for automation, which will be paid back with in 1 month.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 11

AVOID
PASSING
THROUGH
MINIMUM
RECIRCULATION LINE BY INSTALLING MULTISTAGE
DRAG VALVES FOR BOILER FEED PUMP IN UNIT 2
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur flow and pressure measurements of all pumps was
carried out for possibility of reducing the power consumption in detail. The
observations made during the energy audit are given below.
Present status
One BFP is in continuous operation for supplying feed water to boiler
drum from the deareator. Automatic Recirculation valves (ARVs) are
installed to protect the pump when the flow happening through the pump
is less than 30% of its rated capacity. These valves open and discharge
high pressure feed water to de-aerator.
Because of higher operating pressure differences across these valves,
normal ARVs tend to erode faster. To ascertain if any erosion has taken
place for the ARVs for feed pumps connected to Boiler, re-circulation flow
is measured.
The measured re-circulation flow in unit-2 BFP-1 is 5.0 m 3/hr & BFP-2 is
5.5 m3/hr. The percentage of passing is 4.5%.
Re-circulation results in increased power consumption for the same useful
work done.
Recommendations
We recommend the following:
Install multi-stage pressure reduction drag valves in lieu of normal
ARVs. These are typically represented as shown below:

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CII Sohrabji Godrej Green Business Centre

 Pressure reduction for these valves takes place in 12 18 stages. This

purely depends on design.
The erosion rate will be very low for these drag valves and completely
eliminate recirculation for significant amount of time.
Benefits
By installing the multi stage drag reduction valve in the minimum
recirculation line of boiler feed pump will save Rs 4.80 Lakhs. This
requires an investment of Rs 8.0 Lakhs for new valve, which will be paid
back with a simple pay back period of 20 months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 12

AVOID
RECIRCULATION
OF
CONDENSATE
BY
INSTALLING VFD AND REDUCING SPEED OFIN
CONDENSATE EXTRACTION PUMP
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, operation of condensate extraction pump is studied in
detail for possible energy savings.
Present Status
Two pumps are installed for pumping condensate, one pump is running
continuously.
A schematic diagram of the existing setup is as shown:

Condensate extraction pump is pumping water from hot well to deaerator.

Hot well level is being controlled with help of recirculation valve. At
present, the recirculation valve is opened to 93% open and the maximum
of the condensate is being recirculated back to the hot well.
The measured condensate flow is 26m3/hr and the recirculation flow is
24m3/hr.
Recirculation is the most ineffective method of controlling flow. Therefore,
should be avoided to save the power consumption of the pump.

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CII Sohrabji Godrej Green Business Centre

Generally, recirculation is provided to maintain sufficient condensate flow

through the steam ejector heat exchanger. Otherwise, operation of steam
ejector will get affected. The required condensate flow through steam
ejector is 35% of design condensate flow of the pump.
At the present condition, more than 90% of the flow is being circulated
back to hotwell. Flow of the condensate flow can be reduced by reducing
the speed of the pump by installing VFD and operating it with hot well
signal. To maintain the required 35% of the condensate flow, VFD should
be locked at minimum frequency level of 22 Hz.
Recommendation
We recommend to
Install VFD for the pump
Operate it directly based on the hot well level signal
Lock the minimum frequency level at 22 Hz
Close recirculation valve completely and the valve should open only
when the frequency falls below 22 Hz
Benefits
Implementation of the above recommendation will save Rs 2.40 Lakhs
annually. This requires a marginal investment of Rs 1.0 Lakh for VFD &
automation, which will be paid back with a simple pay back period of 5
months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 13

REDUCE AIR INGRESS IN UNIT-1 BOILER FLUE GAS

PATH
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, oxygen measurements of flue gas path were taken
operation of condensate extraction pump is studied in detail for possible
energy savings.
Present Status
In unit-1 boiler, oxygen level was found to be higher across the flue gas
path, which indicates that there is an infiltration across flue gas path.

Air infiltration increases the load on the induced draft fan which in turn
increases the power consumption of the fan. The % infiltration across the
flue gas path is given in the below table:
Description / Boiler number

2.5 MW
AFBC

Boiler Outlet

4.6

Economizer Outlet

7.7

ID Fan outlet

10.3

Calculation
Air ingress across the total system

% infiltration in boiler

=
=

15.70

10.3 4.6 x 100

20.9 4.6
34.8%

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The % air infiltrations in the boiler isinfiltrations in the boiler are 34%.
Major areas of leakage are Air pre-heater, cyclones and washer. There is
good potential to decrease the power consumption of the ID fan by
arresting the air infiltration across the APH, cyclones and washer. Maintain
the overall infiltration to be less than 10 %.
Checking the air leakages with the leak detector and arresting the
leakages for avoiding the % air infiltration in APH, cyclones and washer.
Recommendation
We recommend to arrest the air infiltration in the boiler flue gas path by
arresting the leakages in APH, cyclones & washer.
Action plan
Form a leakage reduction team
Procure a combustion analyzer & monitor infiltration levels regularly
Identify and arrest leakages points
Maintain the overall infiltration at less than 10%
Do the periodic inspection of once in a fortnight
Benefits
Reducing the air ingress in unit-1 boiler flue gas path will save Rs 2.0
Lakhs annually. This requires a marginal investment.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 14

OPERATE ALL THE COOLING TOWER FANS AND

REDUCE THE SPEED BY INSTALLING VFD FOR ALL
FANS IN UNIT-2 POWER PLANT
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, operation of cooling tower fans in unit-2 power plant
were studied in detail for possible energy savings.
Present Status
Cooling water for condenser & other heat exchangers is being cooled with
the help of a single same cooling tower.
The schematic of the operation of the cooling tower is as shown below:

Cooling tower has three cells with one fan each cell. All the three cells are
being used for heat exchange. During favorable conditions, plant team is
switching off the fans one by one. At present, only one fans is running
continuously.
Switching off one fan leads to partial savings as the heat transfer area is
not fully utilized. By switching on all the fans, flow handled by each fan
reduces. By installing VFD and reducing the speed of all the fans reduces
the power consumption of the fans drastically.
Recommendation
We recommend to
Install VFD for all the fans
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CII Sohrabji Godrej Green Business Centre

 Operate VFDs of the fans with the cold well temperature feedback of
300C
Increase and decrease the speed of all the fans based on cold well
temperature.
Benefits
Operating all the cooling tower fans and reducing the speed by
installing VFDs for all the fans in unit-2 power plant will save Rs 4.0
Lakhs annually. This requires an investment of Rs 3.0 Lakhs, which
will be paid back with a simple payback period of 9 months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 15

REDUCE EXCESS FLOW THROUGH HEAT EXCHANGERS

IN UNIT-2 POWER PLANT
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, operation of cooling water pumps in unit-2 power plant
were studied in detail for possible energy savings.
Present status
Two cooling water pumps are operating continuously to circulate cooling
water through heat exchangers (turbine condenser, lube oil cooler,
generator cooler). Cooling water flow & temperature across heat
exchangers measurements were taken to study the cooling water circuit.
The schematic operation layout is shown as below

The temperature difference across heat exchangers is lesser compared to

the general design of any heat exchanger. And the details are given as
below
The operating and recommending values of delta T for various heat
exchangers are as given below:
Sl. No. Heat exchanger

Condenser

T
Recommended
operating
T
4

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Lube oil cooler

Generator air cooler

This lower temperature difference across heat exchangers indicates

excess flow through the circuit that can be reduced. The power
consumption of any pumping system is directly proportional to the flow
hence the excess flow is leading to excess power consumption in the
pump.
Cooling water flow can be reduced by installing VFDs for two cooling
water pumps and reducing the speed of the pump based on the cooling
tower inlet & outlet temperature difference feedback (set point of 60C).
When it is operated with VFD, cooling water flow in the entire circuit will
come down. Except lube oil cooler heat exchanger, heat load on the
remaining heat exchangers (condenser & generator cooler) directly
depends on the turbine load. At lower loads, cooling water through lube
oil cooler reduces and it may affect the performance of heat exchanger.
Therefore, lube oil cooler can be installed with auto flow control valve
controls flow based on the cooling water temperature difference across
the heat exchanger feedback (set point of 50C).
Before implementing this proposal, a trial can be taken by throttling the
pump in steps of 10% till the temperature difference across heat
exchanger reaches 60C.
Recommendation
We recommend to
Install thermocouples in the inlet & outlet of lube oil heat exchanger
Install auto flow control valve for lube oil cooler heat exchanger
o Operate it based on the cooling water temperature difference
across lube oil cooler with a set point of 50C
Install VFD for two cooling water pumps
o Operate it in closed loop with temperature difference of
cooling tower inlet and cold well temperature (set point of
60C)
Benefits
Implementing the above recommendation will save Rs 32.0 Lakhs. This
requires an investment of Rs 8.0 Lakhs, which will be paid back with a
simple payback period of 3 months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 16

SWITCH OFF ONE CONDENSATE EXTRACTION PUMP

COMPLETELY IN UNIT-2 POWER PLANT
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, operation of condensate extraction pumps in unit-2
power plant were studied in detail for possible energy savings.
Present status
Three pumps were installed to pump the condensate to deaerator. All the
three pumps are running continuously to meet the requirement.
The design specification of the condensate extraction pump is as follows
Flow

11 m3/hr

Head

75 m

Rated Power

15 kW

A schematic diagram of the existing setup is as shown:

Maximum steam load on the condenser is 20TPH. Therefore, maximum

quantity of condensate to be pumped is 20m 3/hr. As one pump is
designed to deliver 11m3/hr, two pumps are sufficiently enough to meet
the requirement. At present, three pumps are operating continuously to
pump the condensate and the flow is being controlled by hot well level
control valve.

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Therefore, potential exists to save the power consumption of the

condensate pumping by switching off one pump.
Recirculation line is provided in the condensate line after the steam
ejector back to hot well, which will open during the starting of the turbine
& at lower loads. At present condition, the valve is completely closed.
Flow in this line is measured and found to be 1.4m 3/hr, indicates there is a
passage in this line.
Therefore, potential exists to save the power consumption of the pump by
avoiding the passage in the recirculation line.
Recommendation
We recommend to
Switch off one pump completely
Avoid passage in recirculation line by maintainingcorrecting the
recirculation valve
Benefits
Switching off one condensate pump completely will save Rs 3.20 Lakhs
annually. This doesnt require any investment.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO.17

AVOID PRESSURE DROP ACROSS HOT WELL LEVEL

CONTROL VALVE AND MAINTAIN HOT WELL LEVEL
DIRECTLY BY INSTALLING VFD
During the course of the detailed energy audit at KR Pulp & Papers
Limited, Shahjahanpur, the turbine & its auxiliaries in unit-2 were
studied in detail for possible energy saving.
Present Status
The condensate extraction pump in unit-2 is rated for 11 m 3/hr flow, 75 m
head and has a motor rating of 15 kW. The pump consumes 9 kW of
power during its operation.
A schematic diagram of the existing setup is as shown:

The automatic flow based throttle valve operates based on the level of the
condenser. When the condenser level reaches minimum level, the throttle
valve closes and when condenser reaches maximum level, the throttle
vanve valve opens.
As throttling is an ineffective method of controlling flow. Power gets lost in
the form of pressure drop across control valve.
The estimated pressure drop across different equipment in the circuit is as
follows:
Sl. No.

Parameters

Pressure drop
(kg/cm2)

Steam ejector

0.5

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CII Sohrabji Godrej Green Business Centre

Static head + Losses

3.0

Deaerator

2.0

Total

5.5 kg/cm2

The pump discharge header pressure is 7.8 kg/cm 2. Therefore, pressure

drop of more than 2 kg/cm 2 is happening across the control valve. Thus
there is good potential to avoid the pressure drop by installiing VFD and
control the speed of the pump as per the level.
Control the capacity of the pump based on the level in the condenser.
Open the control valve fully and give the condenser level signal to the
VFD and increase the rpm of the CEP pump when the level of the
condenser increase and vice versa and operate the VFD in closed loop.
Therefore, there exists potential to save the power consumption of the
pump by avoiding the pressure drop across hot well level control valve.
Recommendation
We recommend to
o

Install VFD for two condensate extraction pumps

Open the control valve 100%

Operate the VFD in closed loop with the hot well level

Avoids pressure drop of 2 kg/cm2 across control valve

Benefits
Implementing the above recommendations will save Rs 2.0 Lakhs
annually. This requires an investment of Rs 1.50 Lakhs for VFDs for two
pumps, which will be paid back with a simple payback period of 9
months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 18

AVOID OPERATING ONE PUMP BY PUMPING DM

WATER DIRECTLY TO DEAERATOR AFTER PASSING
THROUGH THE FLASH STEAM HEAT EXCHANGER IN
PAPER MILL SECTION
During the course of the detailed energy audit at KR Pulp & Papers
Limited, Shahjahanpur, the DM water pumping system to deaerator
was studied in detail for possible energy saving.
Present status
DM water is being pumped to make up the deaerator. Firstly, DM water is
being pumped from DM water tank through flash steam heat exchanger
(at a height of 12m) in the paper mill section. After passing through the
paper mill section, the DM water is being pumped to deaerator (at a
height of 17-20m) by a pump near DM water tank. The DM water flow is
being controlled by deaerator level control valve which is operating with
opening 50-60%.

Instead of pumping DM water back to ground level and then pumping to

deaerator, DM water can be directly pumped to deaerator after passing
through flash steam heat exchanger in paper mill section.
The estimated pressure drop across various equipment in the circuit is as
follows:
Sl. No.

Parameters

Pressure drop
kg/cm2

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CII Sohrabji Godrej Green Business Centre

Heat exchanger

0.5

Static head + Losses

2.5

Deaerator

2.0

Total

5.0 kg/cm2

The estimated pressure drop in the circuit to pump DM water from DM

water tank to deaerator is 5 kg/cm2. The DM water transfer pump can
meet this requirement.
The design specification of the DM transfer pump is as follows
Flow

50 m3/hr

Head

50 m

Rated Power

15 kW

DM water can be pumped directly to deaerator by laying a direct line from

flash steam heat exchanger outlet pipe line (at a height of 12m) to the
DM water line at a height of 15m before deaerator level control valve. By
doing this, operation of one pump can be completely eliminated.
Deaerator level is being controlled with help of control valve, which is an
ineffective way of controlling flow. Some of the power will be lost in
overcoming the pressure drop across the control valve. Instead, flow can
be controlled by installing VFD and operating directly with deaerator level
signal.
Recommendation
We recommend to
Connect heat exchanger outlet to second pump outlet line
Switch off the second pump & keep it as a standby
Install VFD for the pump
Maintain the deaerator level directly with VFD with level feedback
Open the control valve 100%
Benefits
Implementing the above recommendations will save Rs 3.20 Lakhs
annually. This requires an investment of Rs 1.0 Lakhs, which will be paid
back with a simple payback period of 4 months.
Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 19

OPTIMIZE THE OPERATION OF INSTRUMENT AIR

COMPRESSORS IN UNIT -2
During the detailed energy audit at KR Pulp and Paper the compressors
were studied in detail and the following observations have been made.
Installed capacity
In paper plant: 5 x 380 CFM screw compressor
o 2 nos with 55 kW rated motor
o 3 nos with 75 kW rated motor
In Power Plant: 2 x 18.5 kW screw compressor
In operation Paper plant
2 nos of 55 kW compressor
1 no of 75 kW compressor
In operation Power plant
1 no of 18.5 kW compressor
The pressure setting of all the identified compressors is as follows:
Capacity
Actual
requirement

Pressure

Suggested
kW Savings
%
Pr
(Pr reduction
Reduction
& Unloading)
Loading Unloading reduction

CFM

%
Unloading

Compressor-1
at PM

380

0.00

380.00

6.5

6.90

5.5

15.6

Compressor-2
at PM

380

0.00

380.00

6.5

6.90

5.5

15.6

Compressor-3
at PM

380

75

95.00

6.5

6.90

5.5

15.6

28

Actual Working pressure required for different applications

For control valve operations, the instrument air requirement is in
between 1.5 3.5 bar
For press roll machine the pressure requirement is

6 bar

There exists a good saving potential to optimize the pressure settings of

the instrument air compressors.

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CII Sohrabji Godrej Green Business Centre

Recommendation
Interconnect the compressed air pipe lines of both paper plant and
power plant and stop the compressor in power plant
As we can see from the above table that the unloading percentage
of compressor-3 is very high, it would easily accommodate the
compressed air requirement from power plant.
Install VFD in Compressor-3 and reduce the operating pressure
setpoint to 5.5 bar. This would have two benefits
o It would reduce the operating pressure thereby reducing the
operating power
o It would completely avoid the loss due to unloading
Press roll user requires 6 bar pressure, hence to cater its need, a
small booster compressor needs to be installed near the user
Benefits
The annual energy saving potential is Rs. 16.40 Lakhs. This will require an
investment of Rs. 10.00 Lakhs, which will have a simple payback period of
7 months.

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ENERGY SAVING PROPOSAL NO. 20

OPTIMIZE THE OPERATION OF INSTRUMENT AIR

COMPRESSORS IN UNIT -1
During the detailed energy audit at KR Pulp and Paper the compressors
were studied in detail and the following observations have been made.
Installed capacity
2 x 380 CFM screw compressor
o 2 nos with 55 kW rated motor
In operation Paper plant
1 nos of 55 kW compressor
The pressure setting of all the identified compressors is as follows:
Capacity
Pressure

CFM
Compressor1

Suggested
kW Savings
%
Actual
Pr
%
(Pr reduction &
Unloading requirement Loading Unloading reduction Reduction Unloading)

380

24

289.25

6.3

5.5

20.2

15.0

Actual Working pressure required for different applications

For control valve operations, the instrument air requirement is in
between 1.5 3.5 bar
For press roll machine the pressure requirement is 6 bar
There exists a good saving potential to optimize the pressure settings of
the instrument air compressors.

Recommendation
Install VFD and reduce the operating pressure setpoint to 5.5 bar.
This would have two benefits
o It would reduce the operating pressure thereby reducing the
operating power
o It would completely avoid the loss due to unloading
Press roll user requires 6 bar pressure, hence to cater its need, a
small booster compressor needs to be installed near the user
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Benefits
The annual energy saving potential is Rs. 5.00 Lakhs. This will require an
investment of Rs. 6.00 Lakhs, which will have a simple payback period of
15 months.

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ENERGY SAVING PROPOSAL NO. 21

OPTIMIZE VACUUM PUMP OPERATION IN UNIT-2

The vacuum system in Unit-2 was studied in detail and the following
observations were made.
Current System
There are 11 numbers of vacuum pumps installed in paper machine to
cater its needs. All are connected to a common header but are isolated
from each other with the help of valves. The vacuum pump connected to
wire mesh user is throttled at the user ends but all other vacuum are
completely open.
Observations:
The vacuum requirement of various sections of paper machines are as
shown below:
Vacuum
Pump No

User

Source Pr

User Pr

Delta P
120

Wire bivac

300

120,140,150, 150,
140,180

Trivac

250

180,180

70

Couch Roll (Low zone)

280

240

40

Couch Roll (High zone)

540

520

20

580

420

160

580

420

160

500

340

160

5
Suction Press (high zone)
6
7

Pickup Roll

Suction Press (low zone)

Pickup felt, 3 press felt, Uhle

box

10

390
60
380

320

440

310

130

440

310

130

1&4 press felt, uhle box

11

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As seen in the table above, the pressure drop between the user and the
pump in each area is hugevery high. The possible reason for the same
could be

Improper line sizing

Moisture carryover to the vacuum pump due to non-availability of

separators

Improper water evacuation from separators leading to moisture

carryover

Recommendation
As it is observed that there is a huge high pressure drop between the user
and the pump, it is evided that the line sizing in each user is not proper. It
is highly recommended to call a third party to conduct a detailed
engineering study only for the pipe sizing so that it could be brought
down to acceptable limits. While conducting the study the following points
needs to be kept in mind

The pressure drop across the separator should be a maximum of

50mmHg

The pressure drop across the complete pipeline should not be more
than 20 mmHg

A detailed study on the pipe sizing alone should be done and the
pressure drop should be brought down to acceptable limits

Also VFD needs to be installed for all vacuum pumps and vacuum needs
to be maintained based on the user requirement from DCS.
Savings
The saving potential is calculated only for those pumps as shown in the
table below where the pressure drop between the source and the user is
high.
Vacuum
Pump No
1
5
6
7
10
11

User
Wire bivac
Suction Press (high zone)
Pickup Roll
1&4 press felt, uhle box

Source Pr in
mmHg

User Pr in
mmHg

Delta P in
mmHg

300
580
580
500
440
440

Max 180
420
420
340
310
310

50
90
90
90
60
60

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In the above table, the pressure drop (Delta-P) is inclusive of 50mmHg

pressure drop across the separator and 20mmHg pressure drop in the
piping.

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Savings calculation
Sample calculation for Wire Bivac
20(piping)

300180-50(separator)-

= 50mmHg
=

Pressure

drop

Power

consumption
Head developed
= 50mmHg x 102 kW
300 mmHg
= 17 kW
Similarly, saving for others is shown in the table below
Vacuum
Pump
No
1
5
6
7
10
11

Source
Pr in
mmHg

User

Wire bivac
Suction Press (high
zone)
Pickup Roll
1&4 press felt, uhle
box
Total

300
580
580
500
440
440

User Pr
in
mmHg
Max
180
420
420
340
310
310

Delta
P in
mmHg

Power
consumption in
kW

50
90
90
90
60
60

102
180
147
141
174
153

savings
in kW
17
28
23
25
24
21
138

Benefits
The annual energy saving potential is Rs. 55.20 Lakhs. This will require
an investment of Rs. 25.00 Lakhs, which will have a simple payback
period of 6 months.

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ENERGY SAVING PROPOSAL NO. 22

REPLACE V BELT WITH COGGED FLAT BELT IN

IDENTIFIED EQUIPMENTS
Background
During the detailed Energy Audit conducted at K.R. Pulp and paper,
various equipments were studied for possible energy saving opportunities.
Some of the auxiliary bag filter fans, pumps, compressors and blowers
uses conventional V-belt drives for power transmission. Use of V belts
causes some energy losses. There is a power transmission loss of about
7% - 8%, when the V-belts WEDGE IN and WEDGE OUT of the grooved
pulleys.
The latest trend in the industry is to use synthetic flat belt drives or
cogged belts in place of the V-belt drives. These belts have the following
advantages:

Non-hygroscopic prevents elongation due to moisture absorption

Ensures better grip on the pulley

Energy savings of at least 5%

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From the above graph it is clear indication that the flat belt is operating at
98% efficiency when the drive is 100% loaded, but V-belt is operating at
the 94% efficiency only. There exists good potential to replace V-belt with
the flat belt drives.
These drives are ideal for steady load applications, such as fans,
compressors, and blowers. However, it should be ensured that the area
around the equipment is free from oil or water spillage.
Also, proper preventive care must be taken to ensure proper alignment
between the drive and driven equipment.
Recommendation
We recommend converting the identified V-belt drives into flat belt drives
for the major auxiliary bag filter fans. The list of identified fans is given
below. Ensure that the area around the equipment is free from oil or
water spillage (cover could be used for protection)
S.No
1
2
3
4
5
6
7
8
9
10
11

Equipment
Mixing Chest
Machine Chest
Pulp dump chest
Agro pulp chest
Vacuum pump - cautisizing plant
ETP drain pump
Bagass chest agitator
Vacuum pumps - 11 nos
Unit-1 Boiler 7TPH FD Fan
Unit-1 Boiler 7TPH ID Fan
Vacuum pumps - 5 nos
Total

Operating kW
33
15
33
30
130
45
55
1398
28
23
366
2156

Saving Potential
1.32
0.6
1.32
1.2
5.2
1.8
2.2
55.92
1.12
0.92
14.64
86.24

Savings
On a conservative basis 4% saving is calculated for the identified
equipments
Benefits
The annual energy saving potential is Rs. 34.40 Lakhs. This will require
an investment of Rs. 20.00 Lakhs, which will have a simple payback
period of 7 months.

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ENERGY SAVING PROPOSAL NO. 23

OPTIMIZE THE CONDENSATE RECOVERY CIRCUIT IN

PAPER AND EVAPORATOR SECTION
During the detailed energy audit at KR Pulp and Paper, the sondensate
recovery circuit was studied in detail and the following observations were
made.
Present status

The following observations were made in the evaporator and paper

section
Steam consumption in evaporator section
Average

- 13 TPH

Recovery

- 55%, 7TPH

Steam consumption in paper machine

Average

- 22 TPH

Recovery

- 75%, 16 TPH

The condensate levels in flash tank and vacuum tank at paper machine
section is maintained by individual pumps associated with each tank with
the help of control valves. The condensate collected in each tank is
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pumped into a recovery tank through a common header, which is again

pumped into the deaerator with the help of a pump as shown in the figure
above.
The condensate from the recovery section is also sent to the recovery
tank which is at 108 deg C.
Observation
Paper Machine: At paper machine section, the individual controls valves
are heavily throttled to the tune of 26% and 49%, which is due to
mismatch between the design and operating condition.
Evaporator Section: As the condensate which is entering the recovery
tank from the evaporator section is at 108 deg C, some portion of the
condensate flashes into steam which is vented into the atmosphere
Recommendation
It is recommended to connect the condensate line from both evaporator
section as well as from paper machine section directly into the deaerator
as indicated by dotted line in the figure below.

Install VFD in pumps associated with Flash tank and vacuum tank and the
logic to VFD would be to maintain the tank level.
Stop the pump that transfers condensate from the recovery tank to the
deaerator
The savings with this modification is as follows
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 The energy loss associated with the pressure drop across the control
valves in Flash tank and vacuum tank pumps can be completely
eliminated.
As the new operating parameters will be matching with the design
values, the pump will be working with better efficiency
Stopping of the recovery tank pump will be saving power to the
tune of 11 kW (operating power)
Flash steam generated from 10TPH of condensate would be
= 152 kg/ hr
Hence 152 kg/ hr of flash steam could be avoided if directly introduced to
deaerator, this would inturn reduces the extraction steam to the deaerator
from the turbine.
Install new pump at the evaporator section, the new pump will have a
specification which will aid the condensate to be sent directly into the
deaerator. The new specification will be as follows
Capacity

-20 m3/ hr

Head

- 50 mtr

Motor

- 5 kW

Savings
Stoppage of recovery tank pump

= 11 kW

Benefits
The annual energy saving potential is Rs. 4.40 Lakhs. This will require
an investment of Rs. 4.00 Lakhs, which will have a simple payback
period of 11 months.

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Observation

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OBSERVATION NO. 1

REPLACE T12 AND T8 LAMPS WITH ENERGY

EFFICIENT T5 LAMPS
During the detailed energy audit at KR Pulp and Papers,
Shahjahanpur, it has been observed that there are T12 and T8
conventional fluorescent lamps with electronic ballasts are installed for
illumination in the plant at different locations.
Background
Majority of the fluorescent lamps in the plants are of 36W conventional
fluorescent lamps with electronic ballasts. The latest trend is to install
energy efficient T5 lamps. The T5 lamps have the following advantages in
comparison to conventional fluorescent lamps.
Advantages of T5 lamps over conventional lamps
Energy efficient T5 Lamps are designed with special powder coating
inside the lamp, hence operate at high efficacy i.e. lumens / watt,
converting more quantity of electromagnetic waves to visible light
High efficacy (Lumens / Watt)
Environmental friendly (Low Hg content, 3-4 mg)
Reduces work related headaches
Reduces sick building syndrome
The below mentioned table gives an overall comparison of T12, T8 and T5
lamps
Lamp
38mm dia,
1200mm long
(T12)
26mm dia,
1200mm long
(T8)
16mm dia,
1160mm long
(T5)

Power
Consumed (W)

Efficacy
(Lumens/Watt)

Lamp Life
(hours)

38

68

12000

36

75

15000

28

103

16000

Recommendation

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There is a good potential to replace existing T12 and T8 lamps with T5

lamps. It is recommended to replace T12 and T8 lamps with energy
efficient T5 lamps. The savings by replacing T8 and T12 lamps with
electronic ballasts with T5 will be around 8 W and 12W respectively.

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OBSERVATION NO. 2

REPLACE EXISTING HPSV AND HPMV LAMPS WITH

ENERGY EFFICIENT LED LAMPS
Latest Design Trend in Lighting
The latest trend in lighting is to utilize the right amount of pupil lumens.
The pupil lumens also considers the variation in sensitivity of the eye in
relation to the environment. The sensitivity of the eye varies between
daytime lighting and night time lighting as shown in the figure below.

The scotopic curve and photopic curve mention the day time lighting
and night time lighting respectively. The eye colour is more sensitive
towards the green colour for photopic curve and is correspondingly for
blue colour in the case of scotpic vision. This data of relative sensitivity of
eye helps us in designing the correct colour of the lamp required for
different lighting conditions. The scotopic vision is well suited for night
environment such as street lights, basements, closed rooms where
sunlight is not available. The photopic on the other hand will be closer to
day time environment.
The earlier system of lighting wherein the quantity of light delivered was
mentioned in lumens and not in pupil lumens considered only the photopic
curve.
Comparison of Lamps
The table below shows a brief comparison of all the lamps. The latest
trend is to go for LED lamps. These LED lamps have very high scotopic to
photopic ratio of 2.4. This is very well suited for street lighting and
lighting in dark surroundings.
S.No

Parameter

LED

Metal
Halide

HPSV

CFL

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FTL T5

INDUCTION

Life

50000
Hours
+

Lamp
Efficacy

90-100

Lumen
30% @
Depreciation 50,000
Hours

10,000- 15,00012,000 20,000

Hours
Hours

60008000
Hours

1200015000
Hours

80000
Hours

65 to
90

90-140

60-65

70-104

60-80

Upto
40% @
12000
Hours

Upto
40% @
15000
Hours

1520%
till end
of life

1520% till
end of
life

15-20% till
end of life

CRI

70-90

65-90

22- 25

65-85

60-95

>80

Color

Variety

White

Yellow

White

White

white

4000k5000k

2100K3000K

30006000K

30006500K

2700
-6500K

1.6

0.62

1.32.2

1.3-2.2

1.85

color
2100temperature 10000K

S/P Ratio

upto
2.4

Warm up
time 90%
Lumens

Instant

Flicker free

yes

5
4
1
10-50
minutes minutes minute Seconds

No

No

No

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No

Instant

yes

Advantages of LEDs
Lower energy consumption
1W/LED
Longer lifetime (50,000 to 100,000 hrs)
High Scotopic to photopic ratio
Smaller size
Faster switching
Greater durability and reliability
Good CRI > 80
The HPSV lamps used for lighting have very low scotopic to photopic ratio
of 0.62 and even though the lamp efficacy is high, 90 140 lumens/watt,
considering only lumen levels and not pupil lumens. Multiplying this
efficacy with the scotopic to photopic ratio from the table will give us the
pupil lumens/watt which is 56 87 pupil lumens/watt. Comparing with
LED the actual pupil lumen/watt will be around 216 240 pupil
lumens/watt, which gives us a good opportunity to replace the existing
HPSV lamps with LEDs. In order to achieve the same amount of pupil
lumens the power consumed by LED is atleast 50% lesser in comparison
to HPSV lamps.
Similarly HPMV lamps can also be replaced with LEDs. Replacement of
sodium vapour and mercury vapour lamps with LEDs are mentioned in the
table below.
Sodium Vapour

Mercury Vapour

LED

75 W

125 W

33 W

150 W

250 W

70 W

250 W

400 W

120 W

Recommendation
It is recommended to replace HPSV and HPMV lamps with LEDs. The
recommended values for standard lamp sizes are mentioned in the table
above.

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OBSERVATION NO. 3

HARMONICS MEASUREMENTS
Background
As a part of theDuring the detailed energy audit detailed energy audit at a
harmonic survey was conducted at K R Pulp and Papers Limited,
Shahjahanpur for major feeders. Harmonic levels are measured using a
Harmonic analyzer at all the PCC (point of common coupling) and the values
are enclosed.
To elaborate the basics of harmonics, a brief write up is enclosed.
What are Harmonics?
A normal supply system operates at 50 Hz power frequency. However, due
to any reason if voltage / current signal of higher frequencies (higher than
50 Hz) are introduced in the supply system, they are termed as
harmonics, e.g. if a waveform of 250 Hz is introduced in a 50 Hz system,
it is termed as 5th harmonic.
Any non-sinusoidal wave which is periodic in nature can be
mathematically decomposed into sine waves of fundamental and higher
frequency which are multiple of the fundamental frequencies.
How does it get into Power Systems?
In case of a linear load the current wave shape are of the same nature as
the applied voltage wave form, for e.g. if we apply a sine wave across
passive elements like resistor, reactor or capacitor, the resulting current
flowing into the circuit is also sinusoidal in nature.
The phase angle between the applied voltage and current depends on
whether the resultant circuit is inductive, resistive, capacitive. Please refer
to Fig. 1 below.
V

I
t

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Fig. 1: Voltage and Current in a Linear Load

However, when the same sinusoidal voltage waveform is applied across a
non-linear device such as diode or thyristors the resultant current is no
more a sine wave. Please refer to Fig. 2 below.

t
I

Fig. 2: Voltage and Current in a Non - Linear Load

This non-sinusoidal waveform, using Fourier Transform can be split into a
fundamental current superimposed with current waveform of higher
frequencies such as 5th, 7th, 11th, etc. Please refer to Fig. 3 below .

Fig. 3: Components of Distorted Wave

The fundamental current flows from the source (alternator) towards the
load. However, the harmonic current, since they are generated by non
linear loads, flow from the load end towards the source, e.g. thyristorised
drives will draw its fundamental current from the alternator while the
harmonics generated by the thyristorised drives will flow from the drives
(which acts as a source of harmonics) towards the network.
In this process, the injected harmonic current passes through the end users
distribution transformer, its main incomer power transformer, cables,
overhead wires upto the generating station. In case there are other loads
connected to the same feeder which is normally applicable to most of the
power distribution systems, the harmonic tend to flow into them in case
they offer a lesser impedance compared to the network, for example,
capacitors offer a very low impedance to higher frequency current and
hence tend to absorb a lot of harmonics from a polluted supply system.

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Some of the loads which are used in a modern power system which
generate harmonics are as below:
Any loads which uses a non linear solid-state device like diode,
thyristor, IGBT, etc. e.g. AC / DC drives, induction furnaces, rectifiers,
etc.
Electronic Ballast
Ferromagnetic Devices like
Transformers operating near saturation level
Induction heating equipment
Arcing Devices
Arc-Discharge lighting, e.g., fluorescent,
Electric arc furnaces
Thyristor welding machine
What are the effects of harmonics?
The harmonics have a multifold effect on various network elements present
in a system. Whenever a harmonic current flows through an equipment,
It causes additional losses due to its higher frequency, devices such as
motors, transformers, etc. which has a laminated core have higher
losses due to higher frequency of the harmonic current.
In cables, the harmonic current tend to flow through the outer skin of
the conductor due to skin effect and results in heating of these
conductors.
Harmonics can cause nuisance tripping of the relays and failure of
capacitors installed in distribution system for power factor
improvement.
Certain harmonic currents (for e.g. 5th harmonic) has the reverse
phase sequence which means any electro mechanical device used for
metering will not register true values. Similarly, in a polluted network a
normal induction motor may not develop necessary torque because of
harmonic current generating a torque in the reverse direction.
Higher order harmonics interfere with telecommunication system also.
Whenever a telephone line runs parallel to a power line having
harmonics, a noise is introduced in the telephone line.
This
phenomenon is known as telephonic interference.

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 A highly polluted voltage may lead to mal operation of devices such as

thyristors, operation of which depend on the zero crossing of the
voltage waveform. This may result in commutation failure in thyristors.
A high harmonic content also results in a low power factor. The angle
between the fundamental component of current and voltage gives the
Displacement Power Factor, whereas, the same between the voltage
and rms current (fundamental and harmonic) gives the total Power
Factor. In a linear load, the P.F. and D.P.F. are same, whereas for the
loads, which generate lot of harmonics, the P.F. is much lower than the
D.P.F.
Some of the harmonic current which are zero sequence current
(3rd harmonic current) tend to flow in the neutral in a 3 phase, 4 wire
system. In most of the domestic and commercial load, which are
non linear in nature generate substantial amount of 3rd harmonic
current, the neutral conductor gets overheated and may lead into
melting of the same. It has been observed that in extreme cases, the
neutral current can exceed 1.5 times the normal line current.
The harmonic current affect the generator also, as most of the big
generators operate at maximum capacity and they do not have
excessive margin to accommodate heating losses resulting due to flow
of harmonic current into it. All such heating losses result in
deterioration of insulation used in electrical equipment.
Remedial actions
To avoid the harmful effect of harmonic current, various techniques are
successfully. Following are the common solutions sought for reducing the
level of the harmonics.
Series reactors
Harmonic Filters (Passive and Active)
Higher Pulse number Rectifiers
Harmonic Measurements
Shahjahanpur

at

Pulp

and

Papers

Limited,

During the audit, the total voltage harmonic distortion (%VTHD) & total
current harmonic distortion (%ITHD) at point of common coupling was
measured for the harmonic distortion. The total harmonic distortion is the
vector sum of all the harmonic content present in system, thus %THD
shows the actual total harmonics present in system. This is taken for
voltage and current separately. The total harmonic distortion voltage and
current are mentioned in a few places.
Limits of THD Voltage and current

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According to IEEE the harmonic distortion levels for voltage and current
are as follows
Total harmonic Distortion voltage
415 Volts

< 5% THD

11 kV

< 4 % THD

132 KV

< 2.5% THD

Total harmonic distortion Current

Depends on Isc/IL ratio of bus
Generally less than 15%

Section

V-THD

I-THD

Unit 1 TG Incomer

7.7

6.6

TG Incomer

5.6

0.3

Transformer 1

5.7

27

Transformer 2

5.4

24

Transformer 3

5.5

2.7

Transformer 4

5.3

Transformer 5

6.1

3.7

Transformer 6

5.8

6.7

Transformer 7

5.4

6.9

Transformer 8

5.2

2.0

Transformer 9

5.5

25

Transformer 10

5.4

22

Transformer 11

5.2

8.1

Transformer 12

5.3

2.9

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The level of voltage harmonics in all the transformers and generator

incomers were found high. The current harmonics were found high in
Transformers 1, 2, 9 and 10. In Unit II the harmonic levels are majorly
due to the VFDs installed in the section and plant team has taken
excellent initiatives to install both passive and active harmonic filters in
the plant to bring down the harmonic levels.
In Unit I the voltage harmonic level was found higher on the generator
incomer. The equipment with VFDs or non linear loads in Unit II are few
in number. The harmonic levels are high due to the alternator itself i.e the
harmonics are generated majorly by the alternator.

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OBSERVATION NO. 4

SEGGREGATE LIGHTING LOADS AND

SEPARATE TRANSFORMERS FOR LIGHTING

INSTALL

Background
During the detailed energy audit, a possibility of energy savings by
reducing lighting voltage in the plant was studied. Since the economics of
this proposal is on the higher side this proposal is projected as an
observation.
Present status
The operating voltage for lighting in the plant is around 240V. The
recommended voltage for lighting is 210V. There is a good potential to
reduce the power consumption of lighting by reducing the voltage for
lighting by installing lighting transformers for various sections.
Usually a thumb rule of 10% reduction in power consumed by lighting is
possible for every 10% reduction in lighting voltage. This thumb rule is
taken on a conservative basis. Different types of lamps have different
reduction in power consumed as mentioned in the table below.
Lamp type

Reduction in input power for

10% decrease in voltage

Fluorescent lamps

Power input Decreases by 15 %

HPMV lamps

Power input Decreases by 16 %

Mercury Blended lamps

Power input Decreases by 20

Metal Halide lamps

Power input Decreases by 20 %

HPSV lamps

Power input Decreases by 20 %

LPSV lamps

Power input Decreases by 8 %

There is a possibility to reduce the lighting circuit voltage by 10% (from

245V to 210V). The value of a 215 V is taken on a conservative basis and
for calculation purposes, though the average plant lighting voltage would
be higher. The reduction in lighting voltage by 2% will result in:
Reduction of lighting power consumption by 10%
Increased life of ballast and lamp
Insignificant drop in lumens emitted by the lamps
Recommendation
It is recommended to segregate the lighting load and maintain 205 210
V for lighting.
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Confederation of Indian Industry

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CHAPTER - V

MANAGEMENT ASPECTS & CONCLUSIONS

7.0

THE OBJECTIVES OF K R
SHAHJAHANPUR SHOULD BE

PULP

&

PAPERS

LIMITED,

Make Energy conservation a permanent activity at K R Pulp &

Papers Limited, Shahjahanpur.
To achieve lowest energy cost per unit of production.
The emphasis should be on production with quality and energy
efficiency rather than production with quality alone.
To achieve this objective, a firm top management commitment is
required at the highest level that the company wants to conserve
energy on a time bound basis.
The top priority is to implement the recommended proposals and
reap benefits.
7.1

Approach to An Energy Conservation Idea

Each energy conservation idea should be seen as an opportunity for
improvement. The approach must be on how to implement each
proposal and overcome the problems, if any. It is easier to say a
proposal is not possible or not implementable but the benefit comes
from the actual implementation, which needs lot of courage,
conviction and will power to implement.

7.2

Specific Recommendation
The K R Pulp & Papers Limited, Shahjahanpur team had
already done commendable jobs in Energy conservation. CII
strongly feels that Plant team should form an energy management
committee which involves senior persons from all departments and
the committee should continue the work and progress towards
World Class Energy Efficient Unit.
The main responsibility of implementing the proposals and
achievement of savings should be with the concerned operating and
maintenance personnel and not with the energy manager.
The immediate task of K R Pulp & Papers Limited,
Shahjahanpur should be to implement the identified proposals and
get the savings.
We would recommend, K R Pulp & Papers Limited,
Shahjahanpur to introduce a suggestion scheme for energy
Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

conservation. The energy conservation committee should review all

suggestions and good proposals should be implemented. The
originator for the good suggestion, which has been successfully
implemented, has to be rewarded.
7.3

Assign Specific Responsibility

While the overall responsibility for energy conservation rests with
the top management, the concerned plants operating /
maintenance personnel should implement and report progress on
energy saving proposals.
Therefore, each energy saving proposal should be assigned to a
specific operating / maintenance personnel for implementation and
monitoring. The suggested format is enclosed as Annexure B.
Specific time bound action plan is required for implementation and
monitoring of energy saving proposals.

7.4

Monitoring of Proposals
All the implemented proposals are to be monitored on a proposalby-proposal basis for actual achievement of savings on a monthly
basis.

7.5

Motivational Aspects
The successful management of energy depends on motivation of
technical personnel and their commitment. For this reason, J K
Fenner should carry out the following motivational aspects to
sustain energy conservation activities.
Send operating / Maintenance personnel for training programmes
in specific areas like
Fans & Blowers
Compressors
Heat Treatment system
Motors
Conduct in-house training programme on energy management.
Organise visits for executives to similar units to know the energy
conservation / process development, etc.
Present papers on energy conservation activities at the plant, in
other seminars.

7.6

Conclusions
Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

 K R Pulp & Papers Limited, Shahjahanpur team and CII

energy audit team together have identified 23 proposals for
implementation.
An annual savings potential of Rs. 434.10 Lakhs can be
realised by implementing the recommended proposals
Out of the total savings identified Rs. 107.30 Lakhs can be
achieved without any significant investment.
The remaining savings of Rs. 326.80 Lakhs can be achieved
with an investment of Rs. 183.90 Lakhs which will be paid back
in 7 Months.
Implementation of identified proposals should be given top
priority and should be done step by step.
The major supplier address is enclosed as Annexure A
K R PULP & PAPERS LIMITED, SHAHJAHANPUR
Assign specific responsibility for implementation of proposals
Monitor savings achieved on a proposal by proposal basis.
K R Pulp & Papers Limited, Shahjahanpur should have the
goal of sustaining the status of the best energy efficient plant in
the world.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Annexure

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

AnnexureA
SUPPLIER ADDRESS
VFD and other drives
1. Rockwell Automation India
Pvt. Ltd. (Allen-Bradley India
Ltd.)
C - 11, Industrial Area
Site - 4, Sahibabad
Ghaziabad - 201 010
Tel: +91 120 2895245, 2895252
Fax: +91 120 2895226

4. Danfoss Industries Pvt. Ltd.

296, Old Mahabalipuram Road
Sholinganallur
Chennai - 600 119
Tel : 044- 24503511-16
Fax: 044-24503521,18
E-mail:
[email protected]

2. Asea Brown Boveri (ABB) Ltd.

Plot No. 5 & 6, II Phase
Peenya Industrial Area
P B No. 5806, Peenya
Bangalore - 560 058
Tel: +91 80 2294 9585
Fax: +91 80 2294 9389

5. Larsen & Toubro Ltd

Headquarters
Mount Poonamallee Road
Manapakkam
P.B.No.979, Chennai 600 089
Tel: 044-22526000, 22528000
Fax: 044-2249 3317

3. Control Techniques India Ltd.

117/B, Developed Plot
Industrial Estate, Perungudi
Chennai - 600 096
Tel : 044 - 2496 1123/1130/1083
044 - 42152091
Fax: 044 2496 1602
Email:
[email protected]

6. Eurotherm DEL India Limited

152, Developed plots Estate
Perungudi
Chennai 600096
Ph: 044 24961129, 24961186,
24961230
Fax: 044 24961831
E-Mail: [email protected]

7. Siemens Ltd., Bangalore -A&D

3rd Floor, Jyoti Mahal.No.49
St. Marks Road
Bangalore - 560 001
Ph: 080 - 22042000, 22219450,
22219460, 22042000
Fax: 080 22224131, 22489320

8. Schneider Electric India Ltd.

(Corporate Office)
A-29, Mohan Co-operative
Industrial Estate, Mathura Road
New Delhi, Delhi
India - 110 044
Tel: 011- 41590000, 42590000;
Fax: 011-41678010/11/12
Email: [email protected]

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY EFFICIENT MOTORS

1.

2.

3.

6.

Kirloskar Electric Co.

Limited
Post Box No. 5555
Malleshwaram West
Bangalore 560 055
Tel : +91-80-23572111,
23371771
Fax : +91-80-23372488
Siemens Limited
Kalwe Works
Belapur Road
Thane 400 601
Tel: +91 22 27600001-04
Fax: +91 22 2762 3730
ABB Global Services Ltd.
#49, 2nd Floor,
E-Wing Khanija Bhavan Race
Course Road
Bangalore - 560 001

Tel: +91 80 22949150-53

Fax: +91 80 2353245
4.

Crompton Greaves Limited.

CG House, 6th Floor,
Dr. Annie Besant Road.
Worli, Mumbai - 400 030
INDIA.
Tel : +91 022 2423 7777
Fax : +91 022 24382288

5.

Bharat Bijilee Limited

37, Lady Curzon Road
II floor, Ramanashree Chambers
Bangalore 560 001
Tel: 080-25595547/ 25592646
Fax: 080-5592823
Email:
[email protected]
m
[email protected]

Baldor Electric India Pvt Ltd

19, Commerce Avenue
Mahaganesh Colony
Paud Road
Pune 411 038
Ph: 020 2545 2717 / 18

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

AUTOMATIC STAR-DELTA-STAR CONVERTOR

1. Vijay Energy Products Pvt.
Ltd.
Sagar Apartmenst G F
No 23 Gopalakrishna Road
T Nagar
Chennai 600017
Tel: 044 28156540, 28152906
Fax: 044 - 28152906
Email: [email protected]

2. Excellent Industrial
Instruments
1/63, E Type, SIDCO Nagar
Villivakkam, Chennai 600 049
Tel : 044 26172977
Fax : 044 26172531
Email: [email protected]
Web: www.xlntenergy.com

LIGHTING ENERGY SAVER / LIGHTING TRANSFORMER

1. BEBLEC (INDIA) PVT. LTD.,
P.O. # 3411, 711, 6th " B" CROSS
3RD BLOCK, KORAMANGALA
BANGALORE - 560 034.
(KARNATAKA) INDIA
Phone: 91 - 080
25520831/25530831/25531752/
25535734
Fax: 91 - 080 25530807
e mail: [email protected]
2. Beblec (India) Pvt. Ltd.,
126, Sipcot Indl. Complex
Hosur - 635 126 (TN)
Tel : 91-4344276358/278658/276958/276959
Fax: 91-4344-276358/59
3. Beblec India Pvt. Ltd.
III, Anand Estates
J M C Compound
189/A, S G Marg
Mumbai - 400 011
Tel: 022 - 23080078/23073321
Fax: 022 - 23071494
Email: [email protected]

4. ES Electronics (India) Pvt.

Ltd.
No. 438, 4th Main Road,
Nagendra Block,
B.S.K. Ist Stage, Bangalore 560050
Karnataka, India
Ph: 91-8026420623/624/26728761/26727
836
Fax: 91-8026420623/624/26728761/26727
836
Key Personnel
Mr. R. Sekar (Managing Director)
Mobile: +91 - 9448491548,
9844136209, 919448354504
5. Jindal Electricals
390 A, Industrial Area-A,
Ludhiana-141003
Phone : 0091-161-2607271,
2220035, 2600051
Fax : 0091-161- 2600385
E-Mail :[email protected]

6. Servomax India Limited

No 38 E.C.Extn, ECIL (post)

Hyderabad-500062. INDIA
Ph: 91 40 27123927, 27123279
www.servomax.net

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

7. Consul Consolidated Private Limited

9/6, Ist Street, Venkateshwara Nagar, Adyar
Chennai -600 020, Tamil Nadu, India.
Phone : +(91)-(44) 24403473/24403476
Fax : +(91)-(44)-24403470
E-mail : [email protected], [email protected]
AUTOMATIC VOLTAGE CONTROLLER/STABILIZER
1. Consul Consolidated Private
Limited
9/6, Ist Street, Venkateshwara
Nagar, Adyar
Chennai -600 020, Tamil Nadu,
India.
Phone : +(91)-(44)
24403473/24403476
Fax : +(91)-(44)-24403470
E-mail : [email protected],
[email protected]
2. Neel Controls
# 112, Minerva Industrial Estate
P K Road, Near Hercules Hoist
Mulund (W)
Mumbai 400 080
Ph: 022 2560 3371 / 2569
5047
Fax: 022 2568 3211
Email: [email protected]
3. Jindal Electric & Machinery
Corp.
C-57, Focal point, Ludhiana
141010
Ph: +91-161-2670250, 2676890,
2676968
Fax: 0161-2670252
E-mail: [email protected]
4. Globe Rectifiers
Plot no. 211, sector-24
Faridabad-05, Haryana
Ph: +91-129-2237896/97,
4060708
Fax: 0129-2442072
E-mail:
[email protected],
[email protected]

5. Muskaan Engineers
423, Industrial area A
Ludhiana 03
Ph: +91-161-5088381
Fax: 5022381
Mob: 99157-03056, 94170-33948
E-mail:
[email protected]
6. Power Engineers &
Consultants
E-731, Phase-VIII, focal point,
Opp. Hero cycle Ltd,
Ludhiana-10
Ph: +91-161-3294989
Fax: 0161-2303021
Mob: 9317562989, 9872862989
E-mail:
[email protected]

Energy Efficient Lighting

GE Lighting
Plot No. 42/1 & 45/14,
Electronic City - Phase II
Bangalore - 560100
Ph: +91-80-28528375-80 (Board
Numbers)
Lighting division Extn: 3128
Fax: +91-80-28528552
[email protected]
Philips India Limited
Ashoka Estate, 9th Floor,
24, Barakhamba Road, Connaught
Place
New Delhi 110001
Ph: +91-1123353280
Ph: +91-1123321167
Fax: +91-1123314332
Email: [email protected]

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Asian Electronics Ltd.

D-11, Road No. 28
Wagle Ind. Estate
Thane - 400 604, India
Ph: 022 - 2583 5504 - 09
Fax: 022 - 2582 7636

Havells India Ltd. (Corporate

office)
E-1, Sector 59, Noida-201307
(U.P.), India
Ph: +91-120 - 2477777
Fax: +91-120 - 2583904 /
2588182 / 2477666

OSRAM India Pvt. Ltd.

Signature Towers, 11th Floor
Tower B, South City-I
Gurgaon 122001,
Haryana, India.
Tel: +91-124-4081581,
+91-124-4150100
Fax: +91-124-4081577

Havells India Ltd.

304, 308, 3rd Floor, 19th
Brigade Garden
Church Street, Bangalore-560001
Ph: 080-25594397-98
Fax: 080-25590130
E-mail: [email protected]

LED LAMPS
1. Binay Opto Electronics Pvt
Ltd.
44, Armenian Street
Calcutta 700 001
Ph: 033 22103807, 22429082,
22102039
Fax : 033 22421493
Email: [email protected]
[email protected]

2. Kanmur Electronics (P) Ltd.

(LED & Motor Control)
44, Puramprakasa road
Balaji Nagar, Royapettah
Chennai-600 014
Tel: 91-44-28130353/91-4428131982
Fax: 91-44-28131982
Email: [email protected]

3. Kwality Electricals Pvt. Ltd.

Mfg. Solar Modules & LED
Lighting
3-6-145/9, Himayatnagar
Hyderabad 500 029
Ph: 040 2322 6889
Fax: 040 2344 0571
Email: [email protected]
[email protected]

5. OSRAM India Pvt. Ltd.

Signature Towers, 11th Floor
Tower B, South City-I
Gurgaon 122001
Haryana, India.
Tel: +91-124-4081581,
+91-124-4150100
Fax: +91-124-4081577

4. CKON VISIONS PVT. LTD.

Oberoi Chambers I
4th Floor, OPP. SAB TV
New Link Road, Andheri (West)
Mumbai - 400053
Ph : 022 - 26733398, 26733472,
73
Fax : 022 26742965
E-mail: [email protected],
[email protected]

6. IC NASA LED Lights

Chandmor Agencies 10/76, Old
Anand Nagar
Next toReliance Energy,
Santacruz (E), Mumbai 400
055
Ph: 022 26101930 / 31 / 32,
Fax: 26102419
Contact Person Name
Mona 0 98201 22652

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

INDUCTION LAMPS
Bajaj Electricals Ltd
H. No. 6-3-1090/2, 3rd Floor
Vithal Das Chambers,
Rajbhavan Road, Somaji guda,
Hyderabad - 500 082
Phone : 040-23442932, 23442933,
23442934
Fax : 040-23302745
Email :
[email protected]
[email protected]

Excess (Excellence In Energy

Saving Solutions)
2nd Street, Kothari Layout, No.
11, Opposite Stock Exchange,
Singanallur
Coimbatore - 641 005, Tamil
Nadu, India
Mr. P V Venkatesh
Mob- 08376806624

CAPACITORS
1. Momaya Capacitors
401, Madhav Apartments
Jawahar Road, Opp. Rly. Stn.
Ghatkopar (East)
Mumbai - 400 077
Tel: 022 - 25168281/82,
65754001/02
Fax: 022 - 2516 0758

4. EPCOS India Private Ltd.

2. Baron Power
No. 3, Karpagambal Nagar,
Mylapore, Tamil Nadu, India
Ph: +91-44-24356383/84/86,
42131849/50
Fax: +91-44-24356385

5. EPCOS India Private Ltd.

3. Meher Capacitors

Mr. Omer Kaiser

(Business Development
Manager)
Meher Capacitors (P) Ltd.
#52/1, Basappa Rd.,
Bangalore
Karnataka, India - 560027
Ph: 080-57704962
Mob: 09845019200
Fax: 080-22225325

14/2, Brunton Road

Bangalore 560 025
Tel : +91 80 40390615,
40390640
Fax : +91 80 40390603
[email protected]
Mehta Industrial Estate
Mathuradas Vasanji Road
Chakala, Anheri (East)
Mumbai 400093
Tel: +91 22 26 83 26 50
+91 22 26 83 26 51
Fax: +91 22 26 83 26 45
6. EPCOS India Private Ltd.

11th Floor
28 Dr. Gopal Das Towers
Barakhamba Road
New Delhi- 110 001
Tel: + 91 11 23 70 41 43
+ 91 11 23 70 41 44
Fax: + 91 11 23 70 41 46

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY MANAGEMENT SYSTEMS

1. Enercon Systems Pvt Ltd.
23, KHB Light Industries Area
P B No.6418, Yelahanka
Bangalore
Tel : 080 8460666 / 8460555
Fax : 080 8460667
Email : [email protected]

2. Conzerv Systems Pvt. Ltd.

44P Electronic City East Phase
Hosur Road, Bangalore - 560 100
INDIA
Ph: 91 80 4118 9700
Fax: 91 80 4118 9729
91 80 41102659
email: [email protected]

3. KLG Systel
Plot No. 70A,
Sector - 34, Gurgaon - 122 004
Haryana (India)
Telephone: +91 (0) 124-4129900
Fax: +91 (0) 124-4129999
e-mail : [email protected]

Product Infra red sensor for lighting energy saving

Blue Technologies
61, shreepal chambers, 481/c shaniwar peth,
opp shaniwarwada, Pune - 411030, India.
Tel : +91 20 65209611 T/ F : 24468058,
Cell : +91 9371042444, 9326042444
[email protected]
Fixed Speed Drive (Power Boss)
ASR ASSOCIATES,
Street No.71/2, 21st A Main
Marenahalli,
JP Nagar 2nd Phase
Bangalore 560 078
Ph: 91 80 26493204
Fax: 91 80 2665 1157
Email: [email protected]

Flat belts
1. Elgi Ultra Industries Ltd.
India House, Trichy Road
Coimbatore - 641 018. India.
Phone: 91 (422) 2304141
Fax: 91 (422) 2301377
Email: [email protected]

2. Habasit-Iakoka Pvt. Ltd.

Goldwins
Civil Aerodrome Post
IND-Coimbatore, 641 014
Tel.: +91-(0)422-262 78 79, 262
84 20/21
Fax: +91-(0)422-262 72 14
Email:[email protected]

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Cogged flat Belts

K. K. Rubber Company (India) Pvt. Ltd.
51, Rani Jhansi Road
New Delhi 110055
India
Telephone: +91 11 23619942, 23531215
23612072, 23679045
Fax: +91 11 23621862
Email: [email protected]
Fenner India Ltd
Khivraj Complex II
V Floor, 480, Anna Salai
Nandanam, Chennai - 600 035
India
Tel: +91-44-24312450 to 57
Fax: +91-44-24349016, 24320193
[email protected]

Agitators
1. Fluidyme Technologies
E-2/4, Popular Prestige,
Near Highway Bridge, Warje,
Pune-411058
Maharashtra, INDIA
TeleFax : +91-20-25293397
Mobile : 09422009479
E-mail :[email protected]
[email protected]
2. Pinnacle Equipments
Gat No - 103, Jyotiba Nagar
Talawade Road, Pune
Maharashtra - 412 114
Ph: 020-27690413/27690890 /
32661602
Fax: 020-27690413/32661602

3. Indofab Industries
Street Address: C/3, Hatkesh
Udyog Nagar
City: Thane
Maharashtra 400 606
Ph: + (91)-9820077092
4. Elof Hansson (India) Pvt. Ltd.
Old No 11, New No. 23
2nd Main Road
Raja Annamalai Puram
Chennai - 600 028
India
Ph: +91-44 461 7901/ 7905
Fax: +91-44 461 7907 / 790

Automatic Power Factor Controllers / Harmonic Filters

Baron Power Ltd
1, Second Cross Street
Seethamma Colony Extension
Teynampet, Chennai - 600018
TamilNadu, India.
Office: 044-24356383/84&86 /
42131849/50, Fax: 044-24356385
Office Mobile: 93810 47234
(Marketing), 93828 21143
(Technical)
Email: [email protected]

[email protected]
[email protected]
Crompton Greaves Limited.
CG House, 6th Floor
Dr. Annie Besant Road
Worli, Mumbai - 400 030
India
Tel: +91 022 2423 7777
Fax: +91 022 2423 7788

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Cummins India Limited

Power Generation Business Unit
35 A/1/2 Erandawana
Pune 411 038
Ph: 020 6602 7525
Fax: 020 6602 8090

Neel Controls
#112, Minerva Industrial Estate
P K Road, Near Hercules Hoist
Mulund (W), Mumbai 400 080
Ph: 022 2560 3371 / 2569 5047
Fax: 022 2568 3211

Contact Person

ABB Limited
Khanija Bhavan, 2nd Floor
East Wing, No. 49, Race Course Road
Bangalore - 560 001
Ph: 080 - 22949150 to 54
Fax: 080 - 22949148

Mr. S Ravichandran
General Manager
Mob: 098220 93785
Email:
subramaniam.ravichandran@cummin
s.com

UPS
APC
# 16, Row House, Goyal Inter City
Behind Drive in cinema, Thaltej
Road, Thaltej
Ahmedabad, Gujarat 380 054
India
Ph: (079) 2684 0124/ 324

APC
# 5, Lake Avenue,
Near Mudiali Bus Stop
Kolkata, West Bengal 700 026
India
Ph: (033)2465 5519, 2463 0064

Numeric Power Systems Ltd

"Numeric House"
No 5, Sir P.S Sivasami Salai
Mylapore, Chennai - 600 004, India.
Phone: 91-44-2499 3266 (10 Lines)
Fax: 91-44-2499 5760, 24998210
Email:
[email protected]

Emerson Network Power

Plot No. C - 20, Road No.19
Wagle Industrial Estate
Thane (West), PIN - 400604
Maharashtra
Tel: 022 67208000/8002/7800
Fax: 022 - 25828358, 25800829,
25824286

Consul Consolidated Private Limited

9/6, Ist Street, Venkateshwara Nagar, Adyar
Chennai -600 020, Tamil Nadu, India.
Phone: + (91)-(44) 24403473/24403476
Fax: + (91)-(44)-24403470
E-mail: [email protected], [email protected]

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Waste Heat Recovery

Thermax Ltd.
Dhanraj Mahal, 2nd Floor
Chatrapati Shivaji Maharaj Marg
Nr. Gateway of India
Mumbai - 400 039
Ph: 022 - 22045391, 22045324
Fax: 022 22040859

Chennai - 600 018

Tel: 04424303400, 24353831-4
Fax: 04424353841
Thermax Limited
6-3-649, Nalanda Complex
2nd Floor, Somajiguda, Behind
Medinova
Hyderabad - 500 482
Ph: 040-23310254, 23312013
Fax: 040-23312335

Thermax Limited
Process Heat Division
Fathima Akhtar Court
3rd Floor, 453, Anna Salai
Thermal Systems (Hyd) Pvt. Ltd.
Plot No.1, Apuroopa Township
IDA, Jeedimetla
Hyderabad - 500 055
Tel: 91-040-23091801-06
Fax(s): 91-040-23097433
[email protected]

Megatherm D'tech Pvt Ltd

Plot 150, Perungudi Industrial Estate
Perungudi, Chennai - 600096. INDIA
Phone: 91-44-65479255 / 42629008
Email ID : [email protected] /
[email protected]
OIL FIRED THERMOPAC/AQUATHERM SYSTEM

Thermax Babcock & Wilcox

Limited
Energy Building, D1 Block, Plot No.
7/2
RD Aga Road, MIDC, Chinchwad,
Pune 411019,
Tel: 020 6612 6464, 66126411
Fax: 020 6612 6612

Aquatherm Engineering
Consultants
St. Thomas Building
Luz Church Road
Chennai
Tamil Nadu
India.
Ph: 91-44-24660462, 24994032,
24660464, 91-44-24996085
Email: [email protected]
[email protected]

ECONOMISERS
Megatherm Engineers & Consultants Pvt. Ltd.
33, Oliver Road, Mylapore
Chennai - 600 004
Tel: 044 2498 7614/38/58
Fax: 044 2498 7638

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Furnace
Thermal Systems
Plot No.150, SIDCO Industrial Estate (NP)
Ambattur, Chennai - 600 098
Tamil Nadu, India
Ph: 044 - 42140877, 26257625, 26255790
Fax: 044 - 42140977
Email: [email protected]
[email protected]
Radiant Recuperative Heaters
Thermax Babcock & Wilcox Limited
Energy Building, D1 Block, Plot No. 7/2
RD Aga Road, MIDC, Chinchwad,
Pune 411019,
Tel: 020 6612 6464, 6612 6411
Fax: 020 6612 6612
Frp Blades For Mancoolers & Air Washers
ENCON (INDIA)
2B/06, Shivkripa,
N. C. Kelkar Road, Dadar (West)
Mumbai - 400 028, India.
Ph: +91 22 2437 2949 / 2430 6578
Fax: +91 22 2431 0992 / 2432 1929
Email: [email protected]
Email: [email protected]
Amalgamated Indl. Composites P. Ltd.
Unit No.111 /112, Ashok Service Industrial Estate
L.B.S. Marg, Bhandup (West)
Mumbai - 400 078. India
Tel: 022-25964566, Tele Fax: 022-25346920 / 25963611
Email: [email protected]

Compressors & compressed air systems

Elgi Industrial Complex
Trichy Road, Singanallur
Coimbatore - 641 005
India. Tel: 0422 - 2589555
Fax: 0422 2573697
Atlas Copco Compressor Sales
6-3-1191, 2nd Floor, Brij Tarang
Greenlands, Begumpet
Hyderabad - 500016
Tel: +91 40 32949090
Fax: +91 40 23417923

(Mr. Dhananjay Desai

Regional Manager)
Atlas Copco Compressor Sales
2nd Floor, Tellus Technologies Pvt
Ltd, 209/1B/1A, Range Hill, Pune
411020, Ph: +91 20 32949090
Fax: +91 20 27145778
Mob: +91 9823014158
Email: [email protected]

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Ingersoll-Rand (India) Ltd Air Center

Solitaire Corporate Park IV
Unit 411-412, 1st Floor
Andheri-Ghatkopar Link Road
Mumbai 400093
Chakala, Andheri (East)
Ph: 022-6697-5555
Fax: 022-6697 5566

Godrej Group EE services

Mr H N Daruwala
Godrej & Boyce Mfg. Co. Ltd.
Pirojshanagar, Vikhroli,
Mumbai - 400079,
Maharashtra,
India.
Ph: +91-22-6796 5656 / 67965959
Fax No. : 91-22-6796 1518

Denvik Technology Private Limited

H 11/5, Arundale Beach Road
Kalakshetra Colony
Besant Nagar, Chennai 600090
http://www.denvik.in
Contact Person
Vijay Krishna, Director, Business Development
Ph: 09840851800 Email: [email protected]

HOC Dryers
Gaso Energy Systems (I) Pvt. Limited
T-122 , M.I.D.C., Bhosari, Pune - 411 026
Tel. : + 91 20 2712 8823 / 3068 5256
Fax: 020 - 27119573
Email:[email protected]
Drytech Engineers
Sh. No. 12-15, Sapana Co.op. Hsg. Soc.,
Opp. Konark Vihar, Off. Pune-Satara Road
Dhankawadi, Pune - 411043.
Maharashtra, INDIA
Tel : +91-20-24371445, 24376601
Fax : +91-20-24376789
Email: [email protected], [email protected],
[email protected], [email protected]

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Energy Efficient Pumps

Sulzer Pumps India Ltd.
9 MIDC, Thane Belapur Road
Digha, Navi Mumbai 400 708
Ph: + 91-22-65134321-28,
39130500
Fax: + 91-22-2760 6814
E-mail: [email protected]
Grundfos Pumps India Private
Ltd.
118 Old Mahabalipuram Road
Thoraipakkam, Chennai 600 097
Tel: +91 44 2496 6800
Fax: +91 44 2496 6969
Kirloskar Brothers Ltd.
Udyog Bhavan, Tilak Road,
Pune 411 002 (India)
Ph: +91 20 24440770
4198,2444-0156
Email: [email protected]

Fax: +91
20 24440824,
2444-

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Energy efficienct fans

Dustech Engineers Pvt Ltd
Contact Person : Mr R K Gupta [Dir]
Address : P-27 2nd Flr malviya Ngr Mkt
New Delhi - 110017,
Delhi,
India.
Telephone No. : 91-011-6686085
Aerotech Equipments & Projects (p) Ltd.
101-a, Ansal Sumedha, Raj Nagar Distt. Centre, Ghaziabad - 201001, Uttar Pradesh,
India.
91-120-2710513 / 2711513
TCF-NADI Industrial Fans Pvt. Ltd.
Ponniammanmedu
No. 34, G.N.T. Road
Madhavaram, Chennai, 600 110 Phone: 91-44-2553-2206
Fax: 91-44-2553-2205
Email: [email protected]
Website: www.nadiindia.com
Low pressure drop flow meters
Emerson Process Management (India) Private Ltd.
D-Wing, 2nd Floor, Modern Mills Compound
Sane Guruji Marg, Jacob Circle, Mahalaxmi
Mumbai 400011
India
Tel +91 22 5662-0566
Fax +91 22 5662-0500
Email : [email protected]
Switzer Instrument Limited
9, South Boag Rd. T.Nagar,
CHENNAI (Madras) - 600 017 India
Phone : +91-44-2434 0999/3956/4321
Fax: +91-44-24347887
email: [email protected]
Chandak Instruments Pvt. Ltd.
G-004, Smruti, Opp. Dhanwatey
National College, Congress Nagar,
Nagpur-440012 (India)
Phone : +91-712-2420025
Fax
: +91-712-2420026
[email protected]
www.chandakinstruments.com

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Air conditioning system

United Engineering Corporation
147, R P Road, Secunderabad-500 003
Telefax: 2754-5501, 1113, 3559, 2753-8956
Email: [email protected] & [email protected]
Visit: www.smartcool.co.in
Steam Turbines (Mini & micro)
Triveni Engineering & Industries Limited
12 A, Peenya Industrial Area Bangalore 560 058,
Tel: 080-28394721
Fax: 080-28995211-5949
Mr S N Prasad,
GM - Mktg & Sales
Ph: 080 28391624
Mob: 9845189472
Email: [email protected]
TurboTech Precision Engineering (P) Ltd.
No.28/29,2nd Main Road
Rajaji Nagar Industrial Town
Bangalore 560 044
Fax: 080 23404341, 23200789, 23307227
Email:[email protected]
Visit: www.turbotechindia.com
Transvector Nozzle
General Imsubs Pvt. Ltd.
3711/A, GIDC, Phase-IV, Vatva
Ahmedabad 382445, India
www.giplindia.com,[email protected]
Ph: +91-79-2584 0845;
25842503; (M) 0 99984 20601
Computational Fluid Dynamics Study
Mech-Well Industries Ltd
7-A, Old Anjirwadi
Mazgaon, Mumbai 400 010
Contact No.:022-66200314 (Direct Line)
Fax No. 022-66200380
E-mail: [email protected]
Mr. Sanaka Prasad
CFD team leader
Satyam Intergrated Engineering Solutions - IES
Satyam Technology Center
Bahadurpally, Hyderabad
Mob: 9849273302
[email protected]
Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Insulations
Megha Insulations Pvt Ltd.
A-11/6th Floor, Dada Saheb Flats
Kalanala, Bhavnagar 364001
Ph: 0278-3004523/26
Fax: 0278-3004728
Email: [email protected]
Contact Person
Mr H V Shah -98252-07723 & 94262-12823
Mrs. Madhu: 98795-46523

Energy Management Software

Manoj Telrandhe
Manager Knowledge Based Businesses & ITes
SEE-Tech Solutions Pvt. Ltd.
11/5, Lets Conserve, MIDC InfoTech Park
Near VRCE Telephone Exchange
South Ambazari Road, Nagpur-440 022
Mobile: +91-9975325831
Ph: 0712-2222177
Fax: 0712-2225293
Web: www.letsconserve.org
Email: [email protected]
[email protected]
Compressed Air Audit and Control Systems
1.

Godrej & Boyce Manufacturing Company Limited.

Godrej Electricals & Electronics, Plant - 1
Pirojshanagar, Vikhroli
Mumbai - 400 079, India.
Tel.: +91 22 6796 1700 / 1800
Fax: +91 22 6796 1525
Contact Details
Mr. Homi. N. Daruwalla
(Vice-President)
Godrej Electricals & Electronics
Tel.: +91 22 6796 2201
Email: [email protected]
Mr. Umesh V. Shah
(Chief General Manager)
Industrial Electronics & Automation
Tel.: +91 22 6796 2211
Email: [email protected];

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

2.

Ingersoll-Rand (India) Limited.

Plot No. 35, KIADB Industrial Area
Bidadi, Bangalore - 562 109
Tel: +91 80 2216 6000
Fax: +91 80 2216 6022

Orchid Industrial Equiments & Energy Utility Services

New no 86, Velmurugan Complex
Arya Gowda Road, West Mamabalam
Chennai 600 033
Tele fax: 044 23712834
Email: [email protected]; [email protected];
Mr S Baskaran
Mobile: 94440 10371
Suppliers for Computational Fluid Dynamics (CFD) Study and Analysis

Mahindra Satyam Technology Centre

Bahadurpally Village
R R Dist, Hyderabad 500 043
Telephone: +91 40 3063 5082
Mr Rahul S. Tamboli
Telephone: 040-3063-5271
Mobile: +91-998-550-6261
Mech-Well Industries Limited
Head Office: Contact person
Mr V T Jadhav
Marketing Executive
Mobile: 09223393614
7 - A, Old Anijrwadi, Mazgaon
Mumbai - 400 010
Tel: +91 - 22 - 2373 74 54
+91 - 22 - 2374 23 54
Fax: +91 - 22 - 2371 94 46
PL Engineering Limited
(A Punj Lloyd Group Company)
76 Institutional Area, Sector 32
Gurgaon - 122001, India
Contact Person
Mr Priya Ranjan Kumar
DGM - Business Development
Mob: 07411021920, Bangalore

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Supplier for Paddle Mixers

BHS-Sonthofen (India) Pvt. Ltd.
6-3-252/1/7/B, 3rd floor
Opp. IIPM, Erramanzil
Banjara Hills, Hyderabad- 500 034
Tel: +91-40-23315341 /45
Fax: +91-40-23315346
Contact Person
Mr Neelesh Desai
National Sales Manager
Mobile no: +91 - 9350990680
Sanghavi Engineering
121, C.I.E, balanagar Expansion
Gandhinagar, Hyderabad -500 037
Andhra Pradesh
Ph 040-23086631/33
E mail [email protected]
Conveyor Belts
Mr Vijay Kumar K
Regional Manager-South
Phoenix Yule (P) Limited
1st Floor, P M Modi, Commercial Complex
Karbala Maidan, 5-4-187/6
Mahatma Gandhi Road
Secunderabad 500 003
Ph: 040-66324542, 66314542
Mob: 0-93932 23112
Email: [email protected]; [email protected]

Disclaimer
While every care has been taken in compiling this list, Confederation
of Indian Industry does not accepts any claim for compensation, if any
entry is found to be wrong, abbreviated, omitted or inserted
incorrectly either as to the wording space or position in the list. While
attempts are being made continuously to make the list as elaborate,
as possible CII wishes to inform that neither the list of technologies
nor list of suppliers for a given product / technology is
comprehensive. The list is only an attempt to create awareness on
energy conservation and sharing of best practices being adopted in
Indian Industry.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Annexure-B
FORMAT FOR MONITORING THE IMPLEMENTATION OF ENERGY SAVING PROPOSALS
Sl.
No

Energy Saving Propsals

Annnual
Savings
(Rs.Lakhs)

Investment Payback
Required
Period
(Rs.Lakhs) (Months)

Reduce the Frequency of Turbo Generator

1 to 49 Hz

100.00

Reduce One Tap Setting of Transformer 5

2.10

Optimize the Lighting Voltage in the Plant

5.00

2.00

Install Variable Frequency Drives in

Identified Pumps In Pulp Mill

56.80

47.40

10

Install Variable Frequency Drives in

Centricleaner Pumps in Pulp Mill

8.80

8.0

11

Install Variable Frequency Drives in

Identified Pumps in Paper Machine

8.40

10.00

15

Install Variable Frequency Drives in

Centricleaner Pumps in Paper Machine

43.00

19.50

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Person/
Department
Responsible

Target
Date

Remarks

10

11

12

Avoid the Pressure Drop Across Feed

Control Valve By Operating Bfp With Vfd in
Unit 1
Avoid Passing Through Minimum
Recirculation Line By Installing Multistage
Drag Valves For Boiler Feed Pump in Unit
1
Avoid the Pressure Drop Across Feed
Control Valve By Operating Bfp in Auto
With Vfd in Unit 2
Avoid Passing Through Minimum
Recirculation Line By Installing Multistage
Drag Valves For Boiler Feed Pump in Unit
2
Avoid Recirculation of Condensate By
Installing Vfd And Reducing Speed of
Condensate Extraction Pump

13

Reduce Air Ingress in Unit-1 Boiler Flue

Gas Path

14

Operate All the Cooling Tower Fans And

Reduce the Speed By Installing Vfd For All
Fans in Unit-2 Power Plant

15

Reduce Excess Flow Through Heat

Exchangers in Unit-2 Power Plant

16

Switch off One Condensate Extraction

Pump Completely in Unit-2 Power Plant

4.00

4.50

14

9.00

5.00

27.00

1.00

4.80

8.0

20

2.40

1.00

2.0

4.00

3.00

32.00

8.00

3.20

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

17

18

Avoid Pressure Drop Across Hot Well Level

Control Valve And Maintain Hot Well Level
Directly By Installing Vfd
Avoid Operating One Pump By Pumping
Dm Water Directly to Deaerator After
Passing Through the Flash Steam Heat
Exchanger in Paper Mill Section

2.00

1.50

3.20

1.00

19

Optimize the Operation of Instrument Air

Compressors in Unit -2

16.40

10.00

20

Optimize the Operation of Instrument Air

Compressors in Unit -1

6.00

5.00

15

21

Optimize Vacuum Pump Operation in Unit2

55.20

25.00

22

Replace V Belt With Cogged Flat Belt in

Identified Equipments

34.40

20.00

23

Optimize the Condensate Recovery Circuit

in Paper And Evaporator Section

4.40

4.00

11

434.10

183.90

Total

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Backup Calculations

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 1

REDUCE THE FREQUENCY OF TURBO GENERATOR 1 TO

49 Hz
The power produced by Unit TG1 is
=

10.97 MW at 50.0 Hz

On a conservative basis it is assumed that around 40% of load is assumed

centrifugal in nature
As per the loading of motors there is a good potential to reduce the frequency
of the alternator TG1 to 49 Hz.
Power consumed by centrifugal equipment

(Speed3) 3

Power consumed by centrifugal equipment

=
40% of 10.9 MW
=
4.36 MW
Power consumed by the centrifugal equipment after reduction in frequency to
49 Hz
=
(49)3 x 4.36
(50)3
=

4.10 MW

Reduction in power consumption

=
~

4.36 4.10
250 kW

Annual energy savings

=
=

250 kW x Rs 5 x 8000 hours

Rs. 100.00 Lakhs

There is no investment required for this proposal.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 2

REDUCE ONE TAP SETTING OF TRANSFORMER 5

Transformer 5 the LT voltage maintained is 427 V. There is a good potential to
reduce the tap setting of the transformer and maintain 415V for transformer
5.
Tap Position

HT Voltage (V)

11650

2(Recommended)

11275

3(Current)

11000

10725

10450

10175

9900

LT Voltage
(V)

433

Reduce the tap setting for the transformer 5 to tap position 2 from tap position
5
Total load of transformers

975 kW

Power savings

0.00625 x 975 kW

6 kW

=
=
=

6 kW x 8000 hrs x Rs. 5.0/kWh

Rs.2,40,000/Rs.2.40 Lakhs

Annual Savings

There is no investment required for this proposal.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 3

OPTIMIZE ELECTRICITY BOARD POWER FACTOR

The monthly average power factor is maintained at 0.97 lag. The EB billing is
in kVAh so for by increasing the power factor towards unity the consumed
kVAh units will decrease resulting in lower billing amount.
Recommend to install auto PF controller and maintain 0.995 PF
Total average kVAh/month
Total average kWh/month
Power factor

=
=
=

248000 kVAh
236000 kWh
0.95

Improved Power factor

=
Average kVAh/month after ENCON =
=

0.995
236000/0.99
238383 kVAh

Savings kVAh/month

=
=

248000- 238383
9,617 kVAh

Annual savings

9617kVAh x Rs 5.0/kVAh
x 12 months
Rs.5,77,020/Say Rs.5.77 Lakhs

=
KVAR required:
Maximum instantaneous kW
Capacitor required

=
=
=
=
=

660kVA x 0.98
647 kW
KW (tan1 tan2)
647 (0.203)
129.4 kVAr
Say 120 kVAr

Recommend to install 120 kVAr HT capacitor bank

Investment for APFC

=
=

120 kVAr X Rs.1500/kVAr

Rs. 1,80,000/-

Payback in months

Rs.1.80 lakhs x 12
Rs.5.77lakhs
3.77 months
Say 4 Months

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 4

INSTALL VARIABLE FREQUENCY DRIVES IN IDENTIFIED

PUMPS IN PULP MILL
Present Status
Many of the pumps in the pulp mill in Unit-II were found to be controlled
through control valves. The flow requirement in the below mentioned pumps
varies on the basis of production levels and the consistency to be maintained
in the respective chests.
Closing of the valve creates an artificial resistance to the flow, additional to the
system resistance. This pressure drop across the valve is a mechanical energy
loss which is also included in the work done by the pump. It is estimated that
about 10-40% of the pump power consumption is lost across the valve.
Savings
Valve
Power
Opening
kW
%

Name of Pump

Tag
Name

kW
Saving

Flow
m3/hr

Screw Press Chest

Pump

PU 76

57

35-60

11

440

Continuous Digester
Dilution Pump

PU 74

48

35

14

72.8

Wet Dilution Pump BSW1

PU 119

60

12

18

400

Back Shower Pump BSW1

PU 100

17

50

120

Wet Dilution Pump BSW 2

PU 96

66

25

19.5

500

Back Shower Pump BSW 2

PU 101

17

50

130

Washed HD Tower
Pump

PU 116

71

80

HD Dilution Pump

PU 126

54

50

16

Secondary Screen
Pump

PU 132

21

30

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Screened HD Tower
Pump

PU 146

24

50

LC Chest Pump

PU 150

24

15

Screened HD Tower
Dilution Pump

PU 165

54

25, 14

16

EOP VAT Dilution

Pump

PU 169

15

28

4.5

EOP Washer Dilution

Pump

PU 171

54

60

10.5

For Savings, considering 10% savings for 75100% open valve; considering
20% savings for 6075% open valve; 30% savings for 1060% open valve
For Example, consider Continuous Digester Dilution Pump PU 74
Saving Potential

=
=
Say

0.2 x 48 kW
14.4 kW
14 kW

Total Saving Potential

146.5 kW

Annual Savings

=
=

146.5 kW x 8000 hrs/yr x Rs. 5/kWh

Rs. 56,80,000

Investment for VFD

Rs. 47.4 Lakhs

Payback period

Rs. 47.40 Lakhs x 12 months

Rs. 56.80 Lakhs
10 months

=
Benefits

The annual savings of Rs. 58.60 Lakhs can be achieved by implementing this
project. The investment required is Rs. 47.40 Lakhs which is paid back in 10
months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 5

INSTALL
VARIABLE
FREQUENCY
CENTRICLEANER PUMPS IN PULP MILL

DRIVES

IN

Present Status
The Centricleaner pump in the pulp mill in Unit-II was found to be controlled
through a control valve. The flow requirement in the pump varies on the basis
of production level.
2.6 bar

0.6 bar

To Screen Washer

Primary Centricleaner
Primary Centricleaner
Standpipe

40% open

3.4 bar

PU 128

84 kW

Closing of the valve creates an artificial resistance to the flow, additional to the
system resistance. This pressure drop across the valve is a mechanical energy
loss which is also included in the work done by the pump. The necessity for
controlling the valve is due to higher design head or design flow.
There is pressure loss of 0.8 bar across the valve for primary Cetricleaner
pump which accounts to more than 30 % of the pump head. As pump power is
directly proportional to the operating head of the pump, there is good potential
to save energy.
Savings
Pump Discharge Pressure

3.4 bar

Pump Head

=
=

3.4 0.4 bar

3 bar

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Pressure Drop across Valve

=
=

3.4 2.6 bar

0.8 bar

Pump Power

84 kW

As pump power is directly proportional to the operating head of the pump

Saving Potential

=
=
Say

0.8 bar x 84 kW
3 bar
22.4 kW
22 kW

Annual Savings

=
=

22 kW x 8000 hrs/yr x Rs. 5/kWh

Rs. 8,80,000

Investment for VFD

Rs. 8 Lakhs

Payback period

Rs. 8.0 Lakhs x 12 months

Rs. 8.8 Lakhs
11 months

=
Benefits

The annual savings of Rs. 8.80 Lakhs can be achieved by implementing this
project. The investment required is Rs. 8.0 Lakhs which is paid back in 11
months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 6

INSTALL VARIABLE FREQUENCY DRIVES IN IDENTIFIED

PUMPS IN PAPER MACHINE
Present Status
Many of the pumps in the paper mill in Unit-II were found to be controlled
through control valves. The flow requirement in the below mentioned pumps
varies on the basis of production levels and the consistency to be maintained
in the respective chests. The pumps would have been designed for maximum
production and hence the flows are generally controlled through valves.
Closing of the valve creates an artificial resistance to the flow, additional to the
system resistance. This pressure drop across the valve is a mechanical energy
loss which is also included in the work done by the pump. It is estimated that
about 10-40% of the pump power consumption is lost across the valve.
Savings
Name of Pump

Tag
Power
Valve
kW
Flow
Name
kW
Opening Saving m3/hr
%

Refined SW Chest Pump

PM
181

< 10

28

22

Broke Chest Pump

PM
190

19

48

5.5

77

Bagasse Pulp Chest

Pump

PM
194

24

76

215

Machine Chest Pump

PM
185

45

50

13.5

For Savings, considering 10% savings for 75100% open valve; considering
20% savings for 6075% open valve; 30% savings for 1060% open valve
For Example, consider Broke Chest Pump PM 190
Saving Potential

=
=
Say

0.3 x 19 kW
5.7 kW
5.5 kW

Total Saving Potential

21 kW

Annual Savings

=
=

21 kW x 8000 hrs/yr x Rs. 5/kWh

Rs. 8,40,000

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Investment for VFD

Rs. 10 Lakhs

Payback period

Rs. 10.0 Lakhs x 12 months

Rs. 8.40 Lakhs
10 months

Benefits
The annual savings of Rs. 8.40 Lakhs can be achieved by implementing this
project. The investment required is Rs. 10.00 Lakhs which is paid back in 15
months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 7

INSTALL
VARIABLE
FREQUENCY
DRIVES
CENTRICLEANER PUMPS IN PAPER MACHINE

IN

Present Status
The Centricleaner pumps in the paper mill in Unit-II were found to be
controlled through control valves. The flow requirement in the pumps varies on
the basis of production levels.
2.9 bar

0.8 bar

To Primary Screen
through PM 234
2 bar

0.5 bar

Primary Centricleaner

From CL Box

40% open

40% open

4 bar
PM 100

3.5 bar
PM 42

234 kW

75 kW

Closing of the valve creates an artificial resistance to the flow, additional to the
system resistance. This pressure drop across the valve is a mechanical energy
loss which is also included in the work done by the pump. The necessity for
controlling the valve could be due to higher design head or design flow.
There is pressure loss of 1.1 bar across the valve for primary Cetricleaner
pump which accounts to more than 25 % of the pump head. Similarly, there is
a 1.5 bar pressure loss across the valve for the secondary centricleaner pump
which is more than 40 % of the pump head. As pump power is directly
proportional to the operating head of the pump, there is good potential to save
energy.
Savings Calculations
Considering Primary Centricleaner pump
Pump Discharge Pressure

4 bar

Pump Head

=
=

4 0.4 bar
3.6 bar

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Pressure Drop across Valve

=
=

4 2.9 bar
1.1 bar

Pump Power

234 kW

As pump power is directly proportional to the operating head of the pump

Saving Potential for PM 100

=
=

Saving Potential for PM 42

1.1 bar x 234 kW

3.6 bar
71.5 kW

1.5 bar x 75 kW
3.1 bar
36 kW

Total Saving Potential

107.5 kW

Annual Savings

=
=

107.5 kW x 8000 hrs/yr x Rs. 5/kWh

Rs. 43,00,000

Investment for VFD

Rs. 19.5 Lakhs

Payback period

Rs. 19.5 Lakhs x 12 months

Rs. 43 Lakhs
6 months

=
Benefits

The annual savings of Rs. 43.0 Lakhs can be achieved by implementing this
project. The investment required is Rs. 19.5 Lakhs which is paid back in 6
months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 8

AVOID THE PRESSURE DROP ACROSS FEED CONTROL

VALVE BY OPERATING BFP WITH VFD IN UNIT 1
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur detailed study was carried out on the operation of boiler feed
pump in unit-1 for any possible savings.
The design specification of the boiler feed pump is as follows
Flow

: 30 m3/hr

Head

: 600 m

Rated Power

: 90 kW

No. of stages

: 9 stages

A schematic diagram of the existing setup is as shown:

Each feed control valve controls the quantity of the flow w.r.t the boiler drum
level. It is observed that the control valve open percentage is varying from 45
to 50%.
The common header pressure is 60 kg/cm 2 and the drum pressure is around
45 kg/cm2. Because of the severe throttling there is huge pressure drop across
the feed control valve. Approximately, 10 kg/cm 2 is the pressure drop is taking
place across the control valve.

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Boiler drum level is being controlled by three element control valve. This
automatic flow based control valve operates based on the level of the boiler
drum. As per the drum level the open % of the control valve varies.
Flow controlling with the control valve is not an energy efficient mechanism.
The loss happening across the control valve can be minimised / reduced by
reducing the speed of the pump.
As the pump is already installed with VFD and running in manual mode. Power
consumption of the pump can be optimized by operating the VFD in auto
mode.
Recommendation
We recommend to
Operate the pump with a closed loop feedback to the VFD
o Option 1: Feedback can be same that of to the valve (3 element
signal)
o Option 2: Feedback can be pressure difference of 2 kg/cm 2 across
the control valve
Saving Caculations
At least pressure drop of 8 kg/cm2 can be reduced
% reduction in pressure drop

8 kg/cm2 x 100
60 kg/cm2
13.3%

Power consumption of BFP

90 kW

Reduction in power consumption

=
=

90 kW x 13.3%
12 kW

=
=
=

10 kWx 8000hrs x Rs.5/kWh

Rs. 4,00,000/Rs. 4.0 Lakhs

Investment for VFD

Rs 4.50 Lakhs

Payback Period

Rs. 4.50 Lakhs x 12 months

Rs. 4.0 Lakhs
14 months

Considering 10kW savings,

Annual Savings

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CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 9

AVOID PASSING THROUGH MINIMUM RECIRCULATION

LINE BY INSTALLING MULTISTAGE DRAG VALVES FOR
BOILER FEED PUMP IN UNIT 1
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur flow and pressure measurements of all pumps was carried out
for possibility of reducing the power consumption in detail. The observations
made during the energy audit are given below.
Present status
One BFP is in continuous operation for supplying feed water to boiler drum
from the deareator. Automatic Recirculation valves (ARVs) are installed to
protect the pump when the flow happening through the pump is less than 30%
of its rated capacity. These valves open and discharge high pressure feed
water to de-aerator.
Because of higher operating pressure differences across these valves, normal
ARVs tend to erode faster. To ascertain if any erosion has taken place for the
ARVs for feed pumps connected to Boiler, re-circulation flow is measured.
The measured re-circulation flow in BFP-1 is 10.0 m 3/hr & BFP-2 is 9 m 3/hr.
The percentage of passing is 28%.
Re-circulation results in increased power consumption for the same useful
work done.
Recommendations
We recommend the following:
Install multi-stage pressure reduction drag valves in lieu of normal ARVs.
These are typically represented as shown below:

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 Pressure reduction for these valves takes place in 12 18 stages. This

purely depends on design.
The erosion rate will be very low for these drag valves and completely
eliminate recirculation for significant amount of time.
Present power consumption of the unit 1 - BFP 2 is 90 kW
ARC passing quantity

9.0 m3/hr

FW main flow

32 m3/hr

% passing through

9 m3/hr x 100
32 m3/hr
28%

On conservative basis considering 25% reduction in the FW flow

Savings in kW
=
25% x 90 kW
=
22.5 kW
Annual savings

=
=

22.5 kWx Rs 5/ kWh x 8000

hrs
Rs. 9,00,000/-

Investment

Rs. 5.00 Lakhs

Payback

Rs. 5.00 Lakhs x 12 months

Rs. 9.0 Lakhs
7 months

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 10

AVOID THE PRESSURE DROP ACROSS FEED CONTROL

VALVE BY OPERATING BFP IN AUTO WITH VFD IN UNIT
2
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur detailed study was carried out on the operation of boiler feed
pump in unit-1 for any possible savings.
The design specification of the boiler feed pump is as follows
Flow

106 m3/hr

Head

983 m

Rated Power

90 kW

No. of stages

9 stages

A schematic diagram of the existing setup is as shown:

Each feed control valve controls the quantity of the flow w.r.t the boiler drum
level.
The common header pressure is 95 kg/cm 2 and the drum pressure is around
70 kg/cm2. Because of the severe throttling there is huge pressure drop across
the feed control valve. Approximately, 22 kg/cm 2 is the pressure drop is taking
place across the control valve.

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Boiler drum level is being controlled by three element control valve. This
automatic flow based control valve operates based on the level of the boiler
drum. As per the drum level the open % of the control valve varies.
Flow controlling with the control valve is not an energy efficient mechanism.
The loss happening across the control valve can be minimised / reduced by
reducing the speed of the pump.
As the pump is already installed with VFD and running in manual mode. Power
consumption of the pump can be optimized by operating the VFD in auto
mode.
Recommendation
We recommend to
Operate the pump with a closed loop feedback to the VFD
o Option 1: Feedback can be same that of to the valve (3 element
signal)
o Option 2: Feedback can be pressure difference of 2 kg/cm 2 across
the control valve
At least pressure drop of 16 kg/cm2 can be reduced
% reduction in pressure drop

=
=

16 kg/cm2 x 100
95 kg/cm2
16.8%

Power consumption of BFP

405 kW

Reduction in power consumption

=
=

405 kW x 16.8%
68 kW

Annual Savings

=
=
=

68 kWx 8000hrs x Rs.5/kWh

Rs. 27,20,000/Rs. 27.0 Lakhs

Investment for automation

Rs 1.0 Lakhs

Payback Period

Rs. 1.0 Lakhs x 12 months

Rs. 27.0 Lakhs
1 month

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 11

AVOID PASSING THROUGH MINIMUM RECIRCULATION

LINE BY INSTALLING MULTISTAGE DRAG VALVES FOR
BOILER FEED PUMP IN UNIT 2
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur flow and pressure measurements of all pumps was carried out
for possibility of reducing the power consumption in detail. The observations
made during the energy audit are given below.
Present status
One BFP is in continuous operation for supplying feed water to boiler drum
from the deareator. Automatic Recirculation valves (ARVs) are installed to
protect the pump when the flow happening through the pump is less than 30%
of its rated capacity. These valves open and discharge high pressure feed
water to de-aerator.
Because of higher operating pressure differences across these valves, normal
ARVs tend to erode faster. To ascertain if any erosion has taken place for the
ARVs for feed pumps connected to Boiler, re-circulation flow is measured.
The measured re-circulation flow in unit-2 BFP-1 is 5.0 m 3/hr & BFP-2 is 5.5
m3/hr. The percentage of passing is 4.5%.
Re-circulation results in increased power consumption for the same useful
work done.
Recommendations
We recommend the following:
Install multi-stage pressure reduction drag valves in lieu of normal ARVs.
These are typically represented as shown below:

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 Pressure reduction for these valves takes place in 12 18 stages. This

purely depends on design.
The erosion rate will be very low for these drag valves and completely
eliminate recirculation for significant amount of time.
Present power consumption of the unit 1 - BFP 2 is 405 kW
ARC passing quantity

5.5 m3/hr

FW main flow

115 m3/hr

% passing through

5.5 m3/hr x 100

115 m3/hr
4.5%

On conservative basis considering 3% reduction in the FW flow

Savings in kW
=
3% x 405 kW
=
12 kW
Annual savings

=
=
=

12 kWx Rs 5/ kWh x 8000

hrs
Rs. 4,80,000/Rs 4.80 Lakhs

Investment

Rs. 8.00 Lakhs

Payback

Rs. 8.00 Lakhs x 12 months

Rs. 4.80 Lakhs
20 months

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 12

AVOID
RECIRCULATION
OF
CONDENSATE
BY
INSTALLING
VFD
AND
REDUCING
SPEED
OFIN
CONDENSATE EXTRACTION PUMP
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, operation of condensate extraction pump is studied in detail
for possible energy savings.
Present Status
Two pumps are installed for pumping condensate, one pump is running
continuously.
A schematic diagram of the existing setup is as shown:

Condensate extraction pump is pumping water from hot well to deaerator. Hot
well level is being controlled with help of recirculation valve. At present, the
recirculation valve is opened to 93% open and the maximum of the
condensate is being recirculated back to the hot well.
The measured condensate flow is 26m 3/hr and the recirculation flow is
24m3/hr.
Recirculation is the most ineffective method of controlling flow. Therefore,
should be avoided to save the power consumption of the pump.
Generally, recirculation is provided to maintain sufficient condensate flow
through the steam ejector heat exchanger. Otherwise, operation of steam
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ejector will get affected. The required condensate flow through steam ejector is
35% of design condensate flow of the pump.
At the present condition, more than 90% of the flow is being circulated back to
hotwell. Flow of the condensate flow can be reduced by reducing the speed of
the pump by installing VFD and operating it with hot well signal. To maintain
the required 35% of the condensate flow, VFD should be locked at minimum
frequency level of 22 Hz.
Recommendation
We recommend to
Install VFD for the pump
Operate it directly based on the hot well level signal
Lock the minimum frequency level at 22 Hz
Close recirculation valve completely and the valve should open only
when the frequency falls below 22 Hz
Saving calculation
Operating power of the pump

12 kW

New operating frequency

22 Hz

Percentage reduction of speed

=
=

(50-22) x 100
50
56%

Power saving

=
=

56% x 12kW
6kW

Annual savings

=
=
=

6kW x 8000hrs x Rs 5/kWh

Rs 2, 40, 000/Rs 2.40 Lakhs

Investment

Rs 1.0 Lakhs

Simple payback period

Rs 1.0 Lakhs x 12
Rs 2.40 Lakhs
5 months

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 13

REDUCE AIR INGRESS IN UNIT-1 BOILER FLUE GAS

PATH
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, oxygen measurements of flue gas path were taken operation
of condensate extraction pump is studied in detail for possible energy savings.
Present Status
In unit-1 boiler, oxygen level was found to be higher across the flue gas path,
which indicates that there is an infiltration across flue gas path.

Air infiltration increases the load on the induced draft fan which in turn
increases the power consumption of the fan. The % infiltration across the flue
gas path is given in the below table:
Description / Boiler number

2.5 MW
AFBC

Boiler Outlet

4.6

Economizer Outlet

7.7

ID Fan outlet

10.3

Calculation
Air ingress across the total system

% infiltration in boiler

=
=

15.70

10.3 4.6 x 100

20.9 4.6
34.8%

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The % air infiltrations in the boiler is 34%. Major areas of leakage are Air preheater, cyclones and washer. There is good potential to decrease the power
consumption of the ID fan by arresting the air infiltration across the APH,
cyclones and washer. Maintain the overall infiltration to be less than 10 %.
Checking the air leakages with the leak detector and arresting the leakages for
avoiding the % air infiltration in APH, cyclones and washer.
Recommendation
We recommend to arrest the air infiltration in the boiler flue gas path by
arresting the leakages in APH, cyclones & washer.
Form a leakage reduction team
Procure a combustion analyzer & monitor infiltration levels regularly
Identify and arrest leakages
Maintain the overall infiltration at less than 10%
Savings Calculations
Boiler ID fan power consumption

45 kW

On conservative basis considering the air infiltration reduces by 50% of

recommended 10%.
Saving in boiler 1 ID fan power

=
=

0.5 x (34%-10%) x 45kW

5.4 kW

Annual savings

=
=
=

5kW x 8000hrs x Rs.5/kWh

Rs. 2,00,000/Rs. 2.0 Lakhs

Investment

Nil

Payback

Immediate

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 14

OPERATE ALL THE COOLING TOWER FANS AND REDUCE

THE SPEED BY INSTALLING VFD FOR ALL FANS IN UNIT2 POWER PLANT
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, operation of cooling tower fans in unit-2 power plant were
studied in detail for possible energy savings.
Present Status
Cooling water for condenser & other heat exchangers is being cooled with
same cooling tower.
The schematic of the operation of the cooling tower is as shown below:

Cooling tower has three cells with one fan each cell. All the three cells are
being used for heat exchange. During favorable conditions, plant team is
switching off the fans one by one. At present, only one fans is running
continuously.
Switching off one fan leads to partial savings as the heat transfer area is not
fully utilized. By switching on all the fans, flow handled by each fan reduces.
By installing VFD and reducing the speed of all the fans reduces the power
consumption of the fans drastically.
Recommendation
We recommend to
Install VFD for all the fans
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 Operate VFDs of the fans with the cold well temperature feedback of
300C
Increase and decrease the speed of all the fans based on cold well
temperature.
Savings calculation
Operating power of the fan

19.5kW

Operating power of two fans

39 kW

After operating three fans, the flow is handled equally by 3 fans

Load on each fan reduces by 33%
Q2
Q1

0.672

New power consumption %

44.5%

Power saving %

55%

N1

Power reduction consumption in three fans =

=

50% x(3x19.5kW)
29kW

Power saving
=
Operating power of two fans New
power consumption of three fans at reduced speed
=
39 kW 29kW
=
10kW
Annual saving

=
=
=

10kW x 8000hrs x Rs 5/kWh

Rs 4, 00, 000/Rs 4.0 Lakhs

Rs 3.0 lakhs

Rs 3.0 Lakhs x 12
Rs 4.0 Lakhs
9 months

Investment for VFDs &

automation
Simple payback period

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 15

REDUCE EXCESS FLOW THROUGH HEAT EXCHANGERS IN

UNIT-2 POWER PLANT
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, operation of cooling water pumps in unit-2 power plant were
studied in detail for possible energy savings.
Present status
Two cooling water pumps are operating continuously to circulate cooling water
through heat exchangers (turbine condenser, lube oil cooler, generator cooler).
Cooling water flow & temperature across heat exchangers measurements were
taken to study the cooling water circuit.
The schematic operation layout is shown as below

The temperature difference across heat exchangers is lesser compared to the

general design of any heat exchanger. And the details are given as below
Sl. No. Heat exchanger

T
Recommended
operating
T

Condenser

Lube oil cooler

Generator air cooler

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This lower temperature difference across heat exchangers indicates excess

flow through the circuit that can be reduced.
Cooling water flow can be reduced by installing VFDs for two cooling water
pumps and reducing the speed of the pump based on the cooling tower inlet &
outlet temperature difference feedback (set point of 60C).
When it is operated with VFD, cooling water flow in the entire circuit will come
down. Except lube oil cooler heat exchanger, heat load on the remaining heat
exchangers (condenser & generator cooler) directly depends on the turbine
load. At lower loads, cooling water through lube oil cooler reduces and it may
affect the performance of heat exchanger.
Therefore, lube oil cooler can be installed with auto flow control valve controls
flow based on the cooling water temperature difference across the heat
exchanger feedback (set point of 50C).
Before implementing this, a trial can be taken by throttling the pump in steps
of 10% till the temperature difference across heat exchanger reaches 60C.
Recommendation
We recommend to
Install thermocouples in the inlet & outlet of lube oil heat exchanger
Install auto flow control valve for lube oil cooler heat exchanger
o Operate it based on the cooling water temperature difference
across lube oil cooler with a set point of 50C
Install VFD for two cooling water pumps
o Operate it in closed loop with temperature difference of cooling
tower inlet and cold well temperature (set point of 6 0C)
Savings calculation
Power consumption of two pumps

=
=

81kW x 2
162 kW

Present temp diff across cooling

tower

30C

Temp diff to be achieved

60C

% Cooling water flow reduction

possible

=
=

30C x100
60C
50%

Power saving possible

50%

Power saving

50% x 162kW

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Annual saving

81kW

=
=
=

81kW x 8000hrs x Rs 5/kWh

Rs 32, 00, 000/Rs 32.0 Lakhs

Investment for 2 VFDs, control valve

& automation =
Simple payback period

=
=

Rs 8.0 Lakhs
Rs 8.0 Lakhs x 12
Rs 32.0 Lakhs
3 months

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 16

SWITCH OFF ONE CONDENSATE EXTRACTION PUMP

COMPLETELY IN UNIT-2 POWER PLANT
During the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, operation of condensate extraction pumps in unit-2 power
plant were studied in detail for possible energy savings.
Present status
Three pumps were installed to pump the condensate to deaerator. All the three
pumps are running continuously to meet the requirement.
The design specification of the condensate extraction pump is as follows
Flow

11 m3/hr

Head

75 m

Rated Power

15 kW

A schematic diagram of the existing setup is as shown:

Maximum steam load on the condenser is 20TPH. Therefore, maximum

quantity of condensate to be pumped is 20m3/hr. As one pump is designed to
deliver 11m3/hr, two pumps are sufficiently enough to meet the requirement.
At present, three pumps are operating continuously to pump the condensate
and the flow is being controlled by hot well level control valve.
Therefore, potential exists to save the power consumption of the condensate
pumping by switching off one pump.
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Recirculation line is provided in the condensate line after the steam ejector
back to hot well, which will open during the starting of the turbine & at lower
loads. At present condition, the valve is completely closed. Flow in this line is
measured and found to be 1.4m3/hr, indicates there is a passage in this line.
Therefore, potential exists to save the power consumption of the pump by
avoiding the passage in the recirculation line.
Recommendation
We recommend to
Switch off one pump completely
Avoid passage in recirculation line by maintaining the recirculation valve
Savings calculation
Operating power of the pump

8 kW

Annual saving

=
=
=

8kW x 8000hrs x Rs 5/kWh

Rs 3, 20, 000/Rs 3.20 Lakhs

Investment

Nil

Simple pay back period

Immediate

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 17

AVOID PRESSURE DROP ACROSS HOT WELL LEVEL

CONTROL VALVE AND MAINTAIN HOT WELL LEVEL
DIRECTLY BY INSTALLING VFD
During the course of the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, the turbine & its auxiliaries in unit-2 were studied in detail for
possible energy saving.
Present Status
The condensate extraction pump in unit-2 is rated for 11 m 3/hr flow, 75 m
head and has a motor rating of 15 kW. The pump consumes 9 kW of power
during its operation.
A schematic diagram of the existing setup is as shown:

The automatic flow based throttle valve operates based on the level of the
condenser. When the condenser level reaches minimum level, the throttle
valve closes and when condenser reaches maximum level, the throttle vanve
opens.
As throttling is an ineffective method of controlling flow. Power gets lost in the
form of pressure drop across control valve.
The estimated pressure drop across different equipment in the circuit is as
follows:
Sl. No.

Parameters

Pressure drop
(kg/cm2)

Steam ejector

0.5

Static head + Losses

3.0

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Deaerator

2.0

Total

5.5 kg/cm2

The pump discharge header pressure is 7.8 kg/cm 2. Therefore, pressure drop
of more than 2 kg/cm 2 is happening across the control valve. Thus there is
good potential to avoid the pressure drop by installiing VFD and control the
speed of the pump as per the level.
Control the capacity of the pump based on the level in the condenser. Open
the control valve fully and give the condenser level signal to the VFD and
increase the rpm of the CEP pump when the level of the condenser increase
and vice versa and operate the VFD in closed loop.
Therefore, there exists potential to save the power consumption of the pump
by avoiding the pressure drop across hot well level control valve.
Recommendation
We recommend to
o

Install VFD for two condensate extraction pumps

Open the control valve 100%

Operate the VFD in closed loop with the hot well level

Avoids pressure drop of 2 kg/cm2 across control valve

Savings calculation
Pressure drop across control valve =
Pump discharge header pressure

2 kg/cm2
7.8 kg/cm2

Reduction in the pressure drop due to valve throttling is 2.0 kg/cm 2.

% loss across control valve
=
2 kg/cm2 x 100
7.8 kg/cm2
=
25%
Operating power of two pump

23kW

Power lost due to pressure drop across control valve

=
25% x 23 kW
=

5.75 kW

Considering power savings

5 kW

Annual Saving

=
=
=

5 kW x 8000 hrs x Rs. 5/kWh

Rs. 2,00,000/Rs. 2.0 Lakhs

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CII Sohrabji Godrej Green Business Centre

Investment

Rs 1.50 Lakhs

Payback

Rs. 1.50 Lakhs x 12 months

Rs. 2.0 Lakhs
9 months

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 18

AVOID OPERATING ONE PUMP BY PUMPING DM WATER

DIRECTLY TO DEAERATOR AFTER PASSING THROUGH
THE FLASH STEAM HEAT EXCHANGER IN PAPER MILL
SECTION
During the course of the detailed energy audit at KR Pulp & Papers Limited,
Shahjahanpur, the DM water pumping system to deaerator was studied in
detail for possible energy saving.
Present status
DM water is being pumped to make up the deaerator. First, DM water is being
pumped from DM water tank through flash steam heat exchanger (at a height
of 12m) in the paper mill section. After passing through the paper mill section,
the DM water is being pumped to deaerator (at a height of 17-20m) by a
pump near DM water tank. The DM water flow is being controlled by deaerator
level control valve which is operating with opening 50-60%.

Instead of pumping DM water back to ground level and then pumping to

deaerator, DM water can be directly pumped to deaerator after passing
through flash steam heat exchanger in paper mill section.
The estimated pressure drop across various equipment in the circuit is as
follows:
Sl. No.

Parameters

Pressure drop
kg/cm2

Heat exchanger

0.5

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Static head + Losses

2.5

Deaerator

2.0

Total

5.0 kg/cm2

The estimated pressure drop in the circuit to pump DM water from DM water
tank to deaerator is 5 kg/cm2. The DM water transfer pump can meet this
requirement.
The design specification of the DM transfer pump is as follows
Flow

: 50 m3/hr

Head

: 50 m

Rated Power

: 15 kW

DM water can be pumped directly to deaerator by laying a direct line from

flash steam heat exchanger outlet pipe line (at a height of 12m) to the DM
water line at a height of 15m before deaerator level control valve. By doing
this, operation of one pump can be completely eliminated.
Deaerator level is being controlled with help of control valve, which is an
ineffective way of controlling flow. Some of the power will be lost in
overcoming the pressure drop across the control valve. Instead, flow can be
controlled by installing VFD and operating directly with deaerator level signal.
Recommendation
We recommend to
Connect heat exchanger outlet to second pump outlet line
Switch off the second pump & keep it as a standby
Install VFD for the pump
Maintain the deaerator level directly with VFD with level feedback
Open the control valve 100%
Savings calculation
Second pump can be avoided completely,
Operating power of second pump =
12kW
On a conservative basis, assuming 8kW saving
Annual saving
=
8kW x 8000hrs x Rs 5/kWh
=
Rs 3, 20, 000/=
Rs 3.20 Lakhs
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Investment for VFD & piping

Rs 1.0 Lakh

Simple payback period

Rs 1.0 Lakh x 12
Rs 3.20 Lakhs
4 months

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 19

OPTIMIZE THE OPERATION

COMPRESSORS IN UNIT -2

OF

INSTRUMENT

AIR

During the detailed energy audit at KR Pulp and Paper the compressors were
studied in detail and the following observations have been made.
Installed capacity
In paper plant: 5 x 380 CFM screw compressor
o 2 nos with 55 kW rated motor
o 3 nos with 75 kW rated motor
In Power Plant: 2 x 18.5 kW screw compressor
In operation Paper plant
2 nos of 55 kW compressor
1 no of 75 kW compressor
In operation Power plant
1 no of 18.5 kW compressor
The pressure setting of all the identified compressors is as follows:
Capacity
Actual
requirement

Pressure

Suggested
kW Savings
%
Pr
(Pr reduction
Reduction
& Unloading)
Loading Unloading reduction

CFM

%
Unloading

Compressor-1
at PM

380

0.00

380.00

6.5

6.90

5.5

15.6

Compressor-2
at PM

380

0.00

380.00

6.5

6.90

5.5

15.6

Compressor-3
at PM

380

75

95.00

6.5

6.90

5.5

15.6

28

Actual Working pressure required for different applications

For control valve operations, the instrument air requirement is in between
1.5 3.5 bar
For press roll machine the pressure requirement is

6 bar

There exists a good saving potential to optimize the pressure settings of the
instrument air compressors.

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Recommendation
Interconnect the compressed air pipe lines of both paper plant and
power plant and stop the compressor in power plant
As we can see from the above table that the unloading percentage of
compressor-3 is very high, it would easily accommodate the compressed
air requirement from power plant.
Install VFD in Compressor-3 and reduce the operating pressure setpoint
to 5.5 bar. This would have two benefits
o It would reduce the operating pressure thereby reducing the
operating power
o It would completely avoid the loss due to unloading
Press roll user requires 6 bar pressure, hence to cater its need, a small
booster compressor needs to be installed near the user
Savings calculation
As a first step, it is recommended to reduce the pressure settings and maintain
the average pressure at 5.5 bar
Loading pressure

6.5 bar

Unloading pressure

6.9 bar

Average Pressure

6.7 bar

Power saving in the compressor by reducing the operating pressure,

% Power saving(IAC # 1,2 & 3)

=
=

6.7 5.5
6.7 + 1
15.58 %

Power saving in IAC # 1, 2 & 3 by reducing pressure:

Average loading of compressor

100 %

Loading Power of compressor

55 kW

Power saving

=
=

55 kW x 1.00 x 0.1558
8.56kW

For 3 Compressors

3 x 8.56 kW

25.68 kW

say 25 kW

Power saving in IAC # 3 by avoiding unloading:

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Average Loading of compressor

75 %

Unloading Power of compressor

22.5 kW

Power saving

=
=

22.5 kW x 0.75
16.87 kW

say 16 kW

Total power saving by avoiding unloading and reducing pressure

=
25 + 16 kW
=
41 kW
Annual saving

=
=
=

41 kW x 8000 hrs x Rs. 5/kWh

Rs. 16,40,000/Rs. 16.40 Lakhs

Investment for booster compressor and VFD for compressor-3 and piping

Payback Period

Rs. 10.00 lakhs

Rs. 10.00 lakhs x 12 months

Rs 16.40 lakhs

7.31 months

Say 7 months

Benefits
The annual energy saving potential is Rs. 16.40 Lakhs. This will require an
investment of Rs. 10.00 Lakhs, which will have a simple payback period of 7
months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 20

OPTIMIZE THE OPERATION

COMPRESSORS IN UNIT -1

OF

INSTRUMENT

AIR

During the detailed energy audit at KR Pulp and Paper the compressors were
studied in detail and the following observations have been made.
Installed capacity
2 x 380 CFM screw compressor
o 2 nos with 55 kW rated motor
In operation Paper plant
1 nos of 55 kW compressor
The pressure setting of all the identified compressors is as follows:
Capacity
Pressure

CFM
Compressor1

Suggested
kW Savings
%
Actual
Pr
%
(Pr reduction &
Unloading requirement Loading Unloading reduction Reduction Unloading)

380

24

289.25

6.3

5.5

20.2

15.0

Actual Working pressure required for different applications

For control valve operations, the instrument air requirement is in between
1.5 3.5 bar
For press roll machine the pressure requirement is 6 bar
There exists a good saving potential to optimize the pressure settings of the
instrument air compressors.

Recommendation
Install VFD and reduce the operating pressure setpoint to 5.5 bar. This
would have two benefits
o It would reduce the operating pressure thereby reducing the
operating power
o It would completely avoid the loss due to unloading
Press roll user requires 6 bar pressure, hence to cater its need, a small
booster compressor needs to be installed near the user
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Savings calculation
As a first step, it is recommended to reduce the pressure settings and maintain
the average pressure at 5.5 bar
Loading pressure

6.3 bar

Unloading pressure

8 bar

Average Pressure

7.15 bar

Power saving in the compressor by reducing the operating pressure,

% Power saving(IAC)

=
=

7.15 5.5
7.15 + 1
20.24 %

Power saving in IAC by reducing pressure:

Average loading of compressor

76 %

Loading Power of compressor

55 kW

Power saving

=
=

55 kW x 0.76 x 0.2024
8.5 kW

Power saving in IAC by avoiding unloading:

Average Loading of compressor

24 %

Unloading Power of compressor

16.5 kW

Power saving

=
=

16.5 kW x 0.24
3.96 kW

say 4 kW

Total power saving by avoiding unloading and reducing pressure

=
8.5 + 4 kW
=
12.5
Annual saving

=
=
=

12.5 kW x 8000 hrs x Rs. 5/kWh

Rs. 50,0,000/Rs. 5.00 Lakhs

Investment for booster compressor and VFD for compressor-3

Payback Period

Rs. 6.00 lakhs

Rs. 6.00 lakhs x 12 months

Rs 5.00 lakhs
Say 15 months

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Benefits
The annual energy saving potential is Rs. 5.00 Lakhs. This will require an
investment of Rs. 6.00 Lakhs, which will have a simple payback period of 15
months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 21

OPTIMIZE VACUUM PUMP OPERATION IN UNIT-2

The vacuum system in Unit-2 was studied in detail and the following
observations were made.
Current System
There are 11 numbers of vacuum pumps installed in paper machine to cater its
needs. All are connected to a common header but are isolated from each other
with the help of valves. The vacuum pump connected to wire mesh user is
throttled at the user ends but all other vacuum are completely open.
Observations:
Vacuum
Pump No

User

Source Pr

User Pr

Delta P
120

Wire bivac

300

120,140,150, 150,
140,180

Trivac

250

180,180

70

Couch Roll (Low zone)

280

240

40

Couch Roll (High zone)

540

520

20

580

420

160

580

420

160

500

340

160

5
Suction Press (high zone)
6
7

Pickup Roll

Suction Press (low zone)

Pickup felt, 3 press felt, Uhle

box

10

390
60
380

320

440

310

130

440

310

130

1&4 press felt, uhle box

11

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As seen in the table above, the pressure drop between the user and the pump
in each area is huge. The possible reason for the same could be

Improper line sizing

Moisture carryover to the vacuum pump due to non-availability of

separators

Improper water
carryover

evacuation from

separators

leading to moisture

Recommendation
As it is observed that there is a huge pressure drop between the user and the
pump, it is evided that the line sizing in each user is not proper. It is highly
recommended to call a third party to conduct a detailed engineering study only
for the pipe sizing so that it could be brought down to acceptable limits. While
conducting the study the following points needs to be kept in mind

The pressure drop across the separator should be a maximum of

50mmHg

The pressure drop across the complete pipeline should not be more than
20 mmHg

A detailed study on the pipe sizing alone should be done and the
pressure drop should be brought down to acceptable limits

Also VFD needs to be installed for all vacuum pumps and vacuum needs to be
maintained based on the user requirement from DCS.
Savings
The saving potential is calculated only for those pumps as shown in the table
below where the pressure drop between the source and the user is high.
Vacuum
Pump No
1
5
6
7
10
11

User
Wire bivac
Suction Press (high zone)
Pickup Roll
1&4 press felt, uhle box

Source Pr in
mmHg
300
580
580
500
440
440

User Pr in
mmHg
Max 180
420
420
340
310
310

Delta P in
mmHg
50
90
90
90
60
60

In the above table, the pressure drop (Delta-P) is inclusive of 50mmHg

pressure drop across the separator and 20mmHg pressure drop in the piping.

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Savings calculation
Sample calculation for Wire Bivac

= 300180-50(separator)-20(piping)
= 50mmHg
= Pressure drop x Power consumption
Head developed
= 50mmHg x 102 kW
300 mmHg
= 17 kW

Similarly, saving for others is shown in the table below

Vacuum
Pump
No
1
5
6
7
10
11

Source
Pr in
mmHg

User

Wire bivac
Suction Press (high
zone)
Pickup Roll
1&4 press felt, uhle
box
Total

300
580
580
500
440
440

The total saving potential is 138 kW

User Pr
in
mmHg
Max
180
420
420
340
310
310

Delta
P in
mmHg

Power
consumption in
kW

50
90
90
90
60
60

102
180
147
141
174
153

savings
in kW
17
28
23
25
24
21
138

= 138 kW x 8000hrs x 5 Rs/ Unit

= Rs. 55,20,000
= Rs 55.20 Lakhs

Investment for conducting a complete engineering study on the pipe line sizing
and for new piping
= Rs. 25,00,000
= Rs. 25 Lakhs
Simple payback period

= Rs. 25,00,000 x 12 months

Rs. 55,20,000
= 6 months

Benefits
The annual energy saving potential is Rs. 55.20 Lakhs. This will require an
investment of Rs. 25.00 Lakhs, which will have a simple payback period of 6
months.
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CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 22

REPLACE V BELT WITH

IDENTIFIED EQUIPMENTS

COGGED

FLAT

BELT

IN

Background
During the detailed Energy Audit conducted at KRPulp and paper, various
equipments were studied for possible energy saving opportunities.
Some of the auxiliary bag filter fans, pumps, compressors and blowers use
conventional V-belt drives for power transmission. Use of V belts causes some
energy losses. There is a power transmission loss of about 7% - 8%, when the
V-belts WEDGE IN and WEDGE OUT of the grooved pulleys.
The latest trend in the industry is to use synthetic flat belt drives or cogged
belts in place of the V-belt drives. These belts have the following advantages:

Non-hygroscopic prevents elongation due to moisture absorption

Ensures better grip on the pulley

Energy savings of at least 5%

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From the above graph it is clear indication that the flat belt is operating at
98% efficiency when the drive is 100% loaded, but V-belt is operating at the
94% efficiency only. There exists good potential to replace V-belt with the flat
belt drives.
These drives are ideal for steady load applications, such as fans, compressors,
and blowers. However, it should be ensured that the area around the
equipment is free from oil or water spillage.
Also, proper preventive care must be taken to ensure proper alignment
between the drive and driven equipment.
Recommendation
We recommend converting the identified V-belt drives into flat belt drives for
the major auxiliary bag filter fans. The list of identified fans is given below.
Ensure that the area around the equipment is free from oil or water spillage
(cover could be used for protection)
S.No
1
2
3
4
5
6
7
8
9
10
11

Equipment
Mixing Chest
Machine Chest
Pulp dump chest
Agro pulp chest
Vacuum pump - cautisizing plant
ETP drain pump
Bagass chest agitator
Vacuum pumps - 11 nos
Unit-1 Boiler 7TPH FD Fan
Unit-1 Boiler 7TPH ID Fan
Vacuum pumps - 5 nos
Total

Operating kW
33
15
33
30
130
45
55
1398
28
23
366
2156

Saving Potential
1.32
0.6
1.32
1.2
5.2
1.8
2.2
55.92
1.12
0.92
14.64
86.24

Savings
On a conservative basis 4% saving is calculated for the identified equipments
Sample savings calculation for Mixing Chest
= 33 kW x 4 % savings
= 1.32 kW
Likewise, calculating for all the equipment, the total savings would be 86 kW
= 86 kW x 8000hrs x Rs 5/ Unit
= Rs 3440000
= Rs 34.40 Lakhs
Investment for pulley change and cogged flat belt
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= Rs 20.00 Lakhs
Simple payback period

= Rs 20.00 Lakhs x 12 months

Rs 34.40 Lakhs
= 7 months

Benefits
The annual energy saving potential is Rs. 34.40 Lakhs. This will require an
investment of Rs. 20.00 Lakhs, which will have a simple payback period of 7
months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

ENERGY SAVING PROPOSAL NO. 23

OPTIMIZE THE CONDENSATE RECOVERY CIRCUIT IN

PAPER AND EVAPORATOR SECTION
During the detailed energy audit at KR Pulp and Paper, the sondensate
recovery circuit was studied in detail and the following observations were
made.
Present status

The following observations were made in the evaporator and paper section
Steam consumption in evaporator section
Average

- 13 TPH

Recovery

- 55%, 7TPH

Steam consumption in paper machine

Average

- 22 TPH

Recovery

- 75%, 16 TPH

The condensate levels in flash tank and vacuum tank at paper machine section
is maintained by individual pumps associated with each tank with the help of
control valves. The condensate collected in each tank is pumped into a
recovery tank through a common header, which is again pumped into the
deaerator with the help of a pump as shown in the figure above.
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The condensate from the recovery section is also sent to the recovery tank
which is at 108 deg C.
Observation
Paper Machine: At paper machine section, the individual controls valves are
heavily throttled to the tune of 26% and 49%, which is due to mismatch
between the design and operating condition.
Evaporator Section: As the condensate which is entering the recovery tank
from the evaporator section is at 108 deg C, some portion of the condensate
flashes into steam which is vented into the atmosphere
Recommendation
It is recommended to connect the condensate line from both evaporator
section as well as from paper machine section directly into the deaerator as
indicated by dotted line in the figure below.

Install VFD in pumps associated with Flash tank and vacuum tank and the logic
to VFD would be maintain the tank level.
Stop the pump that transfers condensate from the recovery tank to the
deaerator
The savings with this modification is as follows
The energy loss associated with the pressure drop across the control
valves in Flash tank and vacuum tank pumps can be completely
eliminated.
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As the new operating parameters will be matching with the design

values, the pump will be working with better efficiency
Stopping of the recovery tank pump will be saving power to the tune of
11 kW (operating power)
Flash steam generated from 10TPH of condensate would be
Inlet water pressure

= 1.3 bar @ 108 Deg C

Enthalpy

= 452 kJ/ kg

Enthalpy at outlet (liquid) @ 1 bar= 417 kJ/ kg

Enthalpy of evaporation at outlet @ 1 bar
= 2257.44 kJ/ kg
kg flash steam/ kg of condensate = (452 417)/ 2257.44
= 0.015
Quantity of condensate

= 10 TPH

Total quantity of flash steam

= 0.015 x 10TPH
= 152 kg/ hr

Hence 152 kg/ hr of flash steam could be avoided if directly introduced to

deaerator, this would inturn reduce the extraction steam to the deaerator from
the turbine.
Install new pump at the evaporator section, the new pump will have a
specification which will aid the condensate to be sent directly into the
deaerator. The new specification will be as follows
Capacity

-20 m3/ hr

Head

- 50 mtr

Motor

- 5 kW

Savings
Stoppage of recovery tank pump

= 11 kW x 8000hrs x Rs 5/ Unit
= Rs 440000
= Rs 4.40 lakhs

Investment is for the piping, VFD and installation of new pump at the
evaporator section
= Rs 4.00 Lakhs
Simple payback period

= Rs. 4.00 lakhs x 12 months

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Rs. 4.40 Lakhs

= 11 months

Benefits
The annual energy saving potential is Rs. 4.40 Lakhs. This will require an
investment of Rs. 4.00 Lakhs, which will have a simple payback period of 11
months.

Confederation of Indian Industry

CII Sohrabji Godrej Green Business Centre

Confederation of Indian Industry

CII-Sohrabji Godrej Green Business Centre
Survey No. 64, Near Kothaguda Cross Road
Kothaguda Post, Ranga Reddy (Dt)
Hyderabad 500 084
Ph: + 91 40 44185111;
Fax +91 40 23112837
Email: [email protected]
Web: www.greenbusinesscentre.com

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